10 CHAPTER 2 LITERATURE SURVEY 2.1 INTRODUCTION This chapter covers a literature review on the production as well as evaluation of mechanical and tribological characteristics of Particulate Aluminium Metal Matrix Composites (PAMCs). Furthermore, the review also includes the use of Design of Experiments(DoE), statistical tools for modelling and optimisation methods for arriving at the optimum performance of the composites has been also covered in detail. The earliest PAMCs date back to the late 1960s and early 1970s with the production of Graphitic aluminium composites for automotive pistons. Studies on PAMCs based on various aluminium alloys and reinforcements have been taken up since. Universal series of wrought aluminium alloys such as 1000 (Pure aluminium), 2000 (Al-Cu), 3000 (Al-Mn) 4000 (Al-Si), 5000 (Al-Mg) 6000 (Al-Si-Mg), 7000 (Al-Zn-Mg) and 8000 (Al-Li) have been used in the preparation of PAMCs. Among the cast aluminium alloys, aluminium-silicon, aluminium- copper and aluminium-magnesium alloy systems have been used extensively in PAMCs applications. A summary of various aluminium alloys explored are given in Table 2.1 and 2.2.
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CHAPTER 2
LITERATURE SURVEY
2.1 INTRODUCTION
This chapter covers a literature review on the production as well as
evaluation of mechanical and tribological characteristics of Particulate
Aluminium Metal Matrix Composites (PAMCs). Furthermore, the review also
includes the use of Design of Experiments(DoE), statistical tools for
modelling and optimisation methods for arriving at the optimum performance
of the composites has been also covered in detail.
The earliest PAMCs date back to the late 1960s and early 1970s
with the production of Graphitic aluminium composites for automotive
pistons. Studies on PAMCs based on various aluminium alloys and
reinforcements have been taken up since. Universal series of wrought
aluminium alloys such as 1000 (Pure aluminium), 2000 (Al-Cu),
7000 (Al-Zn-Mg) and 8000 (Al-Li) have been used in the preparation of
PAMCs. Among the cast aluminium alloys, aluminium-silicon, aluminium-
copper and aluminium-magnesium alloy systems have been used extensively
in PAMCs applications. A summary of various aluminium alloys explored
are given in Table 2.1 and 2.2.
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Table 2.1 Wrought aluminium alloys used as a matrix by previous researchers
Wrought Aluminium Alloy Reference
1060 Rosenberger et al. (2009)
1050 Lim et al. (1999)
1061 Rosenberger et al. (2005)
2024 Abdel-Azim et al. (1995), Narayan and Bai(1995), Kiourtsidis and Skolianos (2002), Kokand Ozdin (2007) and Rao and Das (2011)
2618 Mindivan et al. (2006)
2219 Basavarajappa et al. (2006)
2009 Sannino and Rack (1996) and Srivatsan et al.(2005)
2014 Alpas and Embury (1990), Srivatsan(1995),Modi (2001), Mallikarjuna et al. (2011)and Sahin and Kilicli (2011)
2124 Srivatsan (1992), Muratolu and Aksoy (2006)and Sukumaran et al. (2008)
2011 Sahin and Özdin (2008), Rao and Das (2011)and Sahin and Kilicli (2011)
6061 Jha et al. (1989), Zhang and Alpas (1993),Straffelini et al. (1997), Srivatsan et al. (2002),Yang (2003), Ganesan et al. (2005), SeyedReihani (2006), Yang (2007), Mahadevan et al.(2008), Urena et al. (2009), Kumar et al. (2010)and Ramesh et al. (2011)
6063 Natarajan et al. (2009)
6092 Wang et al. (2001), Salazar and Barrena (2004)and Ghazali et al. (2008)
7005 Ceschini et al. (2006)
7075 Kumar et al. (2010)
8090 Downes and King (1993), Bauri and Surappa(2008) and Rao et al. (2010)
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Table 2.2 Cast aluminium alloys used as matrix by previous researchers
Cast Aluminium Alloy Reference
Pure Al Mandal et al. (2004
A206 / Al-4.5 Cu Lim et al. (1999), Mandal et al. (2004), Daset al. (2007) and Rohatgi et al. (2010)
Al-2Mg Mandal et al. (2007)
A359 /Al-Si10Mg Daoud and Abou El-khair (2010), Huber et al.(2006)
A356 /Al-Si10 Bai et al. (1992), Ravikiran and Surappa(1997), Nagarajan et al. (1999), Chen et al.(2000), Riahi and Alpas (2001), Acilar andGul (2004), Akhlaghi et al. (2004), Gul andAcilar (2004), Natarajan et al. (2006), Yalcinand Akbulut (2006), Sudarshan and Surappa(2008) and Rashed and Mahmoud (2009)
Al-12 Si Cao (2000) and Jun et al. (2004)
Al-12Si-4Mg Anasyida et al. (2010)
Al-12Si-3Cu Basavakumar et al. (2009)
Al-22Si Moustafa (1995)
Al-20Si-3Cu-1Mg Bai and Xue (1997)
Al-13Si-1Mg-1Cu Liu et al. (1997)
Al-Si12Fe Singh et al. (2001)
Al-Si12Cu Akbulut et al. (1998) and Sawla and Das(2004)
Al-4Cu-1.5Mg Nath et al. (1980)
Al–Mg–Si Corrochano et al. (2011)
Al-ZnMg Rao et al. (2010)
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Various particulate reinforcements were added mainly to improve
the wear resistance of aluminium alloys. Hybrid composites containing
addition of more than one particulate have also been investigated. A summary
of various reinforcements added is listed in Table 2.3.
Table 2.3 Particulate Reinforcements used in aluminium MMCs
Reinforcement Reference
Al2O3 Surappa and Rohatgi (1981), Yang (2003), Al-Qutubet al. (2006), De Portu et al. (2007), Rosenberger et al.(2009), Dharmalingam et al. (2010) and Radhika et al.(2011)
SiC Alpas and Zhang (1992), Pai et al. (1995), Zhang et al.(1996), Chen et al. (1997), Tjong et al. (1998), Lim et al.(1999), Haque and Sharif (2001), Srivatsan and Al-Hajri(2002), Shorowordi et al. (2003) , Gomez de Salazar andBarrena (2004), Mart et al. (2005), Yalcin and Akbulut(2006), Rodriguez et al. (2007), Sahin and Özdin (2008),Rashed and Mahmoud (2009), Kumar and Balasubramanian(2010), Rao and Das (2011), Wang and Song (2011) andManigandan et al. (2012)
B4C Ipek (2005), Shorowordi et al. (2006) and Soy et al. (2011)
TiC Sheibani et al. (2007)
SiO2 Pai et al. (1995) and Rohatgi et al. (2010)
Fly ash Sudarshan and Surappa (2008), Tripathy (2009) and VenkatPrasat et al. (2011)
Granite Singh et al. (2001)
TiO2 Pai et al. (1995) and Ramesh et al. (2009)
TiB2 Mandal et al. (2007), Kumar et al. (2008), Natarajan et al.(2009) and Mallikarjuna et al. (2011)
Graphite Pai and Rohatgi (1978), Biswas et al. (1980), Lin et al.(1998), Suresha and Sridhara (2011) and Menezes et al.(2012)
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2.2 MECHANICAL PROPERTIES OF AMCS
The addition of particulates affects the various mechanical
properties of the composites like tensile strength and hardness. Composites
have enhanced mechanical behaviour when compared to the base alloy.
Doel and Bowen (1996) have studied the effect of SiC particles on
composite tensile behaviour and concluded that all the composites exhibited
lower ductility than the unreinforced material, with the composites containing
fine SiCp (5 m) being relatively more ductile and those reinforced with
coarse SiCp (60 m) exhibited very low ductility. Composites reinforced with
5 and 13 m particles respectively showed greater 0.2% proof stress and
tensile strength values than unreinforced material. However, the composite
reinforced with 60 m particles had lower 0.2% proof stress and tensile
strength values compared to unreinforced alloy.
Sahin and Murphy (1996) observed that the hardness of the Al-
Boron fiber MMCs and the matrix alloy increased linearly and their densities
decreased linearly with volume percent of boron fibre (0-32 vol.%). The
average wear rate of a 32 vol.% fibre composite in normal orientation was
reduced by about 84% compared to the matrix alloy.
Lin et al. (1998) observed a reduction in tensile properties of 6061
aluminum alloy/0–6 wt. % graphite particulate composite. However, the
hardness remained practically unchanged.
Achieving uniform distribution of reinforcement is a foremostrequirement for successful performance of AMCs. Hashim et al. (2002)conducted a systematic study on particle distribution in cast AMCs by usingFinite Element Analysis with a specialized Computational Fluid Dynamicssoftware. Optimum stirring conditions were obtained to achieve effective
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flow patterns for uniformly dispersing the solid particles in the melt withoutbreaking the surface layer of the melt. In addition, studies on particledispersion behaviour by Seo and Kang (1995) showed that the size and typeof reinforcement had a significant role in determining the mechanicalproperties of the AMCs.
Miyajima and Iwai (2003) investigated the effect of SiC whisker,Al2O3 fiber and SiCp on the mechanical properties of AMCs produced bypowder metallurgy route. Powder metallurgy route was also used by Ling(1995) to evaluate mechanical properties and porosity in AMCs reinforcedwith SiC. It was found that there existed a strong dependence on the kind ofreinforcement and its volume fraction. The results also revealed thatparticulate reinforcement was most beneficial for improving the mechanicalproperties of AMCs. Further Karnezis et al. (1998) reported that, achievinguniform distribution of reinforcement within the matrix was a major challengein the case of Al/SiC composites which directly affects the properties andquality of composite material.
Singla et al. (2009) developed aluminium alloy/ SiCp compositesusing a two step-mixing method of stir casting technique, to fabricatecomposites of varying weight fraction of SiC (5-30%). Results showed thathardness and impact strength increased with an increase in weight percentageof SiC.
Yu et al. (2004) examined a novel method to fabricate uniformlydistributed Al2O3 particles in Al-based metal matrix composite. Thecomposite was formed by sintering an Al-10 wt% ZnO sample at 1000°C.Al2O3 particles were found to be distributed more uniformly in the Al (Zn)solid solution matrix in oil-quenched sample compared to furnace cooledsample. Dobrzañski et al. (2008) have reported the use of sintered Al2O3
particles were used as reinforcements in Al-Si12 alloy to investigate themicrostructure and corrosion resistance of the composites.
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Xiao-dong et al. (2007) made a study on mechanical properties by
varying the particle size of SiC reinforcement in Al matrix composite
fabricated by squeeze casting technique. They investigated the bending
strength and fracture toughness of the composites and found that as the
particle size decreased, bending strength increased and fracture toughness
decreased. Mechanical properties like bending strength and hardness were
analysed by Altinkok and Koker (2004) in the case of Al2O3/SiC/A332
composites. It was observed that the bending strength and hardness of the
composites increased with decreasing SiCp size.
Das (2004) discussed the development of aluminium alloy
composites for engineering applications. Prototype components of Al-SiC
composites such as brake drums, cylinder block for automobile as well as
parts for mineral processing industries were produced and their performance
under actual operating conditions was evaluated. It was demonstrated that the
composite components have the potential to replace the existing components
made of conventional materials. Enhanced mechanical properties of
composites make them a potential candidate for several engineering
applications
2.3 DRY SLIDING WEAR BEHAVIOUR OF PAMC
According to Sannino and Rack (1995), the important tribological
parameters that control the wear rate and coefficient of friction of
discontinuously reinforced aluminium composites under dry sliding
conditions were the reinforcement type, size, shape, orientation and
reinforcement percentage referred to as the material factors. Applied load,
sliding velocity, sliding distance, environment and temperature as well as
counterfeit material, collectively called as mechanical and physical factors,
also play an important role in controlling the tribological behaviour of
aluminium composites.
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Wear test methods can be grouped into six categories: i) Machinery
Field Tests. ii) Machinery Bench Tests. iii) Systems Bench Tests