Papers by Keyword: Stir Casting

Abstract: The impact of heat treatment on the mechanical characteristics of aluminium metal matrix composite (MMC) was examined in this research work. Here the material chosen for matrix was Al7075-T6, which was aluminium alloy that was tempered with T6 configuration and the Al matrix was reinforced with Silicon nitride (Si₃N₄) powder. For the evaluation of mechanical properties totally two samples were fabricated, one was Al7075-T6 itself without any addition of any reinforcement and the other sample was composed of Al7075-T6 + 5% of Si₃N_4. These two samples were fabricated in necessary testing form with the help of stir casting technique. After fabrication and heat treatment of the samples the sample was mechanically tested to evaluate the tensile and impact strength of the samples prepared to find the changes in the mechanical properties due to the reinforcement of Si₃N₄ and due to the heat treatment process. The samples were subjected to heat treatment process at a temperature of around 500°C for 5 hours, after treating the samples with heat sudden quenching process was done by cooling with distilled water and artificial ageing process was conducted at 150°C for 24 hours. After all this process of fabrication and heat treatment the samples were analysed to find the mechanical properties.

Abstract: This research focuses on evaluating the wear behavior of aluminum 7075 alloy reinforced with titanium diboride (TiB₂), zirconium dioxide (ZrO₂), and nanoclay to develop composites with enhanced wear resistance for industrial applications. The incorporation of these reinforcements improves the mechanical and tribological properties of the alloy by refining the microstructure and promoting uniform dispersion of hard ceramic particles. A total of 20 dry sliding wear tests were conducted, revealing that wear loss increases significantly with rising applied load. Among the influencing factors, ZrO₂ exhibited the highest contribution to reducing wear rate at 37.84%, followed by load (33.21%) and sliding speed (14.92%). Regression analysis confirmed that increasing ZrO₂ content, applied load, and sliding speed reduces wear rate due to improved hardness, grain refinement, and toughness. TiB₂ and nanoclay further enhance the load-bearing capacity and stability of the alloy under severe wear conditions. The synergistic effect of the reinforcements results in superior wear resistance, making the Al7075 hybrid composite a promising material for high-performance and wear-critical applications in the automotive, aerospace, and structural industries.

Abstract: This study aims to investigate the wear behavior of AA7075 alloy with the reinforcement of Silicon carbide (SiC) and Boron carbide (B4C) particles. Process parameters are crucial for component quality improvement, particularly in metal matrix composites (MMCs), a unique class of materials used in a variety of technical applications, such as but not limited to automobiles, marine, and aeronautics.These are frequently utilized in challenging applications due to their significantly better strength to weight ratios, stiffness, and then standard materials. However, it has numerous disadvantages, including high weight ratios, high deformation and stresses, poor fatigue life cycle, early wear and friction, and so on. Up till now, numerous reinforcements have been employed to address these crucial problems. Due to its superior properties, aluminum matrix composites (AMCs) have been used in many different applications. This work attempts to examine the wear behavior of AA7075 alloy reinforced with silicon (SiC) and boron (B4C) particles utilizing the stir casting process AA 7075-(SiC)-(B4C) composites were produced by employing AA 7075 as the matrix material with silicon carbide (SiC) and boron carbide (B4C) particles as reinforcement in various percentages of weight (5%, 10%, and 15%). Parameters of the composites, including wear behavior, coefficient of friction, frictional force, and pin temperature were assessed through graphical representation.

Abstract: Aluminum casting using the stir casting method is a common practice in the industrial sector. This study aims to optimize the effect of stirring speed on the physical and mechanical properties of aluminum casting reinforced with alumina powder (Al2O3). The material used in this study is derived from discarded vehicle rim waste. The stir casting method was performed at varying speeds of 500, 600, and 700 rpm, with a mold temperature of 250°C and a pouring temperature of 700°C. Physical testing to examine the microstructure was conducted using optical metallography, hardness testing was performed using the Rockwell hardness scale B, and tensile strength was measured using a Universal Testing Machine. The microstructure observations showed that a stirring speed of 500 rpm yielded the best results, with minimal porosity. The highest hardness value recorded was 65 HRB at 500 rpm, consistent with the microstructure observations. The highest tensile strength was also recorded at 500 rpm, reaching 262 MPa.

Abstract: The economic, performance, and environmental advantages of accepting Aluminium (Al) metal matrix composites (MMCs) over steel, cast iron and light alloys are driving forces behind their utilisation. The transportation industry benefits from reduced noise, reduced emissions from airplanes, and reduced fuel use. Continuous research in this field has resulted in improved manufacturing procedures, allowing these Aluminium based composite materials to be used in aerospace industry, marine and vehicle applications rather than most monolithic materials. The industrial sector is rapidly developing, which increases demand for innovative materials. In cases where 'wear' is a critical issue, conservative materials and alloys have limits in reaching the appropriate hard characteristic. Al-MMCs are composite materials that contain Al or an alloy of Al. It acts as the matrix and the reinforcement distributed across the matrix. Common reinforcing materials include fibres, whiskers, and particles. Because of its enhanced density, great hardness, and thermal stability, ceramic reinforcement is the most used. However, they have limits such as less ability to wet and compatibility with the Al matrix. The major production processes for Al-MMCs are powder and liquid metallurgy. All the manufacturing procedures outlined are appropriate, however casting with stir to mix is cost-effective, particularly for big production runs. The distribution of reinforcement evenly to generate a flaw-free structure at micro level and hence raise the resistance to hard behaviour is a critical difficulty in the synthesis of MMCs of Al. Al-MMCs with particle reinforcement have increased mechanical characteristics and wear resistance. Furthermore, the production of MMCs reinforced with particulates is an exciting task, with questions arising due to ductility decline as the weight percent of ceramic particulate reinforcement is increased, gravity segregation due to denser particulates, and oxidation due to the use of Al alloy, which is very susceptible to oxidation. In the present study Al6061-3% B₄C MMCs have been developed by stir casting technique. Al6061 is an extruded raw material as purchased from the supplier (and not an ingot) used before remelting and manufacturing the MMCs. The microstructure of the manufactured Al-alloy and Al-MMCs are evaluated. It is observed that stir casting is a suitable method to manufacture Al-MMCs.

Abstract: In the current research, titanium carbide (TiC) is used to reinforce the aluminium alloy (AA 6063) in stir-cast hybrid composites at concentrations of 5, 10, and 15 weight percent together with 3 weight percent of graphite. The application of this developed composite is mainly used for automobile suspension parts. The portrayal of characters was performed, and the mechanical properties of the fabricated samples were investigated. Composites with different TiC weight percentages have their mechanical properties, including hardness, tensile strength, compressive strength, and flexural strength, measured and assessed. The results are shows that AA 6063 alloy with 3 wt. percentage of graphite with an increasing weight percentage of TiC composites are better in the mechanical property. The hardness of the AA 6063 alloy composites is greater than that of the base matrix alloy. The tensile strength of Al 6063 alloy composites has been reported to grow with increasing TiC particle content and to be significantly higher than the strength of the matrix alloy. Also, the SEM microstructure images clearly shows that 15 weight percentage of TiC with 3 weight percentage of Graphite shows the maximum distribution in the matrix.

Abstract: There is a significant improvement in specific strength and wear resistance of metal matrix composites (MMCs) in comparison to unreinforced alloys. Low-density reinforcements such as SiC havethe advantageof beingrelatively inexpensive and readily available abundantly and is cost-effective among the several uneven dispersoids used. Meagre work is carried out on processing of Al2219-SiC MMCs which is the originality of current work. The Al2219 matrix alloy in the current study was reinforced with different weight percentages of SiC (3%, 5%, and 7%), and it was produced by the stir casting process. Its microstructure and physical properties were examined, and it was then compared to the alloy as-cast. A study of SiC reinforced Al2219 MMC characterization and stir casting technology is presented in this paper to illustrate its salient features.

Abstract: Mechanical properties of graphene nanoplatelets (GNPs) reinforced aluminum matrix composite fabricated by the semi-solid stir casting method were investigated. Aluminum alloy A356 is selected based on being widely used in automotive and aircraft industries. Recently, graphene has attracted wide attention from a scientific committee due to its outstanding properties. GNPs are an ideal reinforcement for nanocomposites' productions due to their excellent mechanical properties for strength enhancement. In this study, the effect of different weight fraction of GNPs content (0,0.3,0.5,1.0,and 1.5 wt.%) reinforced with A356 aluminum alloy was analysed. A 45-degree carbide impeller performed the stirring process of 500 rpm for 5 minutes. The samples were then characterised by microscopic examination, Vickers hardness, and tensile test Morphology of the fracture surface of the composite were observed using scanning electron microscopy..The microstructure revealed a homogenous distribution of nanoparticles in the matrix alloy. The composite exhibits improved mechanical properties, maximum tensile strength and hardness of 236MPa and 83 HV are obtained respectively. The composite has shown significant enhancement in the tensile and hardness which is 20% times higher than unreinforced A356 alloy. The hardness increased as the weight fractions of GNP in the A356 matrix has increased. However, when the content of GNPs used above 1.0 wt%, its tensile strength is reduced. Meanwhile, the fracture sample is ductile with a fine dimple structure. These findings may contribute to the process field of semi-solid stir casting, particularly on the GNPs addition to aluminium alloy as their primary material.

Abstract: Magnesium-based materials are in superior demand in auto industries due to their improved properties and behavior. However, processing and further post-treatment of this kind of magnesium composite is a stimulating chore because of its characteristics. In particular, heat treatment of this kind of magnesium composites may induce a change in grain structure which in turn alters the properties according to the need. So, this article is chiefly focused on the fabrication of magnesium composites by filling with SiC and graphite. According to the Taguchi array, the composites were developed by altering the reinforcing material content, stirring period, and rate. Four samples were fabricated accordingly by employing the stir casting technique. The fabricated composites were exposed to diverse forms of heat treatment processes such as annealing, normalizing, tempering, and quenching to learn the upshot of the same on its behavior. The surface structure of the dispersions in the developed composites was analyzed using an optical microscope, and the mechanical and physical behavior like strength, density, wear, and tensile tests were done on the developed samples. The morphology and behavior of the fabricated composites were compared and analyzed pre and post-heat treatment. Keywords. Magnesium Hybrid Composites, Stir Casting, Heat Treatment.

Abstract: Aluminum matrix hybrid composites reveal excellent mechanical behavior compared to traditional materials for a wide range of conditions and applications. However, the machining of this kind of composite is a challenging job due to its improved mechanical hardness. The problems faced during the cutting of these composites are increased machining forces, poor surface quality, and increased tool wear. Many types of research are still in progress across the world to overcome these issues by using a variety of inserts and processing constraints. So, this paper is mainly focused on the study of the machinability of aluminum hybrid composites. The composites are synthesized by employing stir casting via varying the filler content, stirring duration, and speed. The fabricated composites are machined using coated and uncoated carbide inserts. Machining forces, surface roughness, and insert wear are assessed to learn the machinability of these materials by varying the machining constraints. Taguchi analysis was employed to assess the effect of the constraints on the retorts. Keywords. Aluminum Hybrid Composites, Stir Casting, Machinability, Taguchi Analysis.