Vol.2, No.

1 ISSN Number (online): 2454-9614

Proceedings of International Conference on Recent Trends in Mechanical Engineering-2K15(NECICRTME-2K15), 20th – 21st November,2015

MECHANICAL PROPERTIES OF STIR

CASTED AL6063-SiC METAL MATRIX
COMPOSITE
M.Amrutha Pavani#1,M.Venkaiah#2,
2
Assistant professor,Mechanical Engineering, Narasaraopeta Engineering College,

Affiliated toJNTU Kakinada University, Narasaraopeta, A.P. INDIA

1
pavaniamrutha226@gmail.com

2
venkat.mandula304@gmail.com

Abstract: Several technical challenges exist with is essential for automotive application. These
the casting technology in achieving a uniform properties are not achievable with light weight
distribution of reinforcement within the matrix, monolithic titanium, magnesium, and aluminum
which affects directly on the properties and alloys. Particulate metal matrix composites have
quality of composite material .In the present study nearly isotropic properties when compared to long
a modest attempt would be made to develop fiber reinforced composite. But the mechanical
Aluminum based silicon carbide particulate behavior of the composite depends on the matrix
MMCs with an objective to develop a conventional material composition, size, and weight fraction of the
low cost method of producing MMCs and to reinforcement and method utilized to manufacture the
obtain homogenous dispersion of ceramic composite. The distribution of the reinforcement
material. To achieve these objectives two step- particles in the matrix alloy is influenced by several
mixing method of stir casting technique has been factors such as rheological behavior of the matrix
proposed and subsequent property analysis has melt, the particle incorporation method, interaction of
been made. Aluminum 6063 T6 and SiC particle particles and the matrix before, during, and after
has been chosen as matrix and reinforcement mixing. Non homogeneous particle distribution is one
material respectively. Experiments are planned of the greatest problems in casting of metal matrix
for conducting varying weight fraction of SiC (in composites. Nai and Gupta [1] reported that the
the steps of 5%) while keeping all other average coefficient of thermal expansion of the high
parameters constant. The results would be SiC end was reduced as compared to that of the low
evaluated by Tests-Hardness, Impact (including SiC end. Hashim et al. [2] reported that the
micro-structure) for this ’development method’. distribution of the reinforcement material in the
The trend of hardness and impact strength with matrix must be uniform and the wettability or
increase in weight percentage of SiC would be bonding between these substances should be
observed and recommendation made for the optimized. However, aluminum alloy with
potential applications accordingly. discontinuous ceramic reinforced MMC is rapidly
replacing conventional materials in various
KEYWORDS: MMC (Metal Matrix Composites), SiC automotive, aerospace, and automobile industries.
(Silicon Carbide), Stir Casting Method Amongst various processing routes stir casting is one
of the promising liquid metallurgy technique utilized
I.INTRODUCTION to fabricate the composites. The process is simple,
Metal Matrix Composite (MMC) is engineered flexible, and applicable for large quantity production.
combination of metal (Matrix) and hard particles The liquid metallurgy technique is the most
(Reinforcement) to tailored properties. Metal Matrix economical of all the available technique in
Composites (MMC’s) have very light weight, high producing of MMC.
strength, and stiffness and exhibit greater resistance
to corrosion, oxidation and wear. Fatigue resistance is
an especially important property of Al-MMC, which

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South Asian Journal of Engineering and Technology (SAJET)

 Vol.2, No.1 ISSN Number (online): 2454-9614

Proceedings of International Conference on Recent Trends in Mechanical Engineering-2K15(NECICRTME-2K15), 20th – 21st November,2015

In this study stir casting is accepted as a particularly

promising route, currently can be practiced
commercially. Its advantages lie in its simplicity,
flexibility and applicability to large quantity
production. It is also attractive because, in principle,
it allows a conventional metal processing route to be
used, and hence minimizes the final cost of the
product. This liquid metallurgy technique is the most Fig.2: Silicon carbide (SiC)
economical of all the available routes for metal
matrix composite production, and allows very large Table I
sized components to be fabricated. The cost of Chemical composition of AL-6063 T6
preparing composites material using a casting method
is about one-third to half that of competitive methods, Chemical Element % Present
and for high volume production, it is projected that
Manganese(Mn) 0.0-0.10
the cost will fall to one-tenth.In general, the
solidification synthesis of metal matrix composites Iron(Fe) 0.0-0.35
involves producing a melt of the selected matrix Magnesium(Mg) 0.45-0.90
material followed by the introduction of a
reinforcement material into the melt. To obtain a Silicon(Si) 0.20-0.60
suitable dispersion the stir casting method is used. Zinc(Zn) 0.0-0.10
The solidification of the melt containing suspended
SiC particles is done under selected conditions to Titanium(Ti) 0.0-0.10
obtain the desired distribution. Chromium(Cr) 0.0-0.10
From the past review, it is found that the
number of research work on wear behaviour of Copper(Cu) 0.0-0.10
MMCs have been published, but only few work Other(Each) 0.0-0.05
related to the influence of weight fraction on
Others(Total) 0.0-0.15
mechanical properties like hardness, impact strength,
percentage of elongation etc., have been reported. In Aluminium(Al) Balance
this study, different weight fractions of Silicon
Carbide particulates are added with aluminium 2.2. Method
matrix to fabricate the Al/SiC metal matrix
composites. Different samples have been fabricated 2.2.1. Stir casting
by melt-stirring casting and their microstructure,
hardness and impact strength are studied.

II.MATERIALS AND FABRICATED

METHOD
2.1. Materials

The base material for the investigation is aluminium

alloy (6063), as-received in the form of round bar as
shown in Fig.1 with a chemical composition
(determined by the use of a spectrometric analyzer)
as presented in Table I. Silicon carbide (SiC) is used
as reinforcement. 1% by weight of pure magnesium
powder is used as wetting agent.Fig.2 shows the
Silicon carbide powder.
Fig 3:(a), (b) Induction resistance furnaces with
temperature regulator cum indicator and (c) Melt-
stirring setup utilized for casting of composites

Stir casting process starts with placing empty crucible

in the muffle. At first heater temperature is set to
500°C and then it is gradually increased up to 900°C.
Fig.1: Aluminum 6063-T6 material High temperature of the muffle helps to melt

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 Vol.2, No.1 ISSN Number (online): 2454-9614

Proceedings of International Conference on Recent Trends in Mechanical Engineering-2K15(NECICRTME-2K15), 20th – 21st November,2015

aluminium alloy quickly, reduces oxidation level,

enhance the wettability of the reinforcement particles
in the matrix metal. Aluminium alloy Al6063 is used
as Matrix material. Required quantity of aluminium
alloy is cut from the raw material which is in the
form of round bar. Aluminium alloy is cleaned to
remove dust particles, weighed in the crucible for
melting as shown in Fig 3.During melting nitrogen
gas is used as inert gas to create the inert atmosphere
around the molten matrix. Aluminium 6063, silicon
carbide (SiC) and graphite are used as reinforcement. Fig 4: Pattern making for test specimen
1% by weight of pure magnesium powder is used as
wetting agent. At a time total 700 gram of molten
composite was processed in the crucible. Required
quantities of reinforcement powder and magnesium
powder are weighed on the weighing machine. Then
it is thoroughly mixed with each other with the help
of blending machine for 24 hour. This mixture is kept
ready 1 day before the test has to carry out. Prior to
conducting the test this mixture is kept for heating in
another heater.

Reinforcements are heated for half hour and

Fig 5:Pouring of molten metal into mould
at temperature of 500°C. When matrix was in the
fully molten condition, Stirring is started after 2 III.RESULTS AND DISCUSSION
minutes. Stirrer rpm is gradually increased from 0 to
300 RPM with the help of speed controller. 3.1 Microstructure
Temperature of the heater is set to 630°C which is
below the melting temperature of the matrix. A Metallographic samples were sectioned from the
uniform semisolid stage of the molten matrix was cylindrical cast bars. A 0.5 % HF solution was used
achieved by stirring it at 630°C.Pouring of preheated to etch the samples wherever required. To see the
reinforcements at the semisolid stage of the matrix difference in distribution of SiC particles in the
enhance the wetability of the reinforcement, reduces aluminum matrix, microstructure of samples were
the particle settling at the bottom of the crucible. developed on Inverted type Metallurgical Microscope
Reinforcements are poured manually with the help of (Make: Nikon, Range-X50 to X1500). Fig4 show
conical hopper. The flow rate of reinforcements Micrograph of Al/Sic-MMC’s samples for different
measured was 0.5 gram per second. Dispersion time weight fraction (5%, 10%, 15%) of SiC particles.
was taken as 5 minutes. After stirring 5 minutes at Optical micrographs showed reasonably uniform
semisolid stage slurry was reheated and hold at a distribution of SiC particles. In this Al matrix SiC
temperature 900°C to make sure slurry was fully particles are clearly labeled.
liquid. Stirrer RPM was then gradually lowered to the
zero. The stir casting apparatus is manually kept side
and then molten composite slurry is poured in the
metallic mould as shown in Fig 4. Mould is preheated
at temperature 500°C before pouring of the molten
slurry in the mould. This makes sure that slurry is in
molten condition throughout the pouring.

While pouring the slurry in the mould the Fig 6(a): Al6063-SiC 5% Fig 6(b):Al6063-SiC 10%
flow of the slurry is kept uniform to avoid trapping of
gas. Then it is quick quenched with the help of air to
reduce the settling time of the particles in the matrix
as shown in Fig 5.

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 Vol.2, No.1 ISSN Number (online): 2454-9614

Proceedings of International Conference on Recent Trends in Mechanical Engineering-2K15(NECICRTME-2K15), 20th – 21st November,2015

Fig 6(c):Al6063-SiC15%

Micrograph of Al/Sic-MMC’s samples for different

Fig 7: Hardness testing machine
weight fraction (5%, 10%, 15%) of SiC particles

3.2 Hardness

Hardness is another measure of the ability of a

material to be deformed. There are many different
tests of hardness measurement.

3.2.1 BHN

The brinell test consists of indenting the surface of

the metal by a hardened steel ball under a load. The
load is applied by lever system and the specimen is Fig 8(a): Al - 5% of SiC hardness test
placed on stage with its ground face upwards. The
height of the specimen can be raised by hand wheel
so that the specimen is brought into contact with the
indenter which is forced into the specimen by the
specified load.

Formula for Brinell hardness

B.H.N = --(1) where

√

Fig8(b): Al - 10% of SiChardness test specimen

P= load applied (kgf)

D= diameter of indenter (mm)

d = diameter of indentation (mm)

3.2.2 Rockwell

In the Rockwell hardness test, the hardness is

determined by the depth of penetration of a indenter,
Fig 8(c): Al - 15% of SiChardness test specimen
rather than by surface area of the indentation. The
specimen placed on stage is brought into contact with TableII
the penetrator , the penetrator is then slowly forced
into the specimens surface by weights acting through Brinell& Rockwell hardness results in BHN & RCN
a system of levers.
% of sicp 5% 10% 15%
Model RAB from SEU Pvt. Ltd type BRINELL 86 96 97.5
equipment was used tomeasure the two types of ROCKWELL 16 26 27.5
hardness at load=150kgf, ball=2.5mm. Yield &
ultimate strength values were shown in tabular form
in TableIIand test specimens of different Sic
compositions are also shown in Fig8 (a,b,c) and
graphically in Fig 9.

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Proceedings of International Conference on Recent Trends in Mechanical Engineering-2K15(NECICRTME-2K15), 20th – 21st November,2015

150

100
Rockwell
50 Brinell

0
5% 10% 15%

Fig 9: Brinell& Rockwell Vs Wt % OfSiC

Fig 11:Impact test specimens
From the above results, we can observe that the
hardness of composite material increasing by varying Impactis a high force or shock applied over a short
the amount % of sic. time period when two or more bodies collide. Such a
force or acceleration usually has a greater effect than
3.3 Impact strength a lower force applied over a proportionally longer
time period of time. The effect depends critically on
This is also known as the Charpy V-notch test is a the relative velocity of the bodies to one another. The
standardized high strain-rate test which determines test results are shown in tabular form in TableIII and
the amount of energy absorbed by a material during graphically inFig 12.
fracture. The Charpy testing machine is available in
variety of sizes. A usual size is one having a capacity Table III
of about 30 KJ for testing metals. A notched
specimen is mounted as simple supported beam and Impact test results in J
heavy pendulum is allowed to strike the specimen
from a fixed height % of SiC 5% 10% 15%
Charpy 7.4 11 18

wt % of sicp
Impact strength N-m

20
15
10 wt % of
sic
5
0
5% 10% 15%
Fig 10: Impact testing machine
Fig 12: Impact strength Vs Wt % of SiC
The charpy testing machine with following
specifications Maximum capacity: 30J,Minimum From the above results, we can observe that the
capacity: 2J,Distance between supports: composition of 15% sichas the highimpact strength
40mm±0.2mm is used for impact test. Impact test comparing to the compositions of about 5%SiC,
specimens at different Sic compositions are as shown 10%SiC
in Fig11.
IV.CONCLUSION

The composition of aluminum with the

increased weight fraction of silicon carbide increases
the mechanical properties. The mechanical properties
like impact and hardness attained maximum at 15%
of SiC. At the composition of Al 6063-SiC from 5%

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 Vol.2, No.1 ISSN Number (online): 2454-9614

Proceedings of International Conference on Recent Trends in Mechanical Engineering-2K15(NECICRTME-2K15), 20th – 21st November,2015

to 10% there is a drastic change in mechanical

properties and at 10% to 15% there is small vary in
mechanical properties. Homogenous dispersion of
SiC particles in the Al 6063-SiC particle Composite
shows an increasing trend in the samples prepared by
applying stirring process, with manual stirring and
with 2-Step method of stir casting technique
respectively.Due to the extensive applications of
aluminum 6063/SiC metal matrix composites it is
used in manufacturing industries, structural designs,
automotive parts (hydro dynamic tube chassis)

REFERENCES

[1] Nai, S.M.L. and Gupta, M. ,”Synthesis and

Characterization of Free Standing, Bulk Al/Sicp
Functionally Gradient Materials: Effects of Different
Stirrer Geometries,” Material Research Bulletin, 38:
1573-1589. 2003.
[2] Hashim, J., Looney, L. and Hashmi, M.S.J.,
“Particle Distribution in Metal Matrix Composites,”
Part-I, Journal of Materials Processing Technology,
123: 251-257. 2002.

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