Sir C R Reddy College of Engineering Department of Mechanical Engineering

A Project Report on
EXPERIMENTAL STUDIES ON AA5083 B4C METAL MATRIX
COMPOSITES PRODUCED BY STIRCASTING

A project report submitted

in partial fulfilment of the requirements for the award of the degree of
BACHELOR OF TECHNOLOGY

IN

MECHANICAL ENGINEERING
SUBMITTED BY
M. NIVEK 21B85A0323
A. GANESH BABU 20B81A0301
G. NARAYANA RAO
20B81A0318 P. CHAITANYA
20B81A0370 G. MANOJ KUMAR NAIK
20B81A0320

Under the esteemed guidance of

Dr. K. VENKATESWARA RAO Ph.D
Professor

DEPARTMENT OF MECHANICAL ENGINEERING

SIR C R REDDY COLLEGE OF ENGINEERING
(Approved by AICTE, Accredited by NBA, Affiliated to JNTU, Kakinada
Vatluru, Eluru – 534007, A.P, INDIA
(2023-2024)
 Sir C R Reddy College of Engineering Department of Mechanical Engineering

SIR C R REDDY COLLEGE OF ENGINEERING

(Approved by AICTE, Accredited by NBA, Affiliated to JNTUK, Kakinada)
Vatluru, Eluru -534007, Ap., INDIA

DEPARTMENT OF MECHANICAL ENGINEERING

BONAFIDE CERTIFICATE
This is to certify that project work entitled “Experimental Studies on AA5083- B4C
metal matrix composites produced by stir casting” is being submitted by

[Link] 21B85A0323
[Link] BABU
20B81A0301 [Link] RAO
20B81A0318
[Link] 20B81A0370
[Link] KUMAR NAIK 20B81A0320

During the academic year 2023-2024 as a partial fulfilment of the academic requirement for
the award of “Bachelor of Technology” degree in “MECHANICAL ENGINEERING”
from JNTU, Kakinada

Dr. K. Venkateswara rao Ph. D Dr.K. Rambabu Ph. D

Project Guide Head of the Department

EXTERNAL EXAMINAR
 Sir C R Reddy College of Engineering Department of Mechanical Engineering

DECLARATION

We declare that the Project entitled “Investigations on B4C particle-reinforced

5083Aluminum Alloy composites” submitted by us for the degree of bachelor of
Technology in the Department of Mechanical Engineering, Sir C.R.R College of
Engineering, Eluru.

The reported data is based on the project work done entirely by us and no part of this
thesis is copied from the books / journals/ internet and where ever referred, the same has been
duly acknowledged in the report.

M. NIVEK 21B85A0323

A. GANESH BABU 20B81A0301

G. NARAYANA RAO 20B81A0318

P. CHAITANYA 20B81A0370

G.M. KUMAR NAIK 20B81A0320

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 Sir C R Reddy College of Engineering Department of Mechanical Engineering

ACKNOWLEDGEMENT

We express our most sincere and grateful acknowledgement to SIR C R REDDY

COLLEGE OF ENGINEERING for giving us the opportunity to fulfil our aspiration and
become engineers. We are thankful to our Principal, Dr. K. VENKATESWARA RAO, for
providing us with the necessary facilities to carry out this project and his guidance in the
efficient completion of the project work.

We wish to express our deep gratitude to our beloved Head of the Department Dr. K.
RAMBABU, for his constant encouragement throughout the project. We express our deep
gratitude to Dr. K. VENKATESWARA RAO for his valuable guidance and unstinting
encouragement enabling us to accomplish our project successfully in time.

Last but not least we also express our sincere thanks to all the faculty members of the
department for their help and cooperation in completing the project.

M. NIVEK 21B85A0323

A. GANESH BABU 20B81A0301

G. NARAYANA RAO 20B81A0318

P. CHAITANYA 20B81A0370

G.M. KUMAR NAIK 20B81A0320

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ABSTRACT

Due to very good properties such as high modulus, high strength, low density,
excellent wear resistance and good neutron absorption, the boron carbide (B4C) particle
reinforced aluminium (Al) matrix composites have extensively been used in the aerospace,
weaponry, transportation and neutron shielding fields. It is understood from the literature that
achieving uniform distribution of carbide particles in the matrix is a difficult task. In the
present work, AA5083- B4C metal matrix composite was fabricated using stir casting process.
Microstructures were examined using optical microscope to understand the distribution of
boron carbide particles in the aluminium matrix. Mechanical properties of the composite was
evaluated using hardness test and tensile test.

Keywords: AA5083-B4C metal matrix composite, Stir casting, Mechanical properties, Light
microscopy

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TABLE OF CONTENTS

TITLE
CERTIFICATE
DECLARATION i
ACKNOWLEDGEMENT ii
ABSTRACT iii
TABLE
TABLE OF OFCONTENTS
CONTENTS PAGE iv
NO
LIST
CHAPTER OF TABLES
NO: 01 1 v
LIST OF FIGURES
[Link] 1 vi
LIST OF 1.1 Composite materials 1
TABLES 1.2 Importance of MMCS 2
1.3 Fabrication of MMCS 3
1.4 Modified stir casting of MMCS
TABL PAGES 7
DESCRIPTION
E NO
1.5 Aluminium metal matrix composties NO 8
1 Properties of AA5083 10
CHAPTER NO: 02 20
2
[Link] review Base Metal AA5083 Tensile Test Values 11 20
2.1 Introduction 20
3 23
2.2 Aluminium metal Chemical Composition of Aluminium Alloy 5083
matrix composties 21

CHAPTER NO: 03 23
[Link] work 23
3.1 Fabirication of aa5083-b4c MMCS 26
4 Properties of boron carbide 23
3.2 Microstructural examination 30
5
3.3 Hardness tests Hardness values of AA5083-B4C metal matrix composite 33 31
3.4 Tensile tests
6 34
Tensile properties of AA5083-2%B4C metal matrix
composite
CHAPTER NO: 04 32
[Link] & Disscussion 32
4.1 Microstructures 33
4.2 Hardness tests 34
4.3 Tensile tests
7 Tensile values of AA5083-B4C metal matrix composite 38 35

CHAPTER NO: 05 39
5. CONCLUSIONS 39

CHAPTER NO: 06 40
[Link] 40

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LIST OF FIGURES

TABLE PAGE
DESCRIPTION
NO S NO

1 Schematic Operational Sequences during melt stirring (Kainer et al. 2006) 5

2 Modified Stir Casting Equipment (Hashim 2001) 8

3 Microstructure formation in the inter 12

Photograph showing the formation of tribolayer on the worn surface of

4 AMC (disc) slid against brake pad(pin).
15

Fan exit guide vanes (FEGV) component made up of PAMCs

5 used in P and W gas turbine engine.
16

6 PAMC rotating blade sleeves used in helicopter. 16

7 Near net shape PAMC’s flights control hydraulic manifold 17

8 Recreational products made of PAMCs 17

Continuous fibre-reinforced AMCs as struts used in main

9 17
cargo bay of space shuttle.

10 Alumina fibre-reinforced AMC flywheels. 18

11 Alumina fibre-reinforced AMC retainer ring used in high-speed motors. 18

12 Alumina fibre-reinforced AMC callipers 19

13 Bottom line pouring type stir casting setup 24

14 AA5083 plates in as received condition 24

15 Boron carbide powder 25

16 Mild steel rectangular die 25

17 AA5083 - B4C MMC plate fabricated by stir casting process 25

18 Polishing Machine 27

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19 Cleaning and etching agents 28

20 Optical Microscope 29

21 Diagram showing the principle in simple microscope 30

22 Vickers micro hardness tester 30

23 Samples for tensile testing 31

24 Universal testing machine 32

Microstructure of AA5083-B4C metal matrix

25 32
composite in 100x magnification

Microstructure of AA5083-B4C metal matrix

26 33
composite in 200x magnification

27 Tensile tested specimens showing fractures 34

LIST OF GRAPHS

TABLE NO DESCRIPTION PAGES NO

1 Tensile Test graph -1 35
2 Tensile Test graph -2 36
3 Tensile Test graph -3 37
4 Tensile Test graph -4 38

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CHAPTER-1

INTRODUCTION
1.1 COMPOSITE MATERILAS

Composite materials are engineered materials made from two or more constituent materials
with significantly different physical and chemical properties in such a way that the resulting
material has certain desired or improved properties. One constituent is called the reinforcing
phase and the one in which is embedded called the matrix. The reinforcing phase material
may be in the form of fibers, flask or particles. The matrix materials are continuous. By
combining these two materials in a specific proportion, it is possible to design a composite
with desired mechanical properties and functional characteristics. Monolithic metals and their
alloys cannot always meet the demands of today’s advanced technologies. Only by
combining several materials can one meet the performance requirements.

1.1.1 Classification

Composite materials are commonly classified into following two distinct levels

[Link] Classification based on matrix constituent

[Link] Classification based on reinforcement form

[Link] Classification based on matrix constituent

1. Metal Matrix Composites (MMC)

Metal matrix composites are composed of a metallic matrix (aluminum, magnesium,

iron, cobalt, copper) and a dispersed ceramic (oxides, carbides) or metallic (lead, tungsten,
molybdenum) phase.

2. Ceramic Matrix Composites (CMC)

Ceramic matrix composites are composed of a ceramic matrix and embedded fibers of
other ceramic material (dispersed phase).

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3. Polymer Matrix Composites (PMC)

Polymer matrix composites are composed of a matrix from thermoset (Unsaturated

polyesters, Epoxy) or thermoplastic (PVC, Nylon, Polystyrene) and embedded glass, carbon,
steel or Kevlar fibers (Dispersed phase).

[Link] Classification based on reinforcement form

1. Particulate Composites

Particulate composite consists of a matrix reinforced by a dispersed phase in the form

of particles.

2. Fibrous composites

Fibrous reinforced composites consist of a matrix reinforced by a dispersed phase in

the form of continuous of discontinuous fibers.

1.2 IMPORTANCE OF MMCs

Metal matrix composites consist of a metal or an alloy as the continuous matrix and a
reinforcement that can be particle, short fibre or whisker or continuous fiber. Particle or
discontinuously reinforced MMCs have become very popular because they are less expensive
than continuous fibre reinforced composites and they have relatively isotropic properties
compared to fibre reinforced composites. For many researchers the term MMC is often
equated with the term light metal matrix composites. Substantial progress in the development
of light metal matrix composites has been achieved in recent decades, so that they could be
introduced into the most important applications.

Aluminum alloys, because of their low density and excellent toughness, strength and
resistance to corrosion find important applications in the aerospace field. There has been
increasing interest in producing discontinuously reinforced aluminum MMCs for aerospace
applications and commercial applications. Particle-reinforced MMCs could be manufactured
at much lower cost. However, the improvement of properties in such MMCs happens to be
only moderate.

Aluminum Matrix Composites (AMCs) can be reinforced with various oxides,

carbides, nitrides and borides in particulate, whisker or fibre from such as SiC, Al2O3, TiC,
B4C etc.
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But the strength of AMCs can be improved by combining these materials carefully by
controlling the relative amount and distribution of the ingredients of a composite as well as
the processing conditions. The variety of manufacturing process for MMCs such as powder
metallurgy route, stir casting and vapor deposing are available. The stir casting is generally
accepted as it is a low cost casting technique.

The MMC chosen for the present study is of the particulate type, Boron Carbide (B4C)
reinforced aluminum alloy (5083) matrix. B4C has lower density (2.52 g/cm3) and higher
hardness (2900 VHN) relative to SiC and Al2O3. Al-B4C metal matrix composites have been
used as an excellent neutron absorbing material in the nuclear industry. This can be attributed
to the advantages of light weight, superior thermal conductivity, good corrosion resistance
and the unique capability of capturing neutrons in spent fuel pools at nuclear power plants.
The selected AA5083-B4C MMC is processed by modified stir casting method.

1.3 FABRICATION OF MMCs

MMCs can be produced by different techniques. The selection of suitable process

depends on the desired kind, quantity and distribution of reinforcement components, the
matrix alloy and the application. The processing techniques used to manufacture particulate
reinforced MMCs can be grouped as follows (Kaczmar et al 2000).

1.3.1. Solid state process

[Link]. Powder Metallurgy

[Link]. Diffusion Bonding

1.3.2. Liquid state Process

[Link]. Compo-casting or melt stirring

[Link]. Gas Pressure infiltration

[Link]. Squeeze casting or pressure casting

[Link]. Deposition Technique

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1.3.1 Solid State Process

[Link]. Powder Metallurgy

Powder blending and consolidation is a commonly used method for the preparation of
discontinuously reinforced MMCs. In this process, powder of the metallic matrix and
reinforcement are first blended and fed into a mold of the desired shape. Blending can be
carried out dry or in liquid suspension. Pressure is then applied to further compact the powder
(cold pressing). The compact is then heated to a temperature, which is below the melting
point but high enough to develop significant solid state diffusion (sintering). After blending,
the mixture can also be consolidated directly by Hot Pressing or Hot Isostatic Pressing (HIP)
to obtain high density. The consolidated composite is then available for secondary
processing.

This method is popular because it is reliable compared with other alternative methods,
but it has also some demerits. The blending step is a time consuming, expensive and
potentially dangerous operation. In addition, it is difficult to achieve an even distribution of
particulate throughout the product and the use of powders requires a high level of cleanliness,
otherwise inclusion will be incorporated into the product with a deleterious effect on fracture
toughness, fatigue life, etc.

[Link]. Diffusion Bonding

This method is normally used to manufacture fibre reinforced MMC with sheets or
foils of matrix material. Here primarily the metal or metal alloys in the form of sheets and
reinforcement material in the form of fibre are chemically surface treated for the effective
inter diffusion. Then fibres are placed on the metal foil in pre-determined orientation and
bonding takes place by press forming directly. However, sometimes the fibres are coated by
plasma spraying or ion plating for enhancing the bonding strength before diffusion bonding.
After bonding, secondary machining work is carried out. The applied pressure and
temperature as well as their durations for diffusion bonding to develop, vary with the
composite systems. However, this is the most expensive method of fabricating MMC
materials.

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1.3.2. Liquid State Process

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The production of MMCs by liquid state process has greater technical importance at present
than that produced by powder metallurgy. It has more advantages such as highly effective
and economic method compared with other processing of MMCs.

[Link]. Compo-Casting or Melt Stirring

Both the terms compo-casting and melt stirring are used for stirring particles into a
light alloy melt. Figure 2.1 shows the schematic operational sequence of this procedure. The
particles are often tends to form agglomerates, which can be only dissolved by intense
stirring. However, here gas access into the melt must be absolutely avoided, since this could
lead to unwanted porosities or reactions. Careful attention must be paid to the dispersion of
the reinforcement components, so that the reactivity of the components used is coordinated
with the temperature of the melt and the duration of stirring, since reactions with the melt can
lead to the dislocation of the reinforcement components. Because of the lower surface to
volume of spherical particles, reactivity is usually less critical with stirring particles
reinforcement than with fibres. The melt can be cast directly or processed with alternative
procedures such as squeeze casting or thixo casting.

Figure1.1 Schematic Operational Sequences during melt stirring (Kainer et al. 2006)

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[Link]. Gas pressure infiltration

In gas pressure infiltration, the melting of the matrix and the infiltration takes place in
a suitable pressure vessel. There are two procedure variants of gas pressure infiltration: in the
first variant the warmed up preform is dipped into the melt and then the gas pressure is
applied to the surface of the melt, leading to infiltration. The infiltration pressure can thereby
be coordinated with the wettability of the preforms, which depends, among other things, on
the volume percentage of the reinforcement. The second variant of the gas pressure
infiltration procedure reverses the order: the molten bath is pressed to the preform by the
applied gas pressure using a standpipe and thereupon infiltrates the bath. The advantage of
this procedure is that there is no development of pores when completely dense parts are
present. Since the reaction time is relatively short with these procedures, more reactive
materials can be used than with the compo-casting. In gas pressure infiltration, the response
times are clearly longer than in squeeze casting, so that the materials must be carefully
selected and coordinated, in order to be able to produce the approximate composite material
for the appropriate requirements.

[Link]. Squeeze casting or pressure casting

Squeeze casting or pressure casting is the most common manufacturing variants for
MMCs (Vijayaram et al. 2006). After a slow mold filling the melt solidifies under very high
pressure, which leads to a fine-grained structure. In comparison with die-cast parts, the
squeeze-cast parts do not contain a gas inclusion, which permits the thermal treatment of the
produced parts. One can differentiate between direct and indirect squeeze casting. With direct
squeeze casting the pressure for the infiltration of the prefabricated preforms is applied
directly to the melt. The die is thereby a part of the mold, which simplifies the structure of the
tools substantially. However, with the direct procedure there is disadvantage in that the
volume of the melt must be determined exactly, since no gate is present and thus the quantity
of the melt determines the size of the cast construction unit. A further disadvantage is the
appearance of oxidation products, formed in the cast part during dosage. In contrast, in
indirect squeeze casting, where the melt is pressed into the form via a gate system, the
residues will remain in this gate. The flow rate of the melt through a gate is, due to its larger
diameter, substantially less than with die casting.

Both pressure casting processes make the production of composite materials possible,
as prefabricated fibre or particle preforms infiltrated with melt and solidification under
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pressure. A two-stage process is often used. In the first stage, the melt is pressed into the form

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at low pressure and then at high pressure for the solidification phase. This prevents damage to
the preform by too fast infiltration. The squeeze casting permits the use of relatively reactive
materials, since the duration of the infiltration and thus the response time, are relatively short.
A further advantage is the possibility to manufacture complex shapes and to provide partial
reinforcement, to strengthen those areas which are exposed to a higher stress during the
service (Kainer et al. 2006)

[Link]. Deposition Technique

Prominent among the vapor deposition techniques for the fabrication of MMCs is
electron beam/physical vapor deposition (EB/PVD). This process involves continuous
passage of fibre through a region of high partial vapor pressure of the metal to be deposited,
where condensation takes place so as to produce a relatively thick coating on the fibre.
Composite fabrication is usually completed by assembling the coated fibres into a bundle or
array consolidating in a hot press or by HIP operation.

The spray deposition techniques employed fall into two distinct classes, depending on
whether the droplet stream is produced from the molten bat, (Osprey process), or by
continuous feeding of cold metal into a zone of rapid heat injection ( thermal spray
processes). If the reinforcement is particulate, it can be fed into the spray. The matrix metal is
melted in a crucible kept in a furnace. The molten metal is passes through a downward pipe.
A predetermined quantity of ceramic particles is injected into the downstream of molten
metal. The transfer mechanism rotates the downstream pipe which creates a stirring and
mixing action. Then, the composite melt will be poured into a die or deposited on a metal
substrate. The solidified composite can be subjected to other secondary processes.

1.4 MODIFIED STIR CASTING OF MMCs

In a normal practice of stir casting of MMC, it involves adding ceramic particles into
the melt in the crucible which is kept inside the furnace. Stirring is carried out vigorously to
form a vortex where the reinforcing particles are introduced through the side of the vortex.
The melt is transferred to permanent mold after stirring. Modified stir casting involves
directly transferring the melt into a permanent mold with a bottom pouring arrangement
attached to the furnace.

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Hashim et al. 2001 used a modified stir casting method to produce an Al/SiCp MMC.
A specially designed rig with bottom pouring mechanism shown in Figure 1.2 was used to
fabricate the composite. All substance (Al as matrix, SiC as particulates and Mg as wetting
agent) were placed in a graphite crucible and heated in an inert atmosphere until the matrix
alloy is melted and then followed by a two-step stirring action before pouring into a mold.
The stirring action of the slurry produces cast MMC with smaller grain sizes which
strengthen the alloy matrix.

Figure 1.2 Modified Stir Casting Equipment (Hashim 2001)

1.5 Aluminum Metal Matrix Composites (Al-MMCs):

For a long period of time, aluminum alloys were widely used as the matrix
materials in MMCs, both in research and development and in industrial applications.
This is mainly due to its low density and the capability to be strengthened by
precipitation, the good corrosion resistance, high thermal electrical conductivity and
the high damping capacity (Ye et al. 2008). Moreover, they are cheap when compared
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Sir C R Reddy College of Engineering Department of Mechanical Engineering

with other low-density alloys such as Mg or Ti (Torralba et al. 2003). Their excellent
behavior, from different points of view (strength, ductility, corrosion), is very well
known and can be modified in order to satisfy different applications.
Aluminum Matrix Composites (AMCs) have been widely studied since the
1920s and are now used in sporting goods, electronic packaging, armors and
automotive industries. They offer a large variety of mechanical properties
depending on the chemical composition of the Al-matrix. They are usually reinforced
by Al2O3 and SiC.
In a study by Ma et al. (1999), pure aluminum matrix composites reinforced
with 1 and 5% vol. Si-N-C particles were fabricated by a powder metallurgy process.
The tensile strength of the 1% vol. Si-N-C/Al ect a higher value than those of the
monolithic aluminum due to significant reinforcing effect. But 5% vol. Si-N-C/Al
composites had reduced tensile strength due to agglomeration. According to Orowan
bowing mechanism, the yield strength of the particulate reinforced composites was
inversely proportional to the mean inter particle distance. The agglomeration of the
nano metric particles could lead to deterioration in mechanical properties of
composites. It could be concluded that if the particles were well dispersed, it would be
expected to have improved yield strength.
Fogagnolo et al (2004) reported that the incorporation of the ZrB2 particles
into the AA6061 alloy produced a small increase in the hardness, but decrease in the
UTS when conventional powder metallurgy method was employed. It could be
improved by adopting the mechanical alloying, which broke reinforcement particle
clusters, eliminated the most of the cracks present in the surface of reinforcement
particles, decreased its size and improved its distribution and mechanical property.

Here are some key properties of Al5083:

Al5083 is an aluminum alloy known for its excellent corrosion resistance, good
weldability, and moderate strength.

Corrosion Resistance: Al5083 exhibits exceptional resistance to corrosion,

particularly in marine environments. This makes it suitable for applications exposed
to seawater or other corrosive substances.

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Sir C R Reddy College of Engineering Department of Mechanical Engineering

Weldability: It is easily wieldable using various methods, including arc welding, gas
welding, and resistance welding. This makes it versatile for fabrication into different
shapes and structures.

Moderate Strength: Al5083 offers moderate strength, with typical tensile strength
ranging from 320 to 350 MPa and yield strength ranging from 240 to 280 MPa.
While not as strong as some other aluminum alloys, it is still suitable for many
structural applications.

Formability: Al5083 can be easily formed and machined, allowing for the creation
of complex shapes and components. It can also be extruded and forged into various
forms.

Heat Treatability: The alloy can be heat-treated to improve its mechanical

properties, such as strength and hardness, to meet specific application requirements.

Non-heat Treatable: While it can be strengthened through cold working, Al5083 is

considered non-heat treatable, meaning its properties are primarily determined by its
composition and processing

Applications: Due to its combination of corrosion resistance, weldability, and

moderate strength, Al5083 is commonly used in marine and offshore structures,
transportation components (such as shipbuilding, automotive parts, and rail cars),
pressure vessels, and architectural applications.

Overall, Al5083 is valued for its versatility, corrosion resistance, and ease of
fabrication, making it a popular choice for a wide range of applications across
various industries.

TABLE NO :1 Properties of AA5083:

Ultimate tensile strength 317 MPa

Tensile Yield Strength 228 MPa
Hardness (Vickers) 96
Melting point 591 – 638℃
Density 2650 kg/ m3

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TABLE NO: 1.1Base Metal AA5083 Tensile Test Values:

Yield Strength (0.2% proof) Tensile Strength % Elongation

Sample
(MPa) (MPa)
AA5083 Pure 110 270 10

Base Metal AA5083 Hardness Test Values:

The Vickers Hardness Value of AA5083 is 77.

Effect of ceramic reinforcements on the behaviour of aluminium
matrix in AMCs
Presence of relatively large (more than 10%) volume fraction of ceramic reinforcement
(whisker/particle/short fibre/continuous fibre) profoundly affect the behaviour of aluminium
matrix in aluminium matrix composites during manufacturing, heat treatment and their
subsequent use in service. These changes include both intrinsic and extrinsic ones.

Intrinsic effects
Intrinsic effects include microstructural changes, heat treatment characteristics and thermal
stresses. These changes significantly alter and expand the physical, mechanical and
tribological property limits of aluminium alloys. Salient features of intrinsic effects caused
by ceramic reinforcements are summarised below.

Solidification structure of AMCs: Presence of ceramic reinforcement can alter the

solidification behaviour of aluminium alloys in several alloys. Ceramic reinforcement can
serve as a barrier to diffusion of heat and solute, catalyse the heterogeneous nucleation of
phases crystallising from the melt, restrict fluid convection, and induce morphological
instabilities in the solid–liquid interface. Figure 2 shows the influence of interfibre spacing in
an

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(b)
(c) (d)

(a)
DAS
case I
case II
case

DAS III
Figure2. Microstructure formation in the inter- fibreregions
Interfibre ofanAl–4 5 Cu–alumina fibre composite. The primaryphase
spacing morphologyandthedistributionofsecondphasesdepend
upontherelativemagnitudesofsecondaryarmspacing
(DAS)[Link]
Local solidification (b) through(d) correspondtothreecasesshownin
time
(a).

alumina fibre (FP)-reinforced AlCu composite on the segregation of solute during

solidification. When the secondary dendrite arm spacing (DAS) is smaller than the inter fibre
spacing (case 1, see figure 2a), the fibre’s do not influence the matrix solidification
behaviour and normal coring patterns are observed (see figure 2b). When the scale of the
matrix microstructure is comparable to the inter fibre spacing (see figure 2c), the secondary
phases (e.g. eutectic) are deposited onto the fibre surface. Microprobe scans across the
interfibre regions of the matrix confirm that solute content is highest at fibre surface and
smallest in the centre of interfibre regions. Lastly, when the interfibre spacing is smaller than
the secondary dendrite arm spacing (which can be controlled by the rate of external heat
extraction), the segregation is reduced and less secondary phases are precipitated from the
matrix (see figure 2d). Under these conditions, solute content of matrix is higher than that in
unreinforced matrix.
It is well known that heterogeneous nucleation of primary phase crystals on the surface of
some ceramic reinforcement reduces the matrix grain size. However, often grain sizes far in
excess of the fibre or particle diameter are observed in cast aluminium matrix composites.
Matrix grain size larger than reinforcement size indicates that fibres do not nucleate the
primary phase during solidification. The grain size of Al–4·5Cu is not affected by SiC or
alumina fibres. However, reaction sintered porous TiC reinforcement reduces the matrix
grain size by several orders of magnitude. Similarly, heterogeneous nucleation of primary
phases has been observed on alumina dispersions in Al–Cu–Ti alloy.

Effect of ceramic reinforcement on the age-hardening characteristics of aluminium alloys:

The age hardening characteristics of aluminium alloys are generally modified by the
introduction of ceramic reinforcement. These modifications depend on the matrix

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composition, the size, morphology and volume fraction of the reinforcement and the method

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of composite production. Some of the prominent modifications documented are detailed

below.

(i) Composites based on Al–Cu–Mg alloy matrices exhibit accelerated ageing compared
tothe unreinforced alloys.
(ii) The peak temperature of S1 precipitation was found to decrease with increasing volume
fraction.
(iii) Room temperature ageing behaviour of PM processed Al–Cu–SiCp composites
is significantly different compared to that of cast and extruded composites.
(iv) The age hardening characteristics of the 6061 Al alloy are considerably altered by
thepresence of fibres. Fibre array inhibits natural ageing.
(v) Presence of TiC particle retard ageing kinetics of 7075 Al alloys.

Much of these changes in the age hardening characteristics of aluminium alloys due to the
incorporation of ceramic reinforcement is attributed partly due to enhanced dislocation
density. Largemismatchintheexpansioncoefficientofceramicreinforcementandaluminium
alloy matrix is responsible for increased density of dislocations. The increased density and
consequent modifications in the age hardening response of aluminium alloys is an important
intrinsic effect of ceramic reinforcements.

Thermalresidualstresses: Aluminium matrix composites often experience fabrication

temperature in excess of 500◦C, and large thermal residual stresses are included on cooling.
Magnitude of thermal residual stresses developed is related to many variables including the
type of reinforcement, volume fraction, diameter and aspect ratio. For example, thermal
residual stresses (tensile) of more than 200 MPa are present in the matrix of Al-30 vol%
SiCp composites. Mechanical behaviour of AMCs are profoundly effected by thermal
residual stresses. Presence of residual stresses caused by ceramic reinforcement results a
symmetrical yielding, and also affect fatigue and creep behaviour of AMCs.

Extrinsic effects of ceramic reinforcement

Incorporation of ceramic reinforcement in Al alloys leads to significant improvement in
the sliding wear resistance of Al MMCs as measured by the pin-on-disc set up against a
hardened steel disc and this is attributed to the intrinsic effect of SiCp. In recent years
extrinsic effect of SiC reinforcement in Al MMCs has been beneficially utilised in Al MMC
brake disc/ brake pad tribocouple. When AMC brake disc slides against brake pad adherent
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tribolayer are formed on the surface of AMC disc at the contact region. Tribolayers thus
formed further enhances the wear resistance of the AMC discs. Tribolayers consisting of
mixed oxides are formed due to transfer of material from the brake pad on to the AMC disc
during sliding. Material transfer and formation of tribolayers is primarily caused by the SiCp
which stands proud of the matrix on the surface of AMC disc. Hence, tribolayer formation is
caused by the extrinsic effect of SiC reinforcement in AMCs. Figure 3a shows the formation
of tribolayer on AMC disc when slid against automobile brake pad. Figure 3b shows the
plots of the wear rate of AMC disc against automobile brake pad. In the same plot, wear rate
of un-reinforced Al–Si alloy and cast iron are also included. Evidently, figures 3a and b
confirm the immense potential of AMCs as lightweight brake discs in transportation
systems. This is one example where both intrinsic and extrinsic effects of SiC reinforcement
in AMCs is fully exploited advantageously.

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(a)

(b)

Figure 3. (a) Photograph showing the

formation of tribolayer on the worn
surface of AMC (disc) slid against
brake pad(pin).(b)Slidingwearrates of
unreinforced Al-alloy, SiCp reinforced
Al composite and grey cast iron (disc) against brake pad (pin).

Applications of AMCs
AMCs now have a proven track record as successful “high-tech” materials in a range of
applications. AMC utilisation provides significant benefits including performance benefits
(component lifetime, improved productivity), economic benefits (energy savings or lower
maintenance cost) and environmental benefits (lower noise levels and fewer air-borne
emissions). Engineering viability of AMCs in a number of applications have been well-
documented. AMCs having different type of reinforcements (whiskers/particles/short
fibres/continuous fibres) and produced both by solid state and liquid state processing have
found their way to many practical applications. Some of the newer and visible applications of
different types of AMCs are detailed below.

Particle reinforced aluminium matrix composites of all the AMCs, particle reinforced AMCs
constitutes largest quantity of composites produced and utilised on volume and weight basis. PAMCs
are produced by PM stir cast/melt infiltration/spraying/in situ processing techniques at industrial
level. Particulates of SiC, Al2O3, TiC, TiB2, B4C have been used as reinforcements. PAMCs have
been successfully used as components in automotive, aerospace, opto-mechanical assemblies and
thermal management. PAMCs are in use as fan exit guide vane (FEGV) in the gas turbine engine (see
figure 4), as ventral fins and fuel access cover doors in military aircraft. PAMCs are also

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Figure 4. Fan exit guide vanes (FEGV) component made up of PAMCs used in P and W gas
turbine engine.

used as rotating blade sleeves in helicopters (see figure 5). Flight control hydraulic manifolds
made of 40 vol% SiCp reinforced aluminium composites have been successfully used (see
figure 6).
The most notable large size and high volume use of PAMCs is in braking systems of trains
and cars. Presently AMC brake discs are extensively used in European Railways and are in
use in certain models of passenger cars in U.S.A. A major car manufacturing company in
Europe is planning to introduce AMC brake discs by the year 2004. Potential automotive
applications of PAMCs include valves, crankshafts, gear parts and suspension arms.
Particle reinforced AMCs are in use as recreational products including golf club shaft and
head, skating shoe, base ball shafts (see figure 7), horseshoes and bicycle frames. AMCs
containing high volume fraction ceramic particles are being used as microprocessor lids and
integrated heat sinks in electronic packaging. They are also in use as carrier plates and
microwave housing.

Figure 5. PAMC rotating blade sleeves used in helicopter.

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Figure 6. Near net shape PAMCs flight

control hydraulic manifold.

Whisker- and short fibre-reinforced

aluminium matrix composites
In the wake of greater health risks
associated with the handling of ceramic
whiskers, of late production of whisker-
reinforced aluminium composites has
been very limited. However, with
appropriate safety measures, SiC whisker-
reinforced aluminium matrix composites have been produced and used as track shoes in
advanced military tanks. Use of whisker-reinforced AMCs as track shoes help in reducing
the weight of the tank. Short fibre-reinforced AMCs are being used in piston and cylinder
liner applications.

Continuous fibre-reinforced aluminium matrix composites

Carbon fibre (continuous) reinforced Al matrix composites have been used as antenna wave
guides for the Hubble Space Telescope. Here, composites provide high dimensional
accuracy, high thermal and electrical conductivity with no outgassing oxidation resistance.
6061 Al-boron fibre (continuous) composites have been used as struts in main cargo bay of
space shuttle (see figure 8). More recently 3M Tm has developed alumina fibre (continuous)
reinforced aluminium composites. Compared to high strength steel, CFAMCs developed by
3MTm offers equivalent strength at less than half
the density and retains its strength to 300 ◦C and
beyond. Composites possess four times the
electrical conductivity of steel or half that of
purealuminium. These composites have been
targetted for several functional

Figure 7. Recreational products made of PAMCs

Figure 8. Continuous fibre-reinforced AMCs as struts used in main cargo bay of space
shuttle.

applications including: (a) Core of an overhead electrical conductor; (b) automotive push
rods; (c) flywheels for energy storage; (d) retainer rings for high-speed motors; and (e) brake

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callipers.

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AMCs provide benefits in volume critical flywheel applications. Use of AMCs enable
smaller flywheels compared to polymer composites (see figure 9). Thin walled retainer rings
of AMCs provide excellent advantages in high-speed motors. AMC retainer rings can resist
very high rotational speeds and still maintain their precise shape (figure 10). Brake callipers
made of CFAMCs offer the following advantages compared to cast iron brake callipers
(figure 11).

(1) Increased damping.

(2) Reduced unsprung weight.
(3) Increased fuel efficiency.
(4) Improved performance, handling and ride.
(5) Cross-platform utilisation.

Figure 9. Alumina
fibre-reinforced AMC flywheels.
Figure 10. Alumina fibre-reinforced AMC retainer ring used in
high-speed motors.

Challenges and opportunities

Several challenges must be overcome in order to intensify the engineering usage of AMCs.
Design, research and product development efforts and business development skills are
required to overcome these challenges. In this pursuit there is an imperative need to address
the following issues.

• Science of primary processing of AMCs need to be understood more thoroughly,

especially factors affecting the microstructural integrity including agglomerates in

AMCs.
• There is need to improve the damage tolerant properties particularly fracture toughness and
ductility in AMCs.
• Workshouldbedonetoproducehighqualityandlowcostreinforcementsfromindustrial wastes and by-
products.
• Efforts should be made on the development of AMCs based on non-standard aluminium alloys
as matrices.
• There is a greater need to classify different grades of AMCs based on property profile and
manufacturing cost.
• There is an urgent need to develop simple, economical and portable non-destructive kits to
quantify undesirable defects in AMCs.
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Figure 11. Alumina fibre-reinforced AMC callipers.

• Secondary processing is an important issue
in AMCs. Work must be initiated to develop simple
and affordable joining techniques for AMCs.
Development of less expensive tools for machining
and cutting AMCs is of great necessity.
• Work must be done to develop re-cycling
technology for AMCs.
• There must be more consortium/networking
type approaches to share and document wealth of information on AMCs.

Thereexisttremendousopportunitiestodisseminateseveralhighprofilesuccessstoriesonthe
engineering applications of AMCs amongst the materials community. AMCs must be looked
upon as materials for energy conservation and environmental protection. These twin issues
must create awareness at the government and policy formulators level and work to increase
market acceptance by disseminating information on the outstanding potential of AMCs.

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CHAPTER-2

LITERATURE REVIEW

2.1 INTRODUCTION:

The literature survey is carried to have an overview of the manufacturing process of

MMCs. Nowadays the demand for new materials is increasing rapidly due to the growth of
industrial technology. The choice of processing methods depends on the property
requirements, cost factor and future application prospects. Incorporation of hard second phase
particles in the alloy matrix to produce MMC has been reported to be more beneficial and
economical due to its wear resistance and high specific strength properties (Hamound et al
2007). Contemporary composites resulting from research and innovation during the past few
decades have progressed from glass fibre for automobile bodies to particulate composites for
aerospace and a range of other applications (Hemanth et al 2009, Feng et al 2008 and Ramesh
et al 2009). Among all aluminum based metal matrix composites reinforced with ceramic
particles have attracted the industries because of their excellent mechanical and wear
resistance properties. Aluminum alloy has low density (2.57 g/cm3), low melting point, high
specific strength and thermal conductivity and is reinforced with a variety of ceramics such as
SiC, B4C, Al2O3, TiC and graphite (Lashgari et al 2010 and Ramesh et al 2010).

The joining of aluminum matrix composites is really a challenge and limits the
widespread application of these materials. The problems encountered in fusion welding
techniques are solidification shrinkage and porosity, different thermal expansion coefficients
of the metal matrix and the ceramic reinforcement, interfacial chemical reactions between
particles and matrix in the molten metal state and segregation of particles during the
solidification. Hence, the use of MMCs in industrial applications is still emerging. FSW
reduces the undesirable problems associated with conventional joining process, thereby has
the potential to produce strong joints with strengths comparable to those of the parent
material (Lee et al 2006). Extensive investigations are being carried out in FSW include (1)
understanding of FSW process and its parameters (2) prediction of required results and
interface (3) theoretical and numerical studies that are based on mathematical equations
governing the fundamental physical phenomenon such as adiabatic heat generation due to
stir, material flow due to plastic deformation, heat transfer etc., and (4) experimental studies
for validation of results of theoretical and numerical studies.

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2.2 ALUMINUM METAL MATRIX COMPOSITES (AL-MMCs):

Abenojar et al (2007) optimized the processing parameters for the fabrication of

Al+10% B4C composite by mechanical alloying. There was no significant microstructural
change found when the compaction pressure was changed but level of porosity was affected.
The higher compacting pressure promoted better densification in the material and hence
bending strength was improved. Density of AMCs was not significantly affected by sintering
temperature.

Kaczmar et al (2000) discussed the various methods for production of metal matrix
composites and its application depended on the choice of property requirements, cost analysis
and future applications. Initially A356 aluminum alloy strengthened with SiC particles
containing graphite was produced by casting route. Among the variety of manufacturing
processes available for producing metal matrix composites, stir casting was generally
accepted due to its simplysity, flexibility and for large quantities of production. The optimum
properties of the MMCs could be achieved with uniform distribution of the reinforcement,
good wettability between substances and low porosity of material. It depended on the
processing variables such as holding temperature, stirring speed, the size of the impeller and
the position of the impeller in melt (Hashim et al 1999).

Shorowordi et al (2003) was considered the process variables of preheating

temperature of particles at 9000C and 1750C for Al2O3, SiC and B4C respectively for
fabricating Al/(0-20 vol. %) B4C, SiC and Al2O3 composites. The particles stirring time of
10 minutes for SiC, Al2O3 and 16 minutes for B4C was maintained. The Al/B4C MMC
resulted a better interfacial bonding compared to other two composites. But, Viala et al
(1997) found a reaction product such as Al3BC and AlB2 when Al-B4C composite was
produced at a temperature between 6600C and 8680C. Zhang et al (2007) used the titanium
into the composite melt for producing Al-7% Si-10% B4C die casting composite. It formed a
barrier layer on the surface of B4C and limited the interfacial reaction thereby increased the
stability of B4C. In order to increase the wettability and distribution of SiC particles into the
A356 melt, Amirkhanlou and Niroumand (2010) used the compocasting (semisolid state)
technique rather than stir casting and obtained 10% higher hardness and 68% reduced
porosity.

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Naher et al (2003) tried a simulation studies for optimizing some of the compocasting
parameters to obtain uniform particles distribution. The particle dispersion time was reduced
when the blade angles were high. Brabazon et al (2002) designed a novel stir caster for
processing of A356 alloys in mushy state with controlled experiments and showed a
significant improvement in mechanical properties with reduced porosity when compared with
conventional gravity permanent mould chill castings.

Tee et al (1999) fabricated an in-situ AA1100-TiB2 composite using calculated

stoichiometric ratio of elements Ti and B into the molten Al to form TiB2 through traditional
stir casting technique and resulted in improved tensile strength depending upon the vol.
fraction of TiB2 formed.

Kok (2005) fabricated AA2024/10, 20, 30, vol. % Al2O3 composites with particle
sizes of 16 µm, 32 µm, and 66 µm by a vortex method. The density of the composites
increased with increasing wt. % and size of particles, whereas the porosity of composites
increased with decreasing particle size and increasing wt. % of particles. Poddar et al (2007)
used the stir cast vortex method to fabricate Mg-alloy/15 vol. % SiC and resulted in increased
hardness as well as elastic modulus of composite compared to monolithic alloys. Wang et al
(2008) also used the same stir casting technique for fabricating AZ91/10 vol. % SiCp
composite.

Kennedy et al (2002) used a K-Al-Ti-F flux for fabricating Al/5 wt. %, 10 wt. % B4C
MMC by casting route and it was characterized metallographically and mechanically before
and after heat treated conditions. An increased stiffness and a decreased ductility of
composite were obtained after heat treatment.

The authors Kerti and Faith (2008) were used a K2TiF6 flux to increase the wetting
between Al and B4C and facilitated the incorporation of B4C particles into molten aluminum.
The better microstructure was obtained with addition of bigger size of B4C particle without
agglomeration.

Based on the literature survey on the various fabrication methods of MMCs, the
vortex method is selected to fabricate Al-B4C composites. In this method, the matrix material
is melted, stirred vigorously to form a vertex at the surface of melt and the reinforcement
materials are introduced at the side of the vortex. The stirring is continued for a minutes
before the slurry is cast.

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CHAPTER-3

EXPERIMENTAL

WORK

3.1 FABRICATION OF AA5083-B4C MMC

In the present study, aluminium alloy 5083 was used as a matrix metal. The aluminum
alloy 5083 contains about 4.5% - 5% Mg and small amounts of other alloying elements. The
AA5083 is a medium-strength, non-heat treatable wrought aluminium alloy and its strength
increases with increasing Mg content. It is highly resistant to attack by seawater and
industrial chemicals. AA5083 has the highest strength of the non-heat treatable alloys with an
ultimate tensile strength of 317 MPa and a tensile yield strength of 228 MPa. The nominal
composition of AA5083 is given in Table 3.1. The reinforcement used in the fabrication of
metal matrix composite was boron carbide. To improve the mechanical properties such as
hardness and wear resistance, boron carbide is used. Boron carbide of 40 µm grain size was
used for the preparation of AA5083-B4C metal matrix composite. The properties of boron
carbide are given in Table 3.2.

Table 3.1 Chemical Composition of Aluminium Alloy 5083

Element Si Fe Cu Mn Mg Zn Ti Cr Al
Reminde
Weight % 0.4 0.4 0.1 0.4 4.9 0.25 0.15 0.25
r

Table 3.2 Properties of boron carbide

Melting point Temperature 2450 ° C

Hardness (Vickers) 2900-3580
Density(g/cm3) 2.52
Crystal structure Hexagonal

The metal matrix composite of aluminium alloy 5083 with boron carbide was
fabricated by stir casting method. An automatic bottom pouring type stir casting setup was
used to fabricate AA5083-B4C MMC using 2% boron carbide reinforcement. The automatic
bottom pouring type stir casting setup used for making metal matrix composite is shown in
Figure 3.1.
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Aluminium alloy plates (Fig. 3.2) after cutting into suitable pieces were placed in a crucible
which is built-in automatic bottom pouring type stir casting setup and heated to a temperature
of 820°C using electric furnace. A thermal coating (thermo coat) was applied in crucible and

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stirrer blades to avoid oxidation of metallic components. The temperature of furnace was set
to 850°C. To avoid reaction by atmospheric gas with the molten metal, the melting of the
metal is performed under a controlled setup. The molten metal was allowed to be surround
by argon and sulphur hexafluoride to avoid atmospheric reaction. The mechanical stirrer was
lowered into the aluminium melt after the alloy was melted completely. The stirrer was
rotated at a constant speed of 350 rpm to form a vortex. Measured quantity of boron carbide
particles of size around 40 µm (Fig. 3.3), which was preheated to a temperature of 350°C,
was gradually fed to the vortex at a feed rate of 12 g/min. Stirring of melt and feeding of
boron carbide particles continued intermittently for 30 minutes.

Figure 3.1 Bottom line pouring type stir casting setup

Figure 3.2 AA5083 plates in as received condition

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Figure 3.3 Boron carbide powder

The composite melt was then poured into the preheated die which was already heated
to a temperature of 300° C by opening the crucible bottom opening. Finally, AA5083 B4C
metal matrix composit was taken out of the die after the solidification. The rectangular
mild steel die with the dimensions of 210 mm ×100 mm ×15 mm was used and is shown in
Figure 3.4. The fabricated AA5083 B4C MMC plate is given in Figure 3.5
FIGURE: 3.4 Mild steel rectangular die

FIGURE3.5 AA5083 - B4C MMC plate fabricated by stir casting process

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3.2 MCROSTRUCTURAL EXAMINATION:

Weld Microstructures were examined using optical microscopy (OM). The samples
were cut from the fabricated plate using electric discharge machine and polished, then etched
as per the metallographic procedure. Following are the steps followed in sample preparation:

3.2.1 Grinding and Polishing:

Suitable samples were cut from the weld and initial preparation was done using belt
grinding machine. Later, the samples were subjected polishing using emery papers with
several different grit sizes. It is performed in successive steps using Si-abrasive papers of
different grit sizes, usually 180, 220, 320, 400, 600, 800, 1000, 1200, 2400 grit. The starting
sizes of a grit depends on the type of cut surface to be removed. The abrasive particles embed
easily into soft aluminium alloys. So wet grinding (water) to flush away these particles and a
small pressure on the specimen are recommended.

The following step is the cloth polishing. It is important for removing the surface scratches
produced during grinding. The mechanical polishing is usually performed in two steps: 1.
course and 2. fine polishing. The course polishing is performed using 3 and 1μm diamond
paste on a short nap cloth disk. The lubricant can be a solution of alcohol and propylene
glycol. The final step is made by 0.25μm diamond paste. It is important to wash the sample
after every step in an ultrasonic bath to remove all the abrasive particles. In cases where
polishing with 1 or ¼ μm diamond paste does not produce a sufficiently deformation-free and
scratch-free, highly reflective surface, as it is the case of pure aluminium and its soft alloys,
the final polishing can be carried out using metal oxides in aqueous suspension. The most
commonly used oxides are colloidal silica (SiO2) and alumina (Al2O3). Silica comes as a
readymade colloidal suspension OP-S 0.04μm. The advantages of silica over alumina are the
particle size distribution which is much narrower than in alumina and the particles which do
not agglomerate and are always in suspension. This means that there is less chance of fine
scratches and it is easy to apply because it does not need continuous stirring. The cloths used
for final polishing are usually soft compared to the harder cloth for diamond polishing. The
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typical polishing machine is shown in the Figure 3.6

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Figure 3.6 Polishing Machine

3.2.2 Etching:

After polishing, the sample is ready for the last step before observation; this is called
the etching. Etching is basically a controlled corrosion process resulting from electrolytic
action between surface areas of different potential. With pure metals and single-phase alloys,
a potential is produced between differently oriented grains, between grain boundaries and
grain interiors, between impurity phases and the matrix or at concentration gradients in the
single- phase alloys. With two phase or multiphase alloys, potential differences are also
present between phases of different composition. These potential differences are used to
produce controlled dissolution. The quality of the polishing influences the development of the
true microstructure. A faulty preparation can lead to misinterpretation of the structure. In
general wiping of the surface with moist cotton under running water is adequate, although
ultrasonic cleaning especially if cracks or pores are present, is preferable. Cleaning and
etching agents used are shown in Figure 3.7.

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Figure 3.7 Cleaning and etching agents: a) Acetone b) Keller’s

reagent The most common for practical use are the following:
⮚ Keller’s reagent - 2ml HF (48%) + 3ml HCl + 5ml HNO3 + 190ml H 2O. This etchant
gives the possibility to reveal grain boundary contrast and precipitates in several
aluminium wrought alloys.
⮚ 1g NaOH + 100 ml. H2O - This solution is useful for grain boundary contrast in 6xxx
series.
⮚ HF etch - 1 ml (HF) (48%) + 200 ml H2O. It is used for constituent identification
in cast alloys, especially those containing Si.

The optical microscopy, often referred to as the ― light microscopy”, is a type of

microscope which uses visible light and a system of lenses to magnify images of small
samples. The image from an optical microscope can be captured by normal light sensitive
camera to generate a micrograph.

The examination of microstructure is one of the principal means of evaluating alloys

and products to determine the effects of various fabrication and thermal treatments and to
analyse the cause of failure. Main microstructural changes occur during freezing,
homogenization, hot or cold working, annealing, etc. Good interpretation of the structure
relies on having a complete history of the specimen. In general, the metallography of
aluminium and its alloys is a hard job in the meaning that aluminium alloys represent a great
variety of chemical compositions and thus a wide range of hardness and different mechanical

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properties.

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Therefore the techniques required for metallographic examination may vary considerably
between soft and hard alloys. Moreover, one specific alloy can contain several
microstructural features, like matrix, second phases, disperoids, grains, sub-grains and thus
grain boundaries or sub-boundaries according to the type of the alloy and its thermal or
thermo mechanical history. However, some methods of sample preparation and observation
are quite general and apply to all aluminium alloys. In other cases one should refer to
specifically developed methods as a general rule, examination should start at normal eye
vision level and proceed to higher magnification. Simplicity and cost make optical
examination (macro and micro) the most useful. When the magnification and the depth of
focus become too low, the electron microscopies are required. A simple optical microscope
and schematic illustration of the principle involved in optical microscopy are shown in
Figures 3.8 and 3.9 respectively.

Figure 3.8 Optical Microscope

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Figure 3.9 Diagram showing the principle in simple microscope

3.3 HARDNESS TESTS

The sample for hardness evaluation was cut from the fabricated plate using electric
discharge machine. Hardness measurements were taken by Vickers microhardness testing
machine as shown in Figure 3.10. The hardness readings were noted at ten different locations,
using the load of 500 g and 15s dwell time.

Figure 3.10 Vickers micro hardness tester

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3.4 TENSILE TESTS

Transverse tensile test samples were prepared using the wire cut EDM as per ASTM B557
standard as given in Figures 3.11. The room temperature tensile tests were conducted using a
universal testing machine controlled by a computer, as presented in Figure 3.12.

Figure 3.11 Samples for tensile testing

FIG 3.12 UNIVERSAL TESTING MACHINE

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CHAPTER - 4
RESULTS AND DISCUSSION

4.1 MICROSTRUCTURES
The optical micrographs taken using optical microscope are presented in Figs. 4.1 and

4.2. The samples for microstructural examination were cut using Electrical discharge
machine (EDM). The samples were prepared as per the standard metallographic procedure
and etched using standard keller’s reagent for clear visualization of grain structure.
Microstructures were taken at various locations in different magnifications such as 100x,
200x and 500x. As it can be observed, the AA5083-2%B4C sample exhibited uniform
distribution of boron carbide particles in the aluminum matrix (Fig. 4.1), indicating that
carbide particles are properly distributed. For more clarity, the microstructure in 200x
magnification is also presented in Figure 4.2.

Figure 4.1 Microstructure of AA5083-B4C metal matrix composite in 100x magnification

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Figure 4.2 Microstructure of AA5083-B4C metal matrix composite in 200x magnification

4.2 HARDNESS TESTS

The samples for measuring hardness were cut from the fabricated plates using electric
discharge machining. The standard metallographic procedures were followed for further
preparation before conducting the hardness test. Vickers microhardness tester was used to
measure hardness at ten different locations. The measured hardness values are presented in
Table 4.1.

Table 4.1 Hardness values of AA5083-B4C metal matrix composite

Location/Sample 1 2 3 4 5 6 7 8 9 10
AA5083-2%B4C 78 75 68 76 71 72 70 68 74 71

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4.3 TENSILE TESTS

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The tensile properties obtained from room temperature tensile tests carried out on a
computer controlled universal testing machine are presented in Table 4.2. The tensile test
samples were prepared using a electric discharge machine as per ASTM B557 standards. As
can be understood from the table that the AA5083-2%B4C sample exhibited yield strength,
tensile strength and percent elongation values of 113 MPa, 177 MPa and 6.67, respectively .

Table 4.2 Tensile properties of AA5083-2%B4C metal matrix composite

Yield Strength (0.2% proof) Tensile Strength % Elongation

AA5083-2%B4C
(MPa) (MPa)
Sample 1 112 172 6.5
Sample 2 112 170 7
Sample 3 116 188 6.5

Figure 4.3 Tensile tested specimens showing fractures

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Tensile Test Graph-1

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Tensile Test Graph-2

2

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Tensile Test Graph-3

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Table 4.3 Tensile values of AA5083-B4C metal matrix composite

Yield Strength (0.2% proof) Tensile Strength % of

Sample
(MPa) (MPa) Elongation
AA5083-2%B4C 113 177 6.67

AA5083-2%B4C

105

Graph-4

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CHAPTER 5
CONCLUSION
1. AA5083-B4C metal matrix composite with 2% B 4C was successfully made using stir
casting process.
2. Microstructures were examined for distribution B4C carbide particles in the aluminum
matrix and it was found that the the carbide particles distribute uniformly in the
matrix.
3. Tensile properties Were Evaluated using tensile tests and the yield strength was
found to be 113MPa. Which is almost the same as that of the AA5083. Also, the
tensile strength was observed to be [Link] the percentage of elongation was
around 7%.
4. The Hardness of the Fabricatted MMC was also evaluated using vickers
micro hardness tester and it was found to be 73HV.
5. In conclusion, while the mechanical properties of the base metal generally surpass
those of fabricated AA5083 with boron due to its unaltered state, the addition of
boron can enhance specific properties like strength and hardness in AA5083,
depending on the application and processing methods employed. Therefore, the
choice between base metal and fabricated AA5083 with boron should be based on
the desired mechanical characteristics and application requirements.

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REFERENCES:

[1] Kerti, I. and Faith, T. “Microstructure variation in cast B 4C reinforced aluminum

matrix composites (AMCs)”, Mater. Lett., Vol. 62, No. 8-9, 2008, pp. 1215-1218
[2] Ye, H., Y.X Liu. and Hong, H. “Fabrication of metal matrix composites by metal
injection moulding-A review”, J. Mater. Process. Technol., Vol. 200, No. 1-3, 2008,
pp. 12-24.

[3] Abenojar, J., Velasco, F. and Martinez, M.A. “Optimization of processing parameters
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