x
TABLE OF CONTENTS
CHAPTER NO. TITLE PAGE NO.
ABSTRACT v
LIST OF TABLES xvii
LIST OF FIGURES xx
LIST OF SYMBOLS AND ABBREVIATIONS xxiii
1 INTRODUCTION 1
1.1 COMPOSITE MATERIAL 1
1.1.1 Characteristics of Composites 1
1.1.2 Properties Composite Materials 2
1.1.3 Matrix Phase 2
1.1.4 Reinforcing Phase 2
1.2 BASED ON MATRIX MATERIAL 3
1.2.1 Metal Matrix Composites (MMC) 3
[Link] Aluminium 4
[Link] Magnesium 4
[Link] Titanium 5
[Link] Other Metals 5
1.2.2 Polymer Matrix Composite 6
1.2.3 Ceramic Matrix Composite 6
1.3 BASED ON MATERIAL STRUCTURE 6
1.3.1 Whiskers 6
1.3.2 Continuous Fibers 7
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CHAPTER NO. TITLE PAGE NO.
1.3.3 Short Fibers 7
1.3.4 Metal Wires 7
1.3.5 Particulates 8
[Link] Silicon Carbide as
Reinforcement 8
[Link] Boron Carbide as
Reinforcement 8
[Link] Aluminium Oxide as
Reinforcement 9
[Link] Titanium Carbide 9
[Link] Tungsten Carbide 9
1.4 PROCESSING OF COMPOSITES 9
1.4.1 Liquid State Fabrication 10
[Link] Stir Casting 10
[Link] Infiltration 11
[Link] Gas Pressure Infiltration 11
[Link] Squeeze Casting
Infiltration 12
[Link] Pressure Die Infiltration 12
1.4.2 Solid State Fabrication 12
[Link] Diffusion Bonding 13
[Link] Sintering 13
1.5 WIRE ELECTRICAL DISCHARGE
MACHINING 14
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CHAPTER NO. TITLE PAGE NO.
1.6 WEAR 15
1.7 SLIDING WEAR 15
1.8 MACHINABILITY OF COMPOSITES 16
1.9 CORROSION 16
1.10 PROBLEM DEFINITION 17
1.11 OBJECTIVES OF THE WORK 18
1.12 PLAN OF RESEARCH 18
1.13 ORIENTATION OF THESIS 19
2 LITERATURE REVIEW 21
2.1 MECHANICAL PROPERTIES AND
COMPOSITE FABRICATION
TECHNIQUES 21
2.2 TRIBOLOGY CHARACTERSTICS OF
AMMC 28
2.3 MACHINABILITY STUDIES OF AMMC 34
2.4 CORROSION STUDIES OF AMMC 38
3 MATERIALS AND METHODS 40
3.1 DEVELOPMENT OF AMMC 40
3.1.1 Microstructure 40
3.1.2 Matrix Material 40
3.1.3 Reinforcement 41
[Link] Silicon Carbide 42
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CHAPTER NO. TITLE PAGE NO.
[Link] Molybdenum di Sulphide 42
3.2 FABRICATION OF COMPOSITES 42
3.3 BASIC PROPERTY ANALYSIS 45
3.3.1 Density 45
3.3.2 Tensile Test 45
3.3.3 Hardness Test 46
3.4 EXPERIMENTAL DESIGN 46
3.5 TRIBOLOGICAL STUDY 47
3.5.1 Dry Sliding Wear 47
3.5.2 High Temperature Wear 49
3.6 MACHINABILITY STUDY 51
3.6.1 Milling 52
3.6.2 Drilling 55
3.7 CORROSION STUDY 58
3.7.1 Study of Potentiodynamic
Polarization 58
3.7.2 AC impedance spectra
measurement 59
3.8 SINGLE OBJECTIVE OPTIMIZATION 59
3.8.1 Taguchi Signal to Noise Ratios
Analysis 59
3.9 PREDICTION OF EXPERIMENTAL DATA 60
3.9.1 Artificial Neural Network 60
3.10 MULTI OBJECTIVE OPTIMIZATION 62
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CHAPTER NO. TITLE PAGE NO.
3.10.1 Grey Relational Analysis 62
4 BASIC PROPERTY ANALYSIS 64
4.1 DEVELOPED METAL MATRIX
COMPOSITES 64
4.1.1 Aluminium 5059 64
4.1.2 Silicon Carbide 64
4.1.3 Molybdenum di Sulphide 65
4.1.4 Microstructure of Developed
Composites 66
4.2 DENSITY 67
4.3 TENSILE TEST 68
4.4 HARDNESS TEST 69
5 TRIBOLOGY STUDIES 71
5.1 DRY SLIDING WEAR 71
5.1.1 Effect of Input Parameters on Wear
Rate 73
5.1.2 Effect of Input Parameters on Co-
efficient of Friction 74
5.1.3 Analysis of Variance 76
5.1.4 Mathematical Model 77
5.1.5 Worn Out Surface Analysis 78
5.2 HIGH TEMPERATURE WEAR 81
5.2.1 Effect of Control Factors on Wear
Loss 82
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CHAPTER NO. TITLE PAGE NO.
5.2.2 ANOVA for Wear Loss 85
5.2.3 Effect of Control Factors on COF 86
5.2.4 ANOVA for COF 89
5.2.5 Mathematical Modeling and
Prediction 89
5.2.6 Worn Out Surface Analysis 90
6 MACHINABILITY STUDIES 94
6.1 MILLING 94
6.1.1 Effect of Input Parameters on
Surface Roughness 96
6.1.2 Effect of Input Parameters on
Temperature 97
6.1.3 Effect of Input Parameters on MRR 98
6.1.4 Effect of Input Parameters on Feed
Force 99
6.1.5 Effect of Input Parameters on
Radial Force 100
6.1.6 Effect of Input Parameters on
Radial Force 101
6.1.7 Regression Model Analysis 102
6.1.8 Artificial Neural Network Analysis 103
6.1.9 Grey Relational Analysis 107
6.2 ANOVA FOR GREY RELATIONAL GRADE 111
6.3 DRILLING 112
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CHAPTER NO. TITLE PAGE NO.
6.3.1 Effect of Input Parameters on
Surface Roughness 113
6.3.2 Effect of Input Parameters on MRR 115
6.3.3 Effect of Input Parameters on
Temperature 116
6.3.4 Effect of Input Parameters on
Cutting Force 117
6.3.5 Regression Model Analysis 118
6.3.6 Artificial Neural Network Analysis 118
6.3.7 Grey Relational Analysis 121
6.3.8 ANOVA for Grey Relational Grade 124
7 CORROSION STUDIES 126
7.1 ANALYSIS OF POLARIZATION CURVES 126
7.2 ANALYSIS OF AC IMPEDANCE SPECTRA 132
8 CONCLUSION 136
8.1 CONCLUSION 136
8.2 SCOPE OF FUTURE WORK 139
REFERENCES 140
LIST OF PUBLICATIONS 151
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LIST OF TABLES
TABLE NO. TITLE PAGE NO.
Table 3.1 Chemical composition of Al 5059 (wt. %) 41
Table 3.2 Properties of SiC 42
Table 3.3 Nine Composite Samples with different weight
percentages and micron sizes 44
Table 3.4 Process parameters and their levels 48
Table 3.5 L27 orthogonal array for Dry sliding wear 49
Table 3.6 Factors and their levels 50
Table 3.7 L27 orthogonal array for high temperature wear 51
Table 3.8 Control parameters and corresponding levels for
milling 53
Table 3.9 L27 orthogonal array for milling 54
Table 3.10 CNC Drilling Machine Specification 55
Table 3.11 L27 orthogonal array for drilling 57
Table 5.1 L27 orthogonal array and results for
Al5059/SiC/MoS2 composite 72
Table 5.2 Main effect values of S/N ratios for wear rate 74
Table 5.3 Main effect values of S/N ratios co-efficient of
friction 76
Table 5.4 ANOVA on the wear rate of the hybrid composites 77
Table 5.5 ANOVA on the co-efficient of friction of the hybrid
composites 77
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TABLE NO. TITLE PAGE NO.
Table 5.6 L27 Orthogonal array and results 81
Table 5.7 Response Table to S/N ratios for wear loss (smaller
S/N ratios is better) 84
Table 5.8 Analysis of variance for wear loss 86
Table 5.9 Response Table S/N ratios for co-efficient of
friction (smaller S/N ratios is better) 88
Table 5.10 Analysis of variance for co-efficient of friction of
the composite 89
Table 6.1 L27 orthogonal array and results 95
Table 6.2 Normalized value for response parameters 108
Table 6.3 Grey Relational Co-efficient and Grades 109
Table 6.4 Response Table for grey relational grade 111
Table 6.5 The ANOVA results of analysis for grey relational
grade 112
Table 6.6 L27 orthogonal array and results 113
Table 6.7 Normalized, Grey Relational Co-efficient and
Grades value for response parameters 122
Table 6.8 Response Table for grey relational grade 123
Table 6.9 The ANOVA results for grey relational grade 125
Table 7.1 Corrosion potentials obtained from polarization
curves for Al5059 composite with various amount
of wt% 132
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TABLE NO. TITLE PAGE NO.
Table 7.2 AC impedance parameters of Al composites
immersed in 3.5% NaCl solution 133
xx
LIST OF FIGURES
FIGURE NO. TITLE PAGE NO.
Figure 1.1 Stircasting setup 11
Figure 1.2 Powder metallurgy process 14
Figure 1.3 Pin on Disc setup 15
Figure 1.4 Electrochemical corrosion experiment setup 17
Figure 1.5 Thesis Outline 19
Figure 3.1 Stir casting experimental setup 43
Figure 3.2 Steps involved in stir casting process 44
Figure 3.3 Nine Composite Samples and base alloy 45
Figure 3.4 Tensile specimen 46
Figure 3.5 Brinell hardness setup 46
Figure 3.6 Pin on Disc setup and wear workpeice 48
Figure 4.1 EDS spectrum of developed Aluminium Composite 64
Figure 4.2 a) SiC at 10 µm b) SiC at 20 µm c) SiC at 40 µm 65
Figure 4.3 SEM of MoS2 66
Figure 4.4 Microstructure of composites 67
Figure 4.5 Effect of SiC weight percentage and particle size on
Density 68
Figure 4.6 Effect of SiC weight percentage and particle size on
Tensile strength 69
Figure 4.7 Effect of SiC weight percentage and particle size on
Hardness 70
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FIGURE NO. TITLE PAGE NO.
Figure 5.1 Main effect plot for S/N ratios of wear rate (smaller is
better) 73
Figure 5.2 Main effect plot for S/N ratios of co-efficient of
friction 75
Figure 5.3 Optical microscopic and WLI images of damaged
surface of Al 5059/SiC/MoS2 at various input
conditions.(a) 5% &10 µm (b) 10% &10 µm (c) 5%
&20 µm (d) 15% &20 µm (e) 5%& 40 µm (f) 15%&40
µm 80
Figure 5.4 Effect of various parameters on S/N ratios for wear
loss (smaller is better) 83
Figure 5.5 Contour plot of wear loss for weight% VS temperature 85
Figure 5.6 Effect of various parameters on S/N ratios for Co-
efficient of friction 87
Figure 6.1 Mean S/N ratios graph for surface roughness 96
Figure 6.2 Mean S/N ratios graph for temperature 97
Figure 6.3 Mean S/N ratios graph for MRR 98
Figure 6.4 Mean S/N ratios graph for feed force 100
Figure 6.5 Mean S/N ratios graph for radial force 101
Figure 6.6 Mean S/N ratios graph for tangential force 102
Figure 6.7 Architecture of Artificial neural network 103
Figure 6.8 Predicted value of experimental vs regression vs ANN
model on Surface roughness 104
Figure 6.9 Predicted value of experimental vs regression vs ANN
model on Temperature 105
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FIGURE NO. TITLE PAGE NO.
Figure 6.10 Predicted value of experimental vs regression vs ANN
model on MRR 105
Figure 6.11 Predicted value of experimental vs regression vs ANN
model on Feed Force (Ff) 106
Figure 6.12 Predicted value of experimental vs regression vs ANN
model on Radial Force (Fr) 106
Figure 6.13 Predicted value of experimental vs regression vs ANN
model on Tangential Force 107
Figure 6.14 Mean S/N ratios graph Grey relational grade 111
Figure 6.15 Mean S/N ratios graph for surface roughness 114
Figure 6.16 Mean S/N ratios graph for MRR 115
Figure 6.17 Mean S/N ratios graph for Temperature 116
Figure 6.18 Mean S/N ratios graph for Cutting force 117
Figure 6.19 a. Experimental Ra vs Predicted Ra.b. Experimental
MRR vs Predicted MRRc. Experimental vs Predicted
[Link] vs Predicted Cutting force. 120
Figure 6.20 Mean S/N ratios graph for Cutting force 124
Figure 7.1 Potentio dynamic polarization curves for Al5059 alloy
with various amount of Wt%. 131
Figure 7.2 (S0-S9) Nyguist plots for Al5059 alloy with various
amount of reinforcement immersed in 3.5% NaCl
solution 134
xxiii
LIST OF SYMBOLS AND ABBREVIATIONS
AA - Aluminium Alloy
Al - Aluminium
ASTM - American Society for Testing and Materials
ANOVA - Analysis of Variance
AC - Alternate Current
AlN - Aluminium Nitride
AMMC - Aluminium Metal Matrix Composites
ANN - Artificial Neural Network
BUE - Built-up-edge
BPA - Back Propagation Algorithm
BN - Boron Nitride
BHN - Brinell Hardness Number
Cu - Copper
CoF - Co-efficient of Friction
DOE - Design of Experiments
DF - Degrees of Freedom
CNC - Computer Numerical Control
ECM - Electro Chemical Machining
Ecorr - Corrosion Potential
EDM - Electric Discharge Machining
EDS - Energy Dispersive Spectroscopy
% Er - Error Percentage
GFRP - Glass Fibre Reinforced polymers
GRA - Grey Relational Analysis
GRC - Grey Relational Co efficient
GRG - Grey Relational Grade
xxiv
Ff - Feed Force
Fr - Radial Force
Ft - Tangential Force
MMC - Metal Matrix Composites
MRR - Material Removal Rate
MS - Mean Sum of Squares
Icorr - Corrosion Current
SEM - Scanning Electron Microscope
PMC - Polymer Matrix Composites
SS - Sum of Squares
Ra - Surface Roughness
Rt - Charge Transfer Resistance
WEDM - Wire Electric Discharge Machining
XRD - X-Ray Diffraction
WEDM - Wire Electric Discharge Machining