Experimental Investigation of Aluminum Matrix Composite Reinforced by Aluminum Oxide and Graphite Micro Particles.

Abstract

In the present scenario, composite materials are replacing Aluminum and its alloys due to the requirement of lightweight high strength material. This thesis interrogates an experimental study of the mechanical properties and tribological property of Aluminum metal matrix composite reinforced by aluminum oxide and graphite micro-particle by using powder metallurgy production method with 20mm diameter and 6 mm length. Taguchi L16 orthogonal array has been utilized for the plan and design of experiments. This experiment is conducted by using a ball milling machine, hydraulic press, sintering furnace, Vicker hardness testing machine, scanning electron microscope, optical microscope, compression testing machine, tribometer. The sampling method was conducted according to the ASTM standard for each measurement. The mechanical properties investigated are Actual density, Theoretical density, Porosity, hardness, compressive strength, wear loss, and coefficient of friction. The optimizations of parameters have been done by using the Taguchi method and Hybrid Grey relational analyses and Taguchi method. The experimental investigations revealed that with an increase in Al2O3 weight percentage the actual density, hardness and compressive strength increased and decreased with an increase in weight presentation of graphite microparticles. Nevertheless the wear loss and coefficient of friction of the composite decreased with an increase in the weight percentage of graphite. The optimum condition for the grey relational analysis of hardness and compressive strength is 20% Al2O3, 1.5%Gr, compaction pressure of 60 Mpa and 60 minutes of compaction time, and 120 minutes of milling time. The condition corresponding to the optimum condition is 20% Al2O3, 1.5%Gr, compaction pressure of 60 Mpa, 45 minutes of compaction time, and 30 minutes of milling time. The Wear resistance has improved by 43.93% with an increase in weight percentage of graphite from 0% to 4.5% whereas wear resistance increased from 30% to 37% with an increase in reinforcement from 10wt% to 20 wt% of aluminum oxide, nevertheless, increment by 7% was observed for those samples with aluminum oxide reinforcement being permanent when the hybrid graphite reinforcement increased from 0 to 4.5wt%. The developed composite material is found to be of excellent mechanical and metallurgical properties besides high strength to weight ratio.In The Present Scenario, Composite Materials Are Replacing Aluminum And Its Alloys Due To The Requirement Of Lightweight High Strength Material. This Thesis Interrogates An Experimental Study Of The Mechanical Properties And Tribological Property Of Aluminum Metal Matrix Composite Reinforced By Aluminum Oxide And Graphite Micro-Particle By Using Powder Metallurgy Production Method With 20mm Diameter And 6 Mm Length. Taguchi L16 Orthogonal Array Has Been Utilized For The Plan And Design Of Experiments. This Experiment Is Conducted By Using A Ball Milling Machine, Hydraulic Press, Sintering Furnace, Vicker Hardness Testing Machine, Scanning Electron Microscope, Optical Microscope, Compression Testing Machine, Tribometer. The Sampling Method Was Conducted According To The Astm Standard For Each Measurement. The Mechanical Properties Investigated Are Actual Density, Theoretical Density, Porosity, Hardness, Compressive Strength, Wear Loss, And Coefficient Of Friction. The Optimizations Of Parameters Have Been Done By Using The Taguchi Method And Hybrid Grey Relational Analyses And Taguchi Method. The Experimental Investigations Revealed That With An Increase In Al2o3 Weight Percentage The Actual Density, Hardness And Compressive Strength Increased And Decreased With An Increase In Weight Presentation Of Graphite Microparticles. Nevertheless The Wear Loss And Coefficient Of Friction Of The Composite Decreased With An Increase In The Weight Percentage Of Graphite. The Optimum Condition For The Grey Relational Analysis Of Hardness And Compressive Strength Is 20% Al2o3, 1.5%Gr, Compaction Pressure Of 60 Mpa And 60 Minutes Of Compaction Time, And 120 Minutes Of Milling Time. The Condition Corresponding To The Optimum Condition Is20% Al2o3, 1.5%Gr, Compaction Pressure Of 60 Mpa, 45 Minutes Of Compaction Time, And 30Minutes Of Milling Time. The Wear Resistance Has Improved By 43.93% With An Increase In Weight Percentage Of Graphite From 0% To 4.5% Whereas Wear Resistance Increased From 30% To 37%With An Increase In Reinforcement From 10wt% To 20 Wt% Of Aluminum Oxide, Nevertheless, Increment By 7% Was Observed For Those Samples With Aluminum Oxide Reinforcement Being Permanent When The Hybrid Graphite Reinforcement Increased From 0 To 4.5wt%. The Developed Composite Material Is Found To Be Of Excellent Mechanical And Metallurgical Properties Besides High Strength To Weight Ratio.