Fabrication, Characterization and Testing Of Copper Reinforced Metal Matrix Composite and Investigation of the Deformation Behavior through Hot Extrusion Process

Abstract

Copper Metal Matrix Composites (Cmmcs) Are A Class Of Materials That Are Widely Used In The Automotive And Aerospace Industries Due To Their Exceptional Properties. This Thesis Work Was Synthesized Copper Reinforced Composite Materials Through Stir Casting Process As Well As To Examined Numerically And Experimentally Investigated The Deformation Behavior For The Reinforced Composite Material With Different Weight Percentage Of Ceo2,Sic, And Gr Nano Particles. The Investigation Of Distribution Of The Reinforced Particles Over The Matrix As Well As Grain Size Determination Has Been Carried Out Through Optical Microscopy (Om). The Hardness Of The Developed Samples Has Been Measured Through Vickers Hardness Tester And Improvement Of 51.73% Has Been Found And Wear Rate Has Been Investigated Through Pin-On-Disc Equipment. The Wear Morphology Of The Worn Samples Was Done By Scanning Electron Microscopy (Sem) In Order To Determine The Mechanism Of Wear Behavior. The Investigation Of Compressive Strength Has Been Carried Out On Universal Testing Machine And Improvement To 393.758mpa Has Been Observed. The Grey Relational Analysis Method Has Been Used For The Selected (81%Cu-7.5%Sic-Ceo2-4%) For Secondary Operation (Hot Extrusion Process). The Deform 3d Software Was Used For The Numerical Simulation Of Hot Extrusion At Varies Parameters. The Extrusion Ratio Of (2, 3, 4), Ram Speed (1, 2, 3) Mm/S And Deformation Temperature Of (850, 900,950)Have Been Chosen To Investigate The Output Numerical Responses Like Load, Effective Stresses And Damage Value. The Response Surface Methodology Under Box Behnken Method In Design Expert Was Used To The Predicted The Combined Damage, Extrusion Load And Effective Stress From Simulation Corresponding To Input Extrusion Parameters. The Global Optimization Of Input Extrusion Parameters Have Been Done Through Genetic Algorithm For The Minimum Values Of Load, Effective Stresses And Damage Value. The Post Deformation Characteristics Like Hardness Of The Developed Material Were Improved By70.74% After Extrusion And The Porosity Was Reduced By 0.073%. The Proposed Research On Copper Metal Matrix Composites (Cmmcs) Aims To Address The Challenges Faced By Industries And Researchers Working In This Field Such As Electronic Packaging And Contacts ,Resistance Welding Electrodes, Heat Exchangers.