Experimental Investigation of Wear Behaviour of Al(6031)
Metal Matrix Composite
1 1
T.Princy Kanimozhi , K.Sanofar Nisha
1
UG Scholar, Department of Aeronautical Engineering, Nehru Institute of Engineering and Technology, Coimbatore.
2
Assistant Professor, Nehru Institute of Engineering and Technology, Coimbatore
Abstract -- In recent years, a metal matrix application have
been raised in aerospace and automobile industries. In this
work Hybrid Metal Matrix Composite have been developed
using stir casting process for improving the Wear Behaviour
at lower cost. Alumina (Al2O3) as one of the reinforcement
used with 2% weight fraction and Silicon Dioxide (SiO2) in
1%, 3% & 5% weight fraction. Al-6061 has been considered
as the matrix material. The low cost stir casting process has
been used for the development of the composite system. The
matrix material was melted in electric furnace and the heat
treated reinforcement in the desired weight fraction have been
added followed by constant stirring the melt. The temperature
of the melt held at 890C-950C. The casted specimen have
been obtained in the form of cylindrical rod of 20mm
diameter and 200mm length for carrying out tribological tests.
Microstructure analysis reveals the uniform distribution of
reinforcements in the aluminium matrix. The pin on disc wear
test carried on all samples at 358 rpm speed with load of 1 kg.
The overall tribological property improves due to addition of
the two reinforcement.
I. INTRODUCTION
Metal matrix composite material are finding increasing
application in aerospace and automobile industries due to
their enhanced properties such as high strength, high
stiffness, and good wear resistance, hybrid composite
materials are advanced composite materials in order to
achieve the high hardness, tensile strength at room
temperature[1-3]. Wear is the progressive loss of material
due to the relative motion between a surface and the
contacting substance. The wear damage may be in the form
of micro cracks or localized plastic deformation. The
tribological principle parameter that control the wear and
friction performance and material characteristics as well as
a test parameter such as applied pressure, sliding speed,
environment and that type of sliding interaction. Among
the variant of reinforcements, the low aspect ratio particle
reinforcement are much of significant in imparting the
hardness of fibre reinforcement MMC<whisker
reinforcement MMC<particle dispersed MMC. The volume
fraction of reinforcement has the strongest effect on the
wear resistance.
The addition of hard particle in the matrix of the
composite materials influence the wear properties. The hard
ceramic particle such as Al2O3,Sic, Tic etc[4,5]. embedded
in the matrix of the hybrid composite material have shown
to reduce the wear loss compared to the base alloy. The
studies indicated that the wear loss normally decrease with
increase in the hard phase volume fraction and particle size.
The studies on wear of composite material indicated that
wear rate of Al2O3 reinforced composites decrease by two-
, R.Arravind2
fold as the particle size increase for 5 to 142m. at the
fixed volume fraction. During sliding at higher wear rates,
high temperature is developed at the sliding due to which
the specimen softens and becomes plastics. It reacts with
the oxygen and their respective oxides. The hard brittle
oxide formed on the surface of the specimen becomes
thicker and continuous, covering the entire surface. The
mechanical mixed layer formed and partly as an insulator
form of thermal conductivity and responsible for increase
in wear resistance of the composites.
The mixed layer had micro structural features comparing
of a mixture of ultrafine grained structure in which the
constituents varied depending on the sliding loads. The
wear rate thus would be influenced by the formation and
detachment of the matrix layer in the load.
The main aim of the present investigation is to evaluate
the dry sliding metal-metal wear behavior of Al matrix,
discontinuously reinforced with two different types of
particles such as SiO2 and Al2O3. Stir Casting is chosen for
the manufacturing of hybrid metal matrix composites. The
effect of Al2O3 & SiO2 addition on the reinforcement and
the applied load in the dry sliding metal metal wear
behavior of composite is investigated using a pin on disc
wear tester. The micro structure of the specimen are studied
for the particle distribution and worm surface were
examined using Metallographic Image Analyzer.
II. RAW MATERIAL
2.1 Aluminum Matrix Material
The name aluminum is derived from the ancient name
for alum (potassium aluminum sulphate), which was
alumen (Latin, meaning bitter salt). Comprising a little over
8% of the earths crust, aluminum is the most abundant
metal on the planet. It is the third most common element
after oxygen and silicon. Aluminum is lightweight, strong,
recyclable, corrosion-resistant, and an essential part of
daily life.
In our lifestyles and built environment, aluminum
products are just as abundant. Since its commercial
production began little more than a century ago, aluminum
has become the material of choice for a diverse range of
applications and utilities. Aluminum is a soft and
lightweight metal. It has a dull silvery appearance, because
of a thin layer of oxidation that forms quickly when it is
exposed to air. Aluminum is nontoxic (as the metal)
nonmagnetic and non-sparking.
It is very reactive so that in the atmosphere a thin but
equally protective oxide layer forms rapidly. For this
reason it is very resistant to corrosion. By a special
treatment, anodizing, i. e. an electrolytic oxidation process, 2.3. Alumina
the aluminum surface protected by the oxide layer can even
Aluminum oxide is a chemical compound of aluminium
be strengthened and made more resistant to corrosion. It is
a silvery white, soft, ductile metal. Aluminium is the third and oxygen with the chemical formula Al2O3. It is the most
most abundant element (after oxygen and silicon), and the commonly occurring of several aluminium oxides, and
specifically identified as aluminium(III) oxide. It is
most abundant metal, in the Earth's crust. It makes up about
commonly called alumina, and may also be called aloxide,
8% by weight of the Earth's solid surface.
aloxite, or alundum depending on particular forms or
Aluminum has a unique and unbeatable combination of applications. It commonly occurs in its crystalline
properties that make it into a versatile, highly usable and polymorphic phase -Al2O3, in which it comprises the
attractive construction material. Aluminum is light with a mineral corundum, varieties of which form the precious
3
density one third that of steel, 2.700 kg/m . Aluminum is gems ruby and sapphire.
strong with a tensile strength of 70 to 700 MPa depending
Aluminum oxide, commonly referred to as alumina,
on the alloy and manufacturing process. Extrusions of the
possesses strong ionic interatomic bonding giving rise to its
right alloy and design are as strong as structural steel.
desirable material characteristics. It can exist in several
The Youngs modulus for aluminum is a third that of crystalline phases which all revert to the most stable
steel (E = 70,000 MPa). This means that the moment of hexagonal alpha phase at elevated temperatures.
inertia has to be three times as great for an aluminum The composition of the ceramic body can be
extrusion to achieve the same deflection as a steel profile. changed to enhance particular desirable material
A thin layer of oxide is formed in contact with air, which characteristics. An example would be additions of
provides very good protection against corrosion even in chrome oxide or manganese oxide to improve hardness
corrosive environments. This layer can be further and change color. Other additions can be made to
strengthened by surface treatments such as anodizing or improve the ease and consistency of metal films fired
powder coating. The thermal and electrical conductivities to the ceramic for subsequent brazed and soldered
are very good even when compared with copper. assembly
Furthermore, an aluminum conductor has only half the . Alumina is one of the most cost effective and
weight of an equivalent copper conductor. Aluminum has a widely used material in the family of engineering
relatively high coefficient of linear expansion compared to ceramics. The raw materials from which this high
other metals. This should be taken into account at the performance technical grade ceramic is made are
design stage to compensate for differences in expansion. readily available and reasonably priced, resulting in
good value for the cost in fabricated alumina shapes.
2.1.2 Aluminum Matrix Selection With an excellent combination of properties and an
MMC materials have a combination of different, attractive price, it is no surprise that fine grain technical
superior properties to an unreinforced matrix which are; grade alumina has a very wide range of applications.
increased strength, higher elastic modulus, higher service 2.3.1Alumina Reinforcement Selection
temperature, improved wear resistance, low electrical and
thermal conductivity, low coefficient of thermal expansion High purity alumina products can withstand very
and high vacuum environmental resistance. These high temperature under reducing, inert or high vacuum
properties can be attained with the proper choice of matrix condition.
and reinforcement They remain good chemical resistance under high
temperatures, and have excellent wear and abrasion
2.2 Silicon Dioxide Reinforcement Selection resistance. Alumina products can withstand up to
A total of 1,3,5 wt% silicon dioxide particles is added. 1750C (3182F).
Then the microstructure of the alloy particulate composites Molecular Formula Al Al2O3 SiO2
produced was examined, the physical and mechanical
properties measured include: densities, porosity, ultimate Appearence Rod White Powder Black Powder
tensile strength, yield strength, hardness values and impact
energy. The results revealed that, addition of silicon Density 2.7 g/cm3 3.75 g/cm3 3.21 g/cm3
dioxide reinforcement, increased the hardness values and
apparent porosity by 75 and 39%, respectively, and 933 K 2369 K 3000 K
decreased the density and impact energy by 1.08 and 15%,
respectively, as the weight percent of silicon dioxide Melting Point 660C 2096C 2730C
increases in the alloy. The yield strength and ultimate
1220F 3804F 4950F
tensile strength increased by 26.25 and 25% up to a
maximum of 20% silicon dioxide addition, respectively. 2773 K 3853 K 3250 K
These increases in strength and hardness values are
attributed to the distribution of hard and brittle ceramic Boiling Point 2500C 3580C 2977C
phases in the ductile metal matrix.
4550F 6453F 5391F
 Weight composition of Samples

S.No Al 6061 Al2O3 SiO2

E407 standards. The Specimens were grinded and polished with
300,600,900,1000 and 1200 grit emery paper followed by
1. 1000 g 20 g 10 g polishing with diamond paste in polishing machine. The kellers
2. 1000 g 20 g 30 g etchant has been used for etching .The optical micrograph has
3. 1000 g 20 g 50 g been obtained at 100x.

Wear test carried out on Pin on Disc. Rotating disc against

the loaded pin was used to determine the wear loss of the material
III. EXPERIMENT at various conditions. The wear simulations confirms to ASTM
The preparation of aluminum metal matrix (Al + G99 standards. Tests are conducted in dry conditions and with
Al2O3 + SiO2) is carried out by Stir casting process. rotating motion. The test parameter includes load, speed,
temperature, roughness, shape and wear track etc. The variation of
The matrix material Al-6061 obtained in the form of circular coefficient friction also noted during the wear test which will be
rod is cut into smaller pieces and are cleaned to remove the influenced due to addition of the SiO2. The wear and friction
impurity, dust and oil and heated in graphite crucible in electric monitor used in present investigation is shown in fig 2.
furnace. When the material has reached semi-molten state, the
reinforcement heated separately to 450C being added to the
melt. The constant stirring of the melt carried out with alumina
stirrer to get uniform distribution of the ceramic particles. The
stirring was carried out for 10 minutes and the melt was poured
in to sand mold. The stir casting process is shown in fig 1.

Fig 2. Pin On Disc Wear Tester

The disc material includes EN32 Steel , hardened to 60HRc

Fig 1. Stir casting setup
The castings of circular cross section of 20mm diameter
and 200mm length has been casted. The specimens were
machined to reduce the diameter to 16 mm and length to 30
mm for microstructure characterization and hardness test. The
specimen in the form of pin of diameter 10mm and length
50mm have been machined for wear and friction test.
Microstructure analysis has been carried out as per ASTM
and roughness was 1.6Ra. The wear track diameter of 60mm was
selected. The surface of the specimen used are flat and cleaned
after each test. The wear test was carried out at a speed of 358 rpm
with the load on the pin as 1 kg on all the three types of specimen
having different weight percentage. The wear in micron and the
average friction force in Newton were noted.
IV. RESULT AND DISCUSSION
The hybrid metal matrix composite was developed using
stir casting furnace satisfactorily .The distribution of the particles
are uniform without any interface reaction. The particle dispersion
in the melt was achieved through stirring and maintain the
melting temperature at 750C.
The density of the composite measured experimentally
shows that 3% to 4% variation as compared to theoretical
density. The density increases as the weight fraction increases.
Density of the developed composite found to be less than the
density of the conventional material like steel and cast iron.
The porosity found to reduce to 3% due to sand casting.
The micro hardness values indicates that addition of
reinforcement increases the hardness of the composite. This is
due to more amount of ceramic particles in the vicinity of the
indentation resists the deformation and induces hardness due
to strong interface bonding.
Optical micrograph of the developed composite shown in
fig 3 indicates the presence of Al2O3 and SiO2 ceramic
particles in the matrix. The amount of particles increases with
increase in weight fraction. This gives the indication of the
ceramic particles and their distribution in the composite. The
micrograph indicates the presence of reinforcements in the Al
matrix. The degree of clusters are little higher at higher weight
fraction. Hardness was found to increase with increase in
weight fraction.
Fig 3.a MMC reinforced with 1% SiO2
Fig 3.b MMC reinforced with 3% SiO2
Fig 3.c MMC reinforced with 5% SiO2
Tribological study involves the coefficient of friction and its
effect of the wear of the material. It is essential to monitor the
variation of the coefficient of friction along with the wear for a
given speed, load and duration of experiment. The coefficient of
friction was observed to be lower due to addition of SiO 2 in the
matrix. The coefficient of friction reduces for the composite with
highest weight fraction. The reduction in the coefficient of friction
is related to noise and vibration of during the test. It was noticed
that considerable amount of noise level found to reduce for all the
specimens as the SiO2 content in the matrix found responsible for
this behavior. Fig 4 shows the wear rate and variation of
coefficient of friction with time.
Fig 4. Wear Result of 5% SiO2
V. CONCLUSION
By stir casting process the Particulate hybrid metal
matrix composite can be developed effectively.
The porosity can be reduced by constant stirring,
maintaining the optimum melt temperature and using
sand mold.
Uniform distribution of the particulate and isotropic
property of the composite can be obtained my melt
temperature of 750C and stirring by the alumina stirrer
until pouring the melt.

The density of the composite material is half of the
conventional material and it increases with addition of
ceramic material.
Wear resistance is found to increase with increase
amount of reinforcements.
The weight fraction of the composite influences the
wear resistance as the weight fraction increases the
wear reduces.
The addition of SiO2 as secondary ceramic reduces the
coefficient of friction there by reduction in the noise
and vibration during the motion.
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