Process Development in Stir Casting and Investigation On Effect of Tib On Aa6061 Metal Matrix Composites

Process Development in Stir casting and
Investigation on effect of TiB2 on AA6061 Metal

Matrix Composites
T. Siva Parthiban1, A.Saravanapandi Solairajan2.
3
PG Student, Department of Mechanical Engineering, Infant Jesus Colege of Engineering and Technology, Vallanadu,
Tamilnadu, India, E-mail: sivaparthi20@gmail.com
2
Department of Mechanical Engineering, Infant Jesus college of engineering& technology,: Tuticorin, Tamilnadu, India,
Pin:628851, E-mail: solairajan2k@gmail.com
*
Corresponding author
I INTRODUCTION
Abstract- The unique characteristics of the Metal matrix composites (MMCS) have
composite materials for the specific emerged as an important class of materials for
requirements makes these materials more structural, wear, thermal, transportation and
popular in a variety of applications such as electrical applications, primarily as a result of their
aerospace, automotive (pistons, cylinder liners, ability to exhibit superior strength-to-weight and
bearings), and structural components, resulting strength-to-cost ratio when compared to equivalent
in savings of material and energy. In this paper monolithic commercial alloys [8]. Aluminum-based
aluminium alloy Al6061 was reinforced with particulate reinforced metal matrix composite have
TiB2 particles by stir casting method. Metal emerged as an important class of high performance
matrix composites produced by stir casting materials for use in aerospace, automobile,
method have more advantages compare with chemical and transportation industries because of
other methods. Experiments were conducted by their improved strength, high elastic modulus and
varying weight fraction of TiB2 (2%, 4%, 6%, increased wear resistance over conventional base
8%, 10%), while keeping all other parameters alloy [10]. The manufacturing techniques of the
constant. Scanned electron microscopic (SEM) aluminium metal matrix composites are classified
proves the deposition of TiB2 on the aluminium in to three types (1) liquid state methods, (2)
matrix. The results showed that increasing the semisolid methods and (3) powder metallurgy
mechanical properties, such as tensile strength, methods. [2] In liquid state methods, the ceramic
wear resistance and hardness caused by the particulates are incorporated into a molten metallic
percentage of TiB2 present in the samples. matrix and casting of the resulting MMC. Stir
Casting is a liquid state method of composite
Keywords- Metal matrix composites, Aluminum,
materials fabrication, in which a ceramic particle is
Reinforcement, Stir casting and TiB2.
mixed with a molten matrix metal by means of
mechanical stirring. The liquid composite material
is then cast by conventional casting methods [7].
Aluminium 6061 is a metal alloy with low A. Composite Manufacturing Process Development
density and high thermal conductivity. But, it has
poor wear resistance. To overcome this drawback, Many of the researchers are showing
this alloy is reinforced with some other materials so interest in the composite material development
that its hardness, young’s modulus and abrasion only. But the manufacturing cost of the composite
wear resistances are increased [9]. is high, which lead the composites as an expensive
Ceramic materials are generally used to one. In our work we are replacing the electrical
reinforce aluminum alloys like SiC, TiC, TiB2, furnace and the stir set up by the simple blower
ZrB2, AlN, Si3N4, Al2O3, and SiO2. From these furnace and a vertical drilling machine respectively.
reinforcing ceramic particles, titanium diboride By this set up the high operating cost of the
(TiB2) is particularly attractive because it exhibits electrical furnace is eliminated, with the drilling
high Young's modulus (345-409 GPa), low density machine variable speed can be obtained for stirrer
(4.5 g/cm3), superior Vickers hardness (3400 HV), as per our requirement.
good thermal conductivity (̴110Wm-1 K-1 at 25oC), B. Composite Development
high electrical conductivity (22 x106 Ω cm), High
elastic modulus and hardness, high melting point In present work, the Effects of TiB2 in
(3225Cº ± 20), superior wear resistance and good AA6061 are investigated. Metal matrix composites
(MMCs) are a range of advanced materials that can
thermal stability [3, 4]. For these reasons it is used
in a large variety of applications such as aluminium be used for a wide range of applications within the
melting crucibles, corrosion resistant applications, aerospace, automotive, nuclear, biotechnology,
and metal and ceramic matrix composites [5]. The electronic and sporting goods industries and are
addition of titanium diboride to metal matrix rapidly becoming candidates as structural materials
composites has been observed to greatly increase for high temperature applications. There has been
an increasing interest in composites containing low
stiffness, hardness and wear resistance. Historically,
much of the work in this field has been directed at density and low cost reinforcements. Among
aluminium based materials [6]. various discontinuous reinforcements used, TiB2 is
one of the low density reinforcement which is
In this study reinforcement of the TiB2 with giving more advantages properties to composites.
aluminium matrix was carried out, the Hence, composites with TiB2 as reinforcement are
microstructure of the composites were investigated likely for wide spread application used in
by scanning electron microscope, and also the automotive and small engine applications. Material
mechanical properties like tensile strength, selected for experimental purposes was AA6061.
hardness, and wear resistance were analyzed. The addition of TiB2 is done to it in 2 %, 4%, 6%,
II. EXPERIMENTAL PROCEDURE 8% and 10% by weight. The specimens produced
are tested for Strength and Wear properties.
Aluminum alloy 6061 was used as the base
metal. And ceramic material TiB2 was used as a C. Preparation of Samples
reinforcement. Aluminium Alloy (AA6061) was melted in
a crucible by heating it in a blower furnace at
750°C for twenty minutes. The TiB 2 powder is
preheated at 700oC. The furnace temperature was
first raised above the liquid temperature of
Aluminium near about 750oC to melt the scanning electron microscopy. A Vickers pyramid
AA6061completely and was cooled down just diamond hardness testing machine was used to
below the liquidise to keep the slurry in Semi solid measure the hardness of the composites. 5 samples
state. The stirring was carried out with the help of were prepared and 5 tests were accomplished in
the drilling machine for about 10 minutes at stirring each of them.
rate of 450 rpm. At this stage, the preheated TiB2
particles were added manually to the vortex. In the
final mixing processes the furnace temperature was
controlled within 700 ± 10oC. The mixture was
poured in the graphite coated die. The presence of
reinforcement throughout the specimen was
inspected by cutting the casting at different
locations and under microscopic examination. Fig. 3 Before & After Tensile Test Specimen
Taking the same route five specimens with different
compositions of TiB2 was cast. III RESULTS AND DISCUSSION
A. Visual Observations
For the visual observation of the sample here the

SEM with EDAX test is carried out .the various
colours in the figure is represents the presence of
various metal in the composites for example the red
colour dots are the representation for the presence
of Titanium particles in the sample.
Fig. 1 Tensile Specimen Diagram
Fig. 4 SEM Microstructure (AA6061- 8% wt. of

Fig. 2 Tensile Specimen TiB2)
In order to measure the tensile strength of The SEM test were carried out using HITACHI – S
samples they were made in a cylindrical shape 3000 Scanning Electron Microscope and Platinum
according to ASTM.E8 standard which is then sputtering before the test was carried out using Fine
tested for tensile strength as shown in figure 1. For coat Ion sputter JFC 1100. The sputtering time was
testing the samples the UTM machine was used. 2 minutes and 1.2KV, 7 milliamps DC supply was
EDAX was used to determine the phases in the given for the emission of platinum ions. The
composites. The microstructures were found by
photograph of sputtering process was shown in TiB2 4%, and specimen 2 is the composition of
Figure 4. AA6061 92% and TiB2 8%.
Fig. 5 EDAX Analysis of Composition (AA6061-

8% wt. of TiB2)
Fig. 6 Graphical results of Pin on Disc Test
B Strength observations (Al6061- 4% wt. of TiB2)
Table. 1 Tensile strength and Elongation Results
Sl Tensile %
n Combinations Strength Elongation
o N/mm2
1 AA6061-2%
98.16 10
wt. of TiB2
2 AA6061- 4%
135.01 12.5
wt. of TiB2
3 AA6061- 6%
125.54 21.5
wt. of TiB2
4 AA6061- 8%
91.74 5.5
wt. of TiB2
5 AA6061-10%
81.46 5
wt. of TiB2
Fig.7 Graphical results of Pin on Disc Test
(AA6061- 8% wt. of TiB2)
C Wear Observations
Table. 2 Wear Report
Tests were conducted with the load range is
10 N at constant speed of 350 rpm and sliding Wear
Sliding weight
distance of 500 mm. The initial weight of the Specimen Speed Load (grams (µm) COF
(N) x10- =f/fn
specimen was calculated from single pan electronic m/s ) 6
m
weighing machine with the precision of 0.0001. The AA
wear test observation shows the wear resistance of 6061-4% 0.696 30 0.002 4.796 0.013
the composite is increased as the percentage of the TiB2
TiB2 increases. Also the graphite reduces the wear AA
6061-8% 0.55 30 0.001 3.03 0.002
resistance of the composite material here the TiB2
specimen 1 is the composition AA6061 96%, and
IV CONCLUSIONS
The mechanical characteristics of AA6061- and Nanotechnology in Engineering, (2007)
TiB2 aluminium matrix composite was studied Proc. of SPIE Vol. 6423 642369-3.
[3] S.C. Tjong, K.F. Tam, Mechanical and
detail above. This shows the increase in the
thermal expansion behavior of hipped
hardness property of the Aluminium with the
aluminum–TiB2 composites.Materials
reinforcement of TiB2. Inclusion of reinforcement Chemistry and physics 97 (2006) 91- 97.
in the Aluminium improves the micro-hardness [4] I. Sulima a,*, L. Jaworska a,b, P. Wyżga b,
value of the Aluminium. From the result, it’s M. Perek-Nowak c, The influence of
understood that increase in the amount of TiB2 will reinforcing particles on mechanical and
certainly increase the strength of the Aluminium. tribological properties and microstructure of
Increase in the composition of TiB2 was clearly the steel-TiB2 composites. Journals of
Achievements in Materials and
found with the help of the images in the
Manufacturing Engineering.Vol. 48 (2010)
microstructure. Wear tests were conducted on the 52- 57.
specimen and found the characters of wear [5] Ronald G. Munro, Material Properties of
resistance characters and co-efficient of friction of Titanium Diboride. Journal of Research of
the composite specimen. Results from the graph National Institute of Standards and
shows, improvement in the wear resistance Technology, 105 (2000) 709- 720.
[6] C.C. Degnan, P.H. Shipway∗, A comparison
characteristics when there is increase in the amount
of the reciprocating sliding wear behaviour
of TiB2 in the aluminium composite. This shows the
of steel based metal matrix composites
reinforecement will improve the wear resistance processed from self-propagating high-
character of the aluminium. Different loads were temperature synthesized Fe–TiC and Fe–
applied to the specimen and found in the loss of TiB2 master alloys.Wear 252 (2002) 832-
weight when there is high load is applied and 841.
[7] Jasmi hashim*, The production of cast metal
increase content on TiB2 will have lesser loss of
weight in high load than the other less composition matrix composite By a modified stir casting
method. Jurnal Teknologi, 35(A) Dis. (2007)
material. This paper results show that the inclusion
2001: 9–20.
of reinforcement TiB2 will improve the mechanical[8] Lakshmi S, Lu L, Gupta M. In situ
properties of the aluminium composite. preparation of TiB2 reinforced Al based
ACKNOWLEDGEMENT composites. Journal of materials processing
technology 73 (1998) 160- 166.
[9] B. Bobic, S. Mitrovic, M. Babic, I. Bobic,
The author acknowledges the support from
Corrosion of metal-matrix composites with
University College of Engineering, Nagercoil,
aluminium alloy substrate.Tribology in
Tamilnadu, India to complete work successfully. industry, 32 (2010) 1- 9.
[10] Natarajan S, Naraynasamy R, Kumaresh
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Process Development in Stir casting and

Investigation on effect of TiB2 on AA6061 Metal

For the visual observation of the sample here the

Fig. 4 SEM Microstructure (AA6061- 8% wt. of

Fig. 5 EDAX Analysis of Composition (AA6061-

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