Final Review

K.
RAMAKRISHNAN COLLEGE OF
ENGINEERING (AUTONOMOUS)
SAMAYAPURAM, TIRUCHIRAPPALLI – 621 112
INVESTIGATION OF DRY SLIDINGWEAR

CHARACTERIZATION
OF STIR CAST LM13
ALUMINUMALLOY – TiC – FLYASH HYBRID COMPOSITES
ROLL NO REGISTER NO NAME OF THE STUDENT
LMEB2018 8115U20ME318 GOKUL D
LMEB2020 8115U20ME320 HARIHARAN R
LMEB2058 8115U20ME358 THARUN S
LMEB2060 8115U20ME360 THULASRIDHARAN R
Under the guidance of

Name of the :Mr. S.SIVANANTHAN, M.E.,
Supervisor Assistant Professor/ Mechanical Engineering
Date : 17-4-24 FINAL REVIEW

Abstract
• This study explores the dry sliding wear behavior of hybrid composites
fabricated using LM13 aluminum alloy reinforced with titanium carbide (TiC)
and flyash.
• The hybrid composites were preparedvia the stir casting method with
varying weight percentages of TiC and flyash.
• The wear characterizationwas conducted using a pin-on-disc

tribometer under dry sliding conditions
Introduction
•The demand for lightweight and high-strength materials with improved wear
resistance has led to the development of hybrid composites for various
engineering applications.
•Among these, aluminum-based composites have gained significant attention
due to their favorable combination of properties such as low density, high
strength, and good machinability.
•The effects of varying reinforcement compositions on the wear rate,
coefficient of friction, and wear mechanisms were investigated.
Literature
Author Name review
Materials/Process Outcome
Chou T W, Kelly A, and Fibre-reinforced metal- Wear weight loss of samples increased
Okura A, Composites matrix composites with the
16 (1985) addition of weight and sliding distance.
However,
weight loss is reduced with the addition
of weight
percentage of reinforcements.
Dwivedi SP. Sharma S, A356/SiC/Fly-ash / It was evident that alumina

and Mishra RK, J Electromagnetic stir casting nanoparticles (A356) were maintaining
Braz Soc MechSci
embedded into wear fragments
Eng 37 (2014)
after
wear tests,
offering excellent wear properties.
Hosking FM, Portillo FF, Composites of aluminium weight loss of samples decreased with
Wunderlin R, and alloys / fabrication and wear increasing sliding velocity.
Mehrabian R, J Mater behaviour
Sci 17
(1982)
Author Name Materials/Process/Title Outcome
Mandal D, Dutta B Al–2Mg alloy base / Copper coated steel fiber
K. and Panigrahi vortex method reinforcement in aluminium alloy
SC, J Mater Sci 41 exhibited better mechanical
(2006)
properties and wear resistance
compared to matrix.
Manna A, Al-Al2O3/Grp Metal Matrix Dry sliding wear process

Mahapatra PB, and Composites parameters were optimized for
Bains HS, J Compos obtaining minimum wear rate .
Mater 44
(2010)
Miller W, Zhuang L, HANV6016-T4P / Stir The HANV6016 alloy after paint

Bottema J, Casting bake provides sufficient
Wittebrood A, De strength that leads to a much higher
Smet P.
dent resistance than that of steel (1
mm gauge of
Haszler A, and
Vieregge HANV6016-T6 versus 0.8
A. Mater Sci Eng A mm FePO5 steel).
280
(2000)
Research
• Aluminum, renowned forGap
its lightweight nature, serves as a staple material in
numerous engineering applications. Extensive research has been conducted
on various aluminum alloys, with a focus on improving their properties.
• This study targets Al-7075, chosen due to its inadequate wear resistance, aiming
to enhance it through reinforcement.
• Previous research explored diverse reinforcements such as TiC, SiC, WC, Cr3C2,
Al2O3, TiO2, ZrO2, SiO2, M0O3, MoS2, AIN, Si3N4, ZrB2, TiB2, and Gr. In our
investigation, we employ TiC and fly ash as reinforcement materials.
• Utilizing the Pin-on-Disc wear testing method, renowned for its effectiveness in
assessing material wear characteristics, we aim to evaluate the coefficient of
friction and wear rate.
Objectives
• To characterize the dry sliding wear behavior of stir cast LM13 aluminum alloy
– TiC – flyash hybrid composites under varying testing conditions.
• To investigate the influence of different weight percentages of TiC and flyash
on the wear resistance and coefficient of friction of the hybrid composites.
• To identify the dominant wear mechanisms governing the

tribological performance of the hybrid composites through microstructural
analysis of worn
surfaces.
• To optimize the composition of TiC and flyash in LM13 aluminum alloy matrix
to achieve maximum wear resistance and tribological performance.
Material
• Selected
The matrix material chosen for our current studies is the Al-7075
aluminum alloy, renowned for its widespread industrial applications.
• Al-7075 exhibits notable corrosion resistance along with average durability and
strength, while boasting high impact strength and ductility.
• This aluminum alloy, favored for its corrosion resistance and excellent
castability, finds optimal usage in marine ‘on deck’ castings, water-cooled
manifolds, and jackets.
• In our research, we reinforce the Al-7075 alloy with titanium carbide and fly
ash. These materials are selected for their potential to enhance the mechanical
properties and performance of the aluminum alloy, paving the way for
improved industrial applications.
Chemical composition of
•
LM13
LM13 is an aluminum alloy commonly used in casting applications.
Its composition typically consists of:
1. Silicon (Si): 10-13%

2. Copper (Cu): 1.0-
3.0%
3. Magnesium (Mg): 0.3-
0.6%
4. Iron (Fe): 0.6% max
5. Manganese (Mn):
0.1% max
6. Zinc (Zn): 0.1% max
7. Titanium (Ti): 0.1%
max
8. Others (each): 0.05%
max
9. Others (total): 0.15%
max
10. Aluminum (Al):
Balance
Titanium carbide ( TiC )
• Titanium carbide (TiC) is a ceramic compound composed of titanium and

carbon atoms.
• It is renowned for its exceptional hardness, thermal conductivity, and resistance
to wear, making it a valuable material in various industrial applications.
• TiC is often used as a reinforcement material in metal matrix composites, where
it enhances the mechanical properties of the base metal, such as strength,
stiffness, and wear resistance.
• Additionally, TiC finds applications in cutting tools, coatings, and
abrasive materials due to its ability to withstand high temperatures and
abrasive wear. Its unique combination of properties makes titanium carbide a
versatile and widely utilized material across multiple industries.
Fly ash
• Fly ash is a by product of coal combustion in boilers, commonly used in
electric utility or industrial settings.
• Generated from various types of coal-fired boilers such as pulverized coal
(PC), stoker-fired, cyclone, and fluidized-bed combustion (FBC), fly ash is
typically captured using electrostatic precipitators or bag houses.
• This versatile material varies in physical and chemical characteristics
depending on combustion methods, coal source, and particle shape.
• Ranging in size from 10 to 100 microns, fly ash possesses a melting point
between 480 to 1231 degrees Celsius.
• Although fly ashes from FBC boilers are not discussed here, those from PC
boilers are widely utilized, particularly in large electric generating units and
industrial applications, owing to their diverse properties and applications.
Process Selected
• The stir casting process offers an economical method for producing
aluminum matrix composites and hybrid aluminum matrix composites,
making it ideal for mass productionpurposes.
• During stir casting, the molten metal is continuously stirred, exposing it to
the atmosphere, which can lead to oxidation of the aluminum melt.
• This oxidation reduces the wettability of the aluminum, making it difficult
for reinforcement particles to mix uniformly.
• The stir casting setup typically includes a furnace, a feeder for introducing
reinforcements, and a mechanical stirrer to facilitate mixing.
Method of casting
Pre heating
Furnace
The materials are preheated before it placed into the furnace and it’s heated up to
200°C
STIR CASTING
STIR CASTING MACHINE
MELTING OF MATRIX ADDITION OF REINFORCEMENT
The LM13 was placed in the furnace, and it was melted at the 700°C The
preheated reinforcement (TiC and Fly ash) was added with LM13
Casting Specimen
WIRE CUTTING EDM
MACHINE
Measuring Weight before testing
PIN ON DISK APPARATUS
CHECKING THE WEIGHT AFTER THE WEAR TEST
References
1.Chou T W, Kelly A, and Okura A, Composites 16 (1985) 187.
https://doi.org/10.1016/0010-4361(85)90603-2.
2.Dwivedi SP. Sharma S, and Mishra RK, J Braz Soc Mech SciEng 37 (2014)
57. https://doi.org/10.1007/s40430-014-0138-y.
3.Hosking FM, Portillo FF, Wunderlin R, and Mehrabian R, J Mater Sci 17 (1982) 477.
https://doi.org/10.1007/bf00591483.
4. Mandal D, Dutta B K. And Panigrahi SC, J Mater Sci 41 (2006) 4764.

https://doi.org/10.1007/s10853-006-0036-5.
5.Manna A, Mahapatra PB, and Bains HS, J Compos Mater 44 (2010)

3069. https://doi.org/10.1177/0021998310366362.
6.Miller W, Zhuang L, Bottema J, Wittebrood A, De Smet

P. https://doi.org/10.1016/s0921-5093(99)00653-x

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K.

INVESTIGATION OF DRY SLIDINGWEAR

LMEB2020 8115U20ME320 HARIHARAN R

LMEB2058 8115U20ME358 THARUN S

LMEB2060 8115U20ME360 THULASRIDHARAN R

Under the guidance of

Date : 17-4-24 FINAL REVIEW

• The wear characterizationwas conducted using a pin-on-disc

Dwivedi SP. Sharma S, A356/SiC/Fly-ash / It was evident that alumina

Manna A, Al-Al2O3/Grp Metal Matrix Dry sliding wear process

Miller W, Zhuang L, HANV6016-T4P / Stir The HANV6016 alloy after paint

• To identify the dominant wear mechanisms governing the

1. Silicon (Si): 10-13%

• Titanium carbide (TiC) is a ceramic compound composed of titanium and

4. Mandal D, Dutta B K. And Panigrahi SC, J Mater Sci 41 (2006) 4764.

5.Manna A, Mahapatra PB, and Bains HS, J Compos Mater 44 (2010)

6.Miller W, Zhuang L, Bottema J, Wittebrood A, De Smet

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