Mechanical characterization of aluminium – red mud metal matrix composites

Mechanical characterization of aluminium – red mud metal matrix composites

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Available online at www.sciencedirect.com

ScienceDirect Materials Today: Proceedings 5 (2018) 26911–26917

www.materialstoday.com/proceedings

ICAMM_2016

Mechanical characterization of aluminium – red mud metal matrix composites Neelima Devi Chintaa,*, N.Selvaraja, V.Maheshb a

Department of M.E, National Institute of Technology, Warangal, Telangana, Pin Code-506004, India b Department of M.E, S.R Engineering College, Warangal, Telangana, Pin Code-506371, India

Abstract Red mud (bauxite residue) is an industrial waste obtained during the processing of alumina by Bayer’s process. In this work, an attempt has been made to utilize the industrial solid waste as the reinforcement material in aluminium metal matrix composites through powder metallurgy route. Red mud received from NALCO has been subjected to sieve analysis for micron level of 100 µm, 150 µm and 200 µm and milled to nano level of 42 nm using high energy ball mill. Micro and nano structured red mud powders and pure aluminium powder are mixed in a V-Blender, compacted at a pressure of 40 bar and samples are prepared by conventional sintering with vacuum as medium at different weight fractions of 2%, 4%, and 6% red mud. The paper presents mechanical characterization of pure aluminium with red mud such as hardness and compression strength and compression test results are validated with Deform-2D software. An increase in hardness and compression strength is observed with increase in the amount of percentage weight fraction of red mud. Hardness values variation depicts the information that nano red mud specimens have more hardness when compared with micro nature specimens. Hardness and compression strength properties are improved for nano level aluminium-red mud test specimen with 42 nm size and 6% weight fraction of Red mud. © 2018 Elsevier Ltd. All rights reserved. Selection and/or Peer-review under responsibility of ICAMM-2016. Keywords: Aluminium; red mud; hardness; compression test;

1. Introduction Aluminium is the second most widely used metal in the world, after the iron [1-2]. Aluminium composites have the more impact and potential to be utilized in various applications of engineering fields such as aerospace, automobile, naval, mechanical, structural and defence organizations [3-7]. The utilization of red mud in different industrial applications and structural investigation relating to the cement activity of bauxite residue which is also known as red mud was studied [8-10]. Presently it has been difficult for the industries to dispose their wastage and utilization of by-products. The huge amounts of industrial byproducts/wastes are becoming clients for increasing environmental pollution and generation of a huge amount of unutilized resources [11-12]. This research work is aimed at finding out utilization of industrial byproducts for value added applications and also helps to solve the environmental problems. Red mud is one of the wastage produced during manufacturing of alumina. For every 2.5 tons of alumina production, 1.5 tons of red mud is produced. An attempt has been made in the current paper, red mud is mixed with other metals mainly aluminium to form metal matrix composites * Neelima Devi Chinta .Tel.: +91-984-996-5809. E-mail address: [email protected] 2214-7853 © 2018 Elsevier Ltd. All rights reserved. Selection and/or Peer-review under responsibility of ICAMM-2016.

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synthesized by powder metallurgy.The main objectives are to investigate the best weight fraction of red mud as reinforcing material required in the aluminium metal matrix composites for optimum properties and to evaluate the merits of nano red mud reinforcement over micro red mud reinforcement. The hardness test and compression tests are conducted for characterizing the mechanical properties. The compression test results are validated by Deform-2D software with compressive stress at 10%, 20% and 30% reduction. 2. Experimental work The materials used in this experimental work are finely pulverized, pure aluminium powder of 99.72% purity and red mud which is collected from the National Aluminum Company Limited (NALCO) Damanjodi, Odisha, India. The sieve analysis is carried out using mechanical sieve shaker for collecting uniform sizes particles of 100, 150 and 200 microns for preparing the micro sized red mud powder. The chemical composition of pure aluminium and red mud are shown in Table 1 and 2 respectively. Table 1: Chemical composition of Pure Aluminium Element Wt%

Fe 0.17

Si 0.07

Mg 0.001

Mn 0.0008

Cu 0.005

Zn 0.003

Others Balance

Table 2: Chemical composition of Red mud Element

Fe2O3

Al2O3

TiO2

SiO2

Na2O

CaO

V2O5

Others

Wt%

53.8

14.3

3.9

8.34

4.3

2.5

0.38

Balance

2.1. High energy ball milling and X-ray diffraction (XRD) analysis The reduction in particle size of red mud from micron level to the nano level is carried out using a high-energy planetary ball mill in a stainless steel chamber using tungsten carbide of 10 mm Φ size. The micron sized red mud powder is milled for 30 hours by maintaining the rotation speed of the planet carrier at 200 rpm. The ball mill is loaded with ball to powder weight ratio (BPR) of 10:1. Toluene is used as the medium with an anionic surface active agent to avoid agglomeration. The milled sample red mud powder is taken out after 6 hours, 13 hours, 24 hours and 30 hours of high energy ball milling and dried with mechanical drier. The X-Ray Diffraction (XRD) Patterns for 6 hours and 30 hours are shown in Figure 1 and 2 respectively. It is clearly observed that the intensity of the peaks in the XRD pattern got reduced and the peak broadening increased as the duration of milling increases.

Fig. 1. XRD Pattern for 6 hours milled red mud.

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Fig. 2. XRD Pattern for 30 hours milled red mud.

2.2. Mixing and Compacting The micro level red mud powders of 100, 150 and 200 microns and nano level red mud powder of 42 nm (or 0.042 microns) at 2%, 4% and 6% of weight fractions are mixed with pure aluminium powder in a double cone mixer for 10 hours in order to obtain proper mixing of particles with each other. The different proportions of aluminium-red mud sample materials are compacted in a hydraulic press of 100 ton load capacity. During compacting, pressure applied was 40 bar and compact pressing time was 10 seconds. The pure aluminium matrix composite at 2%, 4%, and 6% weight fractions of red mud as reinforcement with 100, 150 and 200 microns size as well as 42 nano meters are prepared. 2.3. Sintering The vacuum sinter furnace is manufactured by ACME (Advanced Corporation for Materials and Equipments), China. The Model No ZSJ-25x25x50 with loaded weight of 50 kg and loaded vacuum of 4x10-3 Pa. The compacted pure aluminium and red mud samples are sintered in vacuum chamber with total sintering cycle time was 5 hours 5 minutes. The Figure 3 shows the compacted pure aluminium and red mud samples in sintering furnace. vacuum chamber Aluminium with red mud

Fig. 3. Compacted pure aluminium and red mud samples in sintering furnace.

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2.4. Hardness and Compression Tests Hardness values are measured using Micro Vickers Hardness tester according to ASTM E-32. The Vickers Hardness Number (VHN) is given by 1.854L/d2 where L is known as the applied load in kgf and d is known as diagonal length of square impression in mm. Using compression testing machine, compression strength values are calculated experimentally at 10, 20, and 30 percent reduction and validated using Deform-2D software. 3. Results and Discussions The hardness results for aluminium- red mud metal matrix composites at normal condition are shown in Table 3. Table 3: Hardness results for aluminium-red mud metal matrix composites at normal condition Aluminium with % weight fraction of Red mud(RM)

Particle size (µm)

Hardness (VHN)

Al+2% RM

100

60.2

Al+4% RM

100

67.6

Al+6% RM

100

74.5

Al+2% RM

150

58.3

Al+4% RM

150

62.4

Al+6% RM

150

69.2

Al+2% RM

200

56.7

Al+4% RM

200

59.3

Al+6% RM

200

63.5

Al+2% RM

0.042

73.6

Al+4% RM

0.042

77.4

Al+6% RM

0.042

83.9

The graph between hardness and percentage (%) weight fraction of red mud with pure aluminium at normal condition is shown in Figure 4. It is observed that, for the same percentage weight fraction of red mud, the hardness is higher for the nano level reinforcement than micro level reinforcement.

90 80

Hardness(VHN)

70 60 50

Pure Al

40

Al+2% RM

30

Al+4% RM

20

Al+6% RM

10 0 42nm

100µm

150µm

200µm

Red mud particle Size

Fig. 4. Hardness Vs % Weight fraction of red mud with pure aluminium at normal condition.

The compressive stress for pure aluminium with 6% weight fraction of red mud of 100 µm at 10% reduction using Deform-2D software is shown in Figure 5. The effective stress value is 70.3 MPa. The compressive stress at 20% reduction for pure aluminium with 6% weight fraction of red mud of 42 nm using Deform-2D software is

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shown in Figure 6. The effective stress value is 92.1 MPa. The compressive stress at 30% reduction for pure aluminium with 6% weight fraction of red mud 42 nm using Deform-2D software is shown in Figure 7. The effective stress value is 98.4 MPa.

Fig. 5. Compressive Stress for aluminium with 6% weight fraction of red mud (100 µm) at 10% reduction.

Fig. 6. Compressive Stress for aluminium with 6% weight fraction of red mud (42 nm) at 20% reduction.

Fig. 7. Compressive Stress for aluminium with 6% weight fraction of red mud (42 nm) at 30% reduction.

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4. Conclusions

The Red mud powder with particle size of 100, 150 and 200 at micron level and 42 at nano level are prepared. The aluminium with red mud of 2%, 4% and 6% weight fractions with 100 µm, 150 µm, 200 µm and 42 nm samples are prepared through conventional sintering. The fresh red mud powder particles after 30 hours of high energy ball milling at 42 nm are in irregular shapes and the surface morphology is rough. The relative lattice strain is increasing with increasing the duration of milling time. This lattice strain is increased from 0.12 to 0.28 after 30 hours of high energy ball milling. The particle size of 42 nm is obtained after 30 hours of high energy ball milling. Hardness values variation depicts the information that nano red mud specimens have more hardness when compared with micro nature specimens. An increase in hardness and compression strength is observed with increase in the amount of percentage weight fraction of red mud. It is also observed that, for the same percentage weight fraction of red mud, the hardness and compression strength are higher for the nano structured reinforcement than micro structured reinforcement. This is due to the increase in surface area of contact and higher bond strengths. Hardness and compression strength properties are improved for nano level aluminium-red mud test specimen with 42 nm size and 6% weight fraction of red mud. Acknowledgements

The corresponding author wish to express her sincere gratitude to Indian Institute of Technology, Madras for providing permissions of doing high energy ball milling and X-Ray Diffraction (XRD) analysis experiments.

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