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Microstructure and mechanical properties of AA 2219-TiB2 composites by squeeze casting technique
Materials Today: Proceedings xxx (xxxx) xxx
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Microstructure and mechanical properties of AA 2219-TiB2 composites by squeeze casting technique A. Karthik a, R. Karunanithi b,⇑, S.A. Srinivasan c, M. Prashanth a a
Dept. of Mechanical Engg, B.S. Abdur Rahman Crescent Institute of Science and Technology, Chennai 600048, India Dept. of Aerospace Engg, B.S. Abdur Rahman Crescent Institute of Science and Technology, Chennai 600048, India c Dept. of MME, National Institute of Technology, Trichy 620015, India b
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Article history: Received 12 August 2019 Received in revised form 18 October 2019 Accepted 21 October 2019 Available online xxxx Keywords: Squeeze casting AA2219 Reinforcement TiB2 Mechanical property X-ray diffraction technique Scanning electron microscope
a b s t r a c t The AA2219 alloy has been investigated by using squeeze casting process and the reinforcement of TiB2 is added to improve mechanical property and grain morphology to match the requirement of aerospace and automotive industries. The AA2219 alloy and composites sample were prepared by squeeze casting process and process parameter were kept at 350 MPa squeeze pressure load, die and melt temperature as 200°C and 650°C respectively with the standard dwell time 60 s. The weight percentage (x = 0,2.5,5 and 7.5) reinforcement of TiB2 added with AA2219 alloy. The morphology and phase of prepared samples are evaluated by using light microscopy, X-ray diffraction, scanning electron microscopic and energy dispersive technique. The reinforcement of TiB2 resulted in grain refinement of alloy attaining equiaxial and homogeneous grain structure. Mechanical properties such as micro hardness and tensile strength have been enhanced by 22% and 89% respectively. Wear analysis performed on the composite with help of pin on disk setup and wear characteristic show excellent wear resistance. Ó 2019 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the scientific committee of the International conference on Materials and Manufacturing Methods.
1. Introduction The aluminium is the third most typical element which comprises 8% of the earth’s crust. The workability of the aluminium makes the foremost widely used metal after steel. For the last three decades’ intensive research has been done on ceramic reinforcement to improve physical properties of base matrix’s in specific alumina alloy as it offers less weight ratio and ductile nature for better utilization [16]. The M K SURAPPA had emphasized the importance of improvement in the damage tolerance such as fracture toughness and ductility of aluminium metals matrix composite [24]. Recent development of the advanced materials due to tremendous improvement in the field of manufacturing which leads to the development of MMC by various economical production methods. One of the interest area for researchers is the squeeze casting process since it offers excellent mechanical property and fine grain without porosity under optimum process parameter [27]. Squeeze casting process basically is a combinations of casting and forging with the maximum utilization of raw ⇑ Corresponding author. E-mail address: [email protected] (R. Karunanithi).
material when compared to other casting processes [1,2]. D.J. Britnell et al reported on Squeeze casting process which offer refined grain structure when compared to the other casting process. The molten liquid is subjected to a high squeeze pressure load up to the component solidify which in turn reduces the shrinkage and porosity with good surface finish (0.4–3.2) and dimensional accuracy (0.2 mm/100 mm) [13]. Z. Sadeghiana et al reported about the improvement of mechanical properties for a metal matrix composites by grain refinement to survive in the competitive industries like aerospace and automotive industries [3]. S. Y. Wang et al reported on the improvement of Al–Cu–Mg alloy by stir casting method with SiC as a reinforcement since the alloy has a wider application in the automotive and aerospace manufacturing industries [4]. Major reinforcement Ceramic particles are TiC, TiB2, B4C, SiO, MgO, and SiC which offer an excellent elastic modulus, strength, hardness, and thermal resistance. The reinforcement in the aluminium metal matrix appears to be an excellent way to manufacture composites for the automotive and aerospace industries [5,6,17]. The investigation of wear behavior of Al-Si (eutectic) – ENAC48000 showing the higher wear resistance when manufactured by Squeeze casting technique along with 40 nm nano alumina reinforcement. The increasing hardness and wear abrasion
https://doi.org/10.1016/j.matpr.2019.10.143 2214-7853/Ó 2019 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the scientific committee of the International conference on Materials and Manufacturing Methods.
Please cite this article as: A. Karthik, R. Karunanithi, S. A. Srinivasan et al., Microstructure and mechanical properties of AA 2219-TiB2 composites by squeeze casting technique, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.10.143
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phenomena was observed with the increase reinforcement. At the high temperatures oxide formation take place which offer better wear resistance [22]. R. Ashiria et al had made an attempt to compare the squeeze casting process with gravity casting for LM13 piston alloy materials which offer low coefficient of thermal expansion and excellent cast ability. The squeeze casted sample had an excellent mechanical property with increase of hardness and tensile strength. The squeeze pressure has played important role in reduction of porosity and better solidification along with refinement of grain [23]. The Najib Souissi et al had investigated on the relationship between mechanical property and process capability squeeze casting for the wrought aluminium alloy optimized by Taguchi method. The process capability of squeeze casting has produced significant improvement in the alloy [25]. In this work AA2219 alloy was reinforced with TiB2 using squeeze casting process and the microstructure evolution done by SEM, Optical microscope. The Mechanical property such as hardness and tensile test was performed under ASTM condition [19].
2. Materials and methods The Fenfe Metallurgical, Karnataka, India have supplied the AA2219 aluminium ingots materials and the chemical composition of the aluminium ingots was analyzed by the Optical Emission Spectrometer as wt.% Al: 92.87% Cu: 6.2% Si: 0.15%Zr: 0.22% va: 0.11%. The alloy was loaded in 2-liter capacity electric furnace with bottom pouring setup. The squeeze casting equipment had a hydraulic press for liquid forging the liquid metal which poured into the H13 die. The degausser was used to remove slag and dust particle by adding small quantity of hex-chloro ethane tablets. The composites were prepared by following wt.% of TiB2 (X = 0, 2.5, 5 and 7.5). The furnace temperature was held at 1000°C for 20 min before pouring. The molten metal path was pre-heated up to 700°C by adjusting temperature control present in squeeze casting setup to ensure smooth flow of liquid metal. Molten melt was stirred using graphite coated stirrer at 200 rpm while the adding reinforcement of TiB2 particle. The Squeeze casting process parameter are maintained as squeeze pressure load at 350 MPa, die and melt temperature as 200°C and 650°C respectively with the standard dwell time 60 s. The phase composition of squeeze casted component was analyzed by X-ray diffraction technique and patterns arrived by indexing ICDD patterns available in PCPDF database. The sample were prepared for micro graphical examination by cutting a portion of materials from the squeeze casted sample and polished with help of emery sheet, subsequently by alumina and diamond polishing. The pre-etched samples were done using Phosphoric acid (H2PO4 – 40%) and subsequently followed by 1g NaCl at 70°C and Weck’s reagent (1g NaOH + 4g KMnO4 + 100 ml H2O) for 120 s to in order to expose micro structure. The optical image was captured by the Olympus optical microscope and foundry plus image analyzing software was used to find out the porosity, crack and grain structure. Matsuwa Vickers’s hardness test was used to find out hardness at standard 100 gf load with 15 s dwell time. The density value was calculated by Archimedes principle. The microstructural examination was further carried out to examine the second phase particles using SEM with EDS to find the elemental compositions. The tensile sample were made for ASTM A-370 to estimate the ultimate tensile strength. Wear characteristic curve obtained from the TR-20 HTVT, DUCOM pin on disk experiment and SEM micrograph record for wear sample. The samples were weighed before and after wear using a digital weighing balance with accuracy of 0.0001 mg. An EN32 with 64HRC disc was used as a counter body with normal force acting and was pressed along the side surface of the rotating disc with track radius 50 mm. The samples are kept stationary and pin were polished by emery paper
before the start experiment. The disc surface is cleaned regularly before and after wear testing by acetone. The laws governing wear V/X = K*(W/H) Where, V = Wear volume X = Sliding distance W = Normal load applied H = Initial hardness of the softer sliding components K = Wear coefficient. The above mention equation used for both adhesive and abrasive wear. The dry sliding wear was done at room temperature with a constant sliding time of 1000 s. The LVDT is used to measure the wear rate in lm and frictional force in newton. The coefficient of friction measured by control system. The sliding velocity kept at 2.5 m/s to study the wear morphology and the linearity was formed between increase wear rate and sliding distance. 3. Results and discussion 3.1. Optical microscopic AA2219 alloy optical image reveals the coarse grain boundary and hot tear along with porosity which has been represented in Fig. 1(a). Hot tears are considered as a major drawback of 2xxx series aluminium alloys [11]. The Fig. 1(b) shows normal Dendritic orientation and the cabbage-like structure with the minute porous and a non-uniform mushy central zone. The TiB2 reinforcement and squeeze pressure played significant impact on the grain morphology of AA2219 alloy. Mark Alan Eastonit et al discussed the importance refinement of grain and reduction of the hot tearing. The fine dendritic equiaxed grain morphology resulted in resistance to hot tearing and squeeze pressure arresting the hot tears formation [7]. The columnar to equiaxed transition resulted in decrease of grain size. [8]. Fig. 1(c) reveal the dispersion of TiB2 uniformly and cabbage structure along with the nucleated grain. The squeeze pressure load provided excellent mechanical properties and fine grain which resulted in good casting quality when compared to other casting process [9]. Joel Hemanth reported about ZrO2 Nano particular dispersion effect on aluminium alloy creating the fine grain structure for hot extrusion process [26]. The Fig. 1(d) indicted that grain start to elongate with agglomeration due to 7.5 wt% TiB2 [10,20]. 3.2. SEM analysis Fig. 2(a) represent the SEM micrographs of AA2219 alloy revealing the network coarse grain boundary with crack and porosity. Fig. 2(b) reveal the uniform dispersion of TiB2 particles in the base matrix created equaxial grains and reduction course grain when compared to base alloy. Fig. 2(c) reveal the homogeneously distribution of grain and good interface between the matrix and reinforcement which has increased the load bearing capability and mechanical properties of the AA2219 alloy. Squeeze pressure load plays a vital role in the heat diffusion and rate of solidification which result in the better refinement of the grain AA2219 alloy [28]. The Fig. 2(d) agglomeration takes place due to 7.5 wt% TiB2 particles were fine grain crushed and elongated [14,15]. 3.3. X-Ray diffraction techniques and energy dispersive X-Ray spectroscopy The Bruker D8 advance X-ray diffraction machine used in analysing AA2219 composites of weight percentage (x = 0, 2.5,5 and 7.5) reinforcement of TiB2 with the scan range and scan speed around 25° to 95° and 1.5 degree per minute respectively. The TiB2 peaked at 28° and 33° in 2H for composites samples and aluminium peaked 38°,44°,65°,78° and 82° respectively. The TiB2 elements were compressed in the AA2219 alloy during the squeeze casting process and dissolution of Al peak shift (1 1 1) with incon-
Please cite this article as: A. Karthik, R. Karunanithi, S. A. Srinivasan et al., Microstructure and mechanical properties of AA 2219-TiB2 composites by squeeze casting technique, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.10.143
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Fig. 1. Show the optical image of (a) AA2219 alloy, (b) AA2219 alloy + 2.5 wt% TiB2 (c) AA2219 alloy + 5 wt% TiB2 (d) AA2219 alloy + 7.5 wt% TiB2.
Fig. 2. Show the SEM image of (a) AA2219 alloy, (b) AA2219 alloy + 2.5 wt% TiB2, (c) AA2219 alloy + 5 wt% TiB2 (d) AA2219 alloy + 7.5 wt% TiB2.
Please cite this article as: A. Karthik, R. Karunanithi, S. A. Srinivasan et al., Microstructure and mechanical properties of AA 2219-TiB2 composites by squeeze casting technique, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.10.143
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Fig. 3. Show the Phase composition of squeeze casted sample (a) X-ray diffraction for weight of TiB2 (x = 0,2.5,5 and 7.5) with AA2219 alloy. show the Phase composition of squeeze casted sample (b) EDS mapping of AA2219 composites.
sistent intensity in the composite materials and peak intensity TiB2 get stronger as matrix reinforcement get thermodynamic stability [21]. Indexing of the XRD peaks has showed the presence of a-Al and TiB2 segments in the composite and there is no formation of intermetallic compound in the composites [28]. The reinforcement of TiB2 further conformed by Quantitative elemental method and elemental mapping of prepared composites represented in Fig. 3 (b). The lithium drift silicon detector used with 20KV voltage at 200x magnification for the detection of aluminium, copper, titanium and born as major peaks of the AA2219 composites which represented in Fig. 3(c). 3.4. Hardness Fig. 4(a) reveals the increase of TiB2 particles which increase the hardness of AA2219 alloy. The 7.5 wt% TiB2 shown the maximum response of hardness number when compared to base alloy. The TiB2 particular decrease the plasticity of alloy which in turn increase the hardness of AA2219 alloy [12,18]. The wettability and surface finishing property has been enhanced by the squeezing casting process capability when compared with other casting process [1]. 3.5. Density A minor variation of the densities found among the sample with the increase in TiB2 content. The difference of density between the base matrix and reinforced TiB2 matrix less than 2.88 g/cm^3 is
negligible. Suspension of particles in molten alumina matrix leads to homogenous distribution over a period of time. The density improvement has results in reduction of porosity due to application squeeze pressure. 3.6. Tensile test The effect of dispersion of the TiB2 particular act as an obstacle to the dislocations movements which contribute towards the enrichment tensile strength of AA2219 alloy. Fig. 4(b) reveals the increase of TiB2 particles with the increase the tensile strength of AA2219 alloy. The maximum response of tensile strength was around 153 N/mm2 for the 7.5 wt% of TiB2 and materials tends behave as a brittle nature. According to Hall–Petch relation the materials yield strength is directly proportionate to the inverse root of the grain size of the particles. The dispersion of TiB2 particles refines grains in the alloy, which leads to higher yield strength [18]. 3.7. Wear mechanism Wear is unwanted, slow mild polishing to rapid and material removal with surface roughness which results in a continuous loss of weight and change in size over a certain time. The TiB2 contribute towards the resistance of wear for the AA2219. Overall composites provided a significant resistance to the micro cutting and the abrasion which leads to less metal removal rate from the surface of AA2219 alloy. The effect of TiB2 reinforcement increase
Please cite this article as: A. Karthik, R. Karunanithi, S. A. Srinivasan et al., Microstructure and mechanical properties of AA 2219-TiB2 composites by squeeze casting technique, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.10.143
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Fig. 4. Mechanical properties of AA2219 alloy and composites (a) Hardness number, (b) Tensile strength.
hardness so that wear performance improved. The wear morphology reveals the abrasives and adhesive wear types along with delamination present. The incorporation of TiB2 reinforcement in AA2219 alloy, restricts the plastic deformation by a protective layer between the abrasive opposing material and counter. The small amount of heat generated and lower shearing effect resulted in fewer metal removal rate from the pin surface at lower frictional load 10 N. Wear tracks obviously show less wear resistance towards the counter-facing disc due to presence of softer aluminium and less wt.% TiB2 particles. Fig. 5(a) and 5(b) represent the wear rate vs wt.% of TiB2 reinforcement for the frictional load 10 N, 20 N, 30 N with the sliding distance 500 m and 1000 m respectively. Gradually decrease of wear rate was observed with increasing percentage on TiB2 reinforcement with the sliding distance and frictional load, this mainly due to the increase of hardness and grain refinement. The AA2219 composites has better wear rate compared to that base alloy [29]. Fig. 5(c) and (d) represent the coefficient of friction vs wt.% of TiB2 reinforcement for friction load 10 N, 20 N, 30 N with respect to sliding distance 500 m and 1000 m respectively. The coefficient of friction decreases with the increasing wt.% TiB2 reinforcement with respect to sliding distance and frictional load. The coefficient of friction varies between 0.34 and 0.16 for sliding distance and frictional load of 500 m and10 N. The AA2219 composites shown less coefficient of friction when compared to base alloy. The formation of Al2O3 oxide on the surface which decrease friction at higher load. The decrease coefficient of friction take place due to the mating between the surfaces which induce plastic deformation which hinder dislocation movement [30]. Fig. 5(e) and (f) represent the weight loss vs wt.% of TiB2 reinforcement for friction load 10 N, 20 N, 30 N with respect to sliding distance 500 m and 1000 m respectively. The weight loss decreases with the increasing wt. % TiB2 reinforcement with respect to sliding distance and frictional load. The reduction of weight loss happens due to strain hardening of the material that happens in any wear process. The weight loss of AA2219 composites less when compared to base alloy [30].
3.8. SEM analysis of worn samples Fig. 6(a) represent the 7.5wt.%TiB2 reinforcement with AA2219 alloy at the frictional load at 30 N and reveal about the substantial scratches and scars. The ploughing phenomenon is commonly observed and deep grooves formation take place due to the plastic
flow of alloy material at higher frictional load. The TiB2 particular shows shearing effect on wear action which causes plastic deformation [31]. Adhesive wear is identified by the plastic deformation and existence of pits and prows. Fig. 6(b) represent the 5wt. %TiB2 with AA2219 alloy at the frictional load 10 N and occurrence of delamination by excessive fracture on the material along with flake. The sequence of minor cracks interconnected due to lower bonding strength of the AA2219 alloy due contamination at the surface and oxidation take place. The formation of loose fragment seen in the middle track because of poor surface bonding and mild ploughing action have been observed [32]. Fig. 6(c) represent the wear morphology of 7.5 wt% TiB2 alloy at 20 N and sliding distance 1000 m. The wear rate of composites decreased due to action of TiB2 particles which provide good interfacial bonding [33]. The alloy gets harder which tend to resist the scratch induced by counter-facing disc. The matrix and reinforcement interaction improved so the formation loose fragment found to be lesser along the wear direction at mild frictional loads. Fig. 6(d) show particles pull out of AA2219 composites at 30 N and the abrasive material increase the metal removal rate from the pin surface due to 7.5 wt. %TiB2 reinforcement. The large flakes had been produced and kept along the wear path for a long time because of heat generation. The flakes had been exposed to intense plastic deformation and spread over the wear surface which causes high metal removal rate at 30 N frictional load and 1000 m sliding distance.
4. Conclusion In order to maximum benefits, the squeeze casting parameter and the component must be in correlation with the alloy chosen. A good design squeeze cast will be able to manufacture the component with excellent mechanical properties due to fine grain structure and a good surface finish to compete with other casting techniques. Squeeze casting process parameter such as squeeze pressure load at 350 MPa, die and melt temperature as 200°C and 650°C respectively used for AA2219 alloy with TiB2 particulate reinforcement. The excellent bond exists between AA2219 alloy and TiB2 particles which results in excellent and homogeneous grain structure. Squeeze pressure provide better solidification rate when compare to other casting process. XRD analysis revealed the presence of TiB2 phases in the composites. Casted composites have significant improvement in the tensile strength, hardness and wear resistance when compared with base AA2219 alloy. The 7.5 wt%
Please cite this article as: A. Karthik, R. Karunanithi, S. A. Srinivasan et al., Microstructure and mechanical properties of AA 2219-TiB2 composites by squeeze casting technique, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.10.143
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Fig. 5. Wear rate vs wt.% of TiB2 reinforcement at constant sliding velocity 2.5 m/s (a) Sliding distance 500 m and (b) Sliding distance 1000 m. Coefficient of friction vs Wt.% of TiB2 reinforcement at constant sliding velocity 2.5 m/s (c) Sliding distance 500 m and (d) Sliding distance 1000 m. Weight loss vs % of TiB2 reinforcement at constant sliding velocity 2.5 m/s (e) Sliding distance 500 m and (d) Sliding distance 1000 m.
Please cite this article as: A. Karthik, R. Karunanithi, S. A. Srinivasan et al., Microstructure and mechanical properties of AA 2219-TiB2 composites by squeeze casting technique, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.10.143
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Fig. 6. Wear morphology of AA2219 alloy and composites (a) Deep groves, (b) Delamination, (c) Ploughing (d) Particular pull out.
TiB2 reinforcement shown the maximum response of hardness 101 and the tensile strength of composites is 153 N/mm2. The AA2219 alloy show better wear resistance with increase of TiB2 under squeeze casting process.
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Declaration of Competing Interest
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The authors declare that they have no known competing financial interests or personal relationships that could have appeared to influence the work reported in this paper. Acknowledgements
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We would like to acknowledge the support of Dr. S.P. Kumareshbabu, Prof, Department of MME, NIT, for their valuable help in carrying out this work and also extend our thankfulness to the Dr. S. Rasool Mohideen Prof. & Dean, School of Mechanical Sciences, Crescent Institute of Science and Technology, B.S. Abdur Rahman University for their valuable suggestions at various stages of the project.
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Please cite this article as: A. Karthik, R. Karunanithi, S. A. Srinivasan et al., Microstructure and mechanical properties of AA 2219-TiB2 composites by squeeze casting technique, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.10.143
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Materials Today: Proceedings journal homepage: www.elsevier.com/locate/matpr
Microstructure and mechanical properties of AA 2219-TiB2 composites by squeeze casting technique A. Karthik a, R. Karunanithi b,⇑, S.A. Srinivasan c, M. Prashanth a a
Dept. of Mechanical Engg, B.S. Abdur Rahman Crescent Institute of Science and Technology, Chennai 600048, India Dept. of Aerospace Engg, B.S. Abdur Rahman Crescent Institute of Science and Technology, Chennai 600048, India c Dept. of MME, National Institute of Technology, Trichy 620015, India b
a r t i c l e
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Article history: Received 12 August 2019 Received in revised form 18 October 2019 Accepted 21 October 2019 Available online xxxx Keywords: Squeeze casting AA2219 Reinforcement TiB2 Mechanical property X-ray diffraction technique Scanning electron microscope
a b s t r a c t The AA2219 alloy has been investigated by using squeeze casting process and the reinforcement of TiB2 is added to improve mechanical property and grain morphology to match the requirement of aerospace and automotive industries. The AA2219 alloy and composites sample were prepared by squeeze casting process and process parameter were kept at 350 MPa squeeze pressure load, die and melt temperature as 200°C and 650°C respectively with the standard dwell time 60 s. The weight percentage (x = 0,2.5,5 and 7.5) reinforcement of TiB2 added with AA2219 alloy. The morphology and phase of prepared samples are evaluated by using light microscopy, X-ray diffraction, scanning electron microscopic and energy dispersive technique. The reinforcement of TiB2 resulted in grain refinement of alloy attaining equiaxial and homogeneous grain structure. Mechanical properties such as micro hardness and tensile strength have been enhanced by 22% and 89% respectively. Wear analysis performed on the composite with help of pin on disk setup and wear characteristic show excellent wear resistance. Ó 2019 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the scientific committee of the International conference on Materials and Manufacturing Methods.
1. Introduction The aluminium is the third most typical element which comprises 8% of the earth’s crust. The workability of the aluminium makes the foremost widely used metal after steel. For the last three decades’ intensive research has been done on ceramic reinforcement to improve physical properties of base matrix’s in specific alumina alloy as it offers less weight ratio and ductile nature for better utilization [16]. The M K SURAPPA had emphasized the importance of improvement in the damage tolerance such as fracture toughness and ductility of aluminium metals matrix composite [24]. Recent development of the advanced materials due to tremendous improvement in the field of manufacturing which leads to the development of MMC by various economical production methods. One of the interest area for researchers is the squeeze casting process since it offers excellent mechanical property and fine grain without porosity under optimum process parameter [27]. Squeeze casting process basically is a combinations of casting and forging with the maximum utilization of raw ⇑ Corresponding author. E-mail address: [email protected] (R. Karunanithi).
material when compared to other casting processes [1,2]. D.J. Britnell et al reported on Squeeze casting process which offer refined grain structure when compared to the other casting process. The molten liquid is subjected to a high squeeze pressure load up to the component solidify which in turn reduces the shrinkage and porosity with good surface finish (0.4–3.2) and dimensional accuracy (0.2 mm/100 mm) [13]. Z. Sadeghiana et al reported about the improvement of mechanical properties for a metal matrix composites by grain refinement to survive in the competitive industries like aerospace and automotive industries [3]. S. Y. Wang et al reported on the improvement of Al–Cu–Mg alloy by stir casting method with SiC as a reinforcement since the alloy has a wider application in the automotive and aerospace manufacturing industries [4]. Major reinforcement Ceramic particles are TiC, TiB2, B4C, SiO, MgO, and SiC which offer an excellent elastic modulus, strength, hardness, and thermal resistance. The reinforcement in the aluminium metal matrix appears to be an excellent way to manufacture composites for the automotive and aerospace industries [5,6,17]. The investigation of wear behavior of Al-Si (eutectic) – ENAC48000 showing the higher wear resistance when manufactured by Squeeze casting technique along with 40 nm nano alumina reinforcement. The increasing hardness and wear abrasion
https://doi.org/10.1016/j.matpr.2019.10.143 2214-7853/Ó 2019 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the scientific committee of the International conference on Materials and Manufacturing Methods.
Please cite this article as: A. Karthik, R. Karunanithi, S. A. Srinivasan et al., Microstructure and mechanical properties of AA 2219-TiB2 composites by squeeze casting technique, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.10.143
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phenomena was observed with the increase reinforcement. At the high temperatures oxide formation take place which offer better wear resistance [22]. R. Ashiria et al had made an attempt to compare the squeeze casting process with gravity casting for LM13 piston alloy materials which offer low coefficient of thermal expansion and excellent cast ability. The squeeze casted sample had an excellent mechanical property with increase of hardness and tensile strength. The squeeze pressure has played important role in reduction of porosity and better solidification along with refinement of grain [23]. The Najib Souissi et al had investigated on the relationship between mechanical property and process capability squeeze casting for the wrought aluminium alloy optimized by Taguchi method. The process capability of squeeze casting has produced significant improvement in the alloy [25]. In this work AA2219 alloy was reinforced with TiB2 using squeeze casting process and the microstructure evolution done by SEM, Optical microscope. The Mechanical property such as hardness and tensile test was performed under ASTM condition [19].
2. Materials and methods The Fenfe Metallurgical, Karnataka, India have supplied the AA2219 aluminium ingots materials and the chemical composition of the aluminium ingots was analyzed by the Optical Emission Spectrometer as wt.% Al: 92.87% Cu: 6.2% Si: 0.15%Zr: 0.22% va: 0.11%. The alloy was loaded in 2-liter capacity electric furnace with bottom pouring setup. The squeeze casting equipment had a hydraulic press for liquid forging the liquid metal which poured into the H13 die. The degausser was used to remove slag and dust particle by adding small quantity of hex-chloro ethane tablets. The composites were prepared by following wt.% of TiB2 (X = 0, 2.5, 5 and 7.5). The furnace temperature was held at 1000°C for 20 min before pouring. The molten metal path was pre-heated up to 700°C by adjusting temperature control present in squeeze casting setup to ensure smooth flow of liquid metal. Molten melt was stirred using graphite coated stirrer at 200 rpm while the adding reinforcement of TiB2 particle. The Squeeze casting process parameter are maintained as squeeze pressure load at 350 MPa, die and melt temperature as 200°C and 650°C respectively with the standard dwell time 60 s. The phase composition of squeeze casted component was analyzed by X-ray diffraction technique and patterns arrived by indexing ICDD patterns available in PCPDF database. The sample were prepared for micro graphical examination by cutting a portion of materials from the squeeze casted sample and polished with help of emery sheet, subsequently by alumina and diamond polishing. The pre-etched samples were done using Phosphoric acid (H2PO4 – 40%) and subsequently followed by 1g NaCl at 70°C and Weck’s reagent (1g NaOH + 4g KMnO4 + 100 ml H2O) for 120 s to in order to expose micro structure. The optical image was captured by the Olympus optical microscope and foundry plus image analyzing software was used to find out the porosity, crack and grain structure. Matsuwa Vickers’s hardness test was used to find out hardness at standard 100 gf load with 15 s dwell time. The density value was calculated by Archimedes principle. The microstructural examination was further carried out to examine the second phase particles using SEM with EDS to find the elemental compositions. The tensile sample were made for ASTM A-370 to estimate the ultimate tensile strength. Wear characteristic curve obtained from the TR-20 HTVT, DUCOM pin on disk experiment and SEM micrograph record for wear sample. The samples were weighed before and after wear using a digital weighing balance with accuracy of 0.0001 mg. An EN32 with 64HRC disc was used as a counter body with normal force acting and was pressed along the side surface of the rotating disc with track radius 50 mm. The samples are kept stationary and pin were polished by emery paper
before the start experiment. The disc surface is cleaned regularly before and after wear testing by acetone. The laws governing wear V/X = K*(W/H) Where, V = Wear volume X = Sliding distance W = Normal load applied H = Initial hardness of the softer sliding components K = Wear coefficient. The above mention equation used for both adhesive and abrasive wear. The dry sliding wear was done at room temperature with a constant sliding time of 1000 s. The LVDT is used to measure the wear rate in lm and frictional force in newton. The coefficient of friction measured by control system. The sliding velocity kept at 2.5 m/s to study the wear morphology and the linearity was formed between increase wear rate and sliding distance. 3. Results and discussion 3.1. Optical microscopic AA2219 alloy optical image reveals the coarse grain boundary and hot tear along with porosity which has been represented in Fig. 1(a). Hot tears are considered as a major drawback of 2xxx series aluminium alloys [11]. The Fig. 1(b) shows normal Dendritic orientation and the cabbage-like structure with the minute porous and a non-uniform mushy central zone. The TiB2 reinforcement and squeeze pressure played significant impact on the grain morphology of AA2219 alloy. Mark Alan Eastonit et al discussed the importance refinement of grain and reduction of the hot tearing. The fine dendritic equiaxed grain morphology resulted in resistance to hot tearing and squeeze pressure arresting the hot tears formation [7]. The columnar to equiaxed transition resulted in decrease of grain size. [8]. Fig. 1(c) reveal the dispersion of TiB2 uniformly and cabbage structure along with the nucleated grain. The squeeze pressure load provided excellent mechanical properties and fine grain which resulted in good casting quality when compared to other casting process [9]. Joel Hemanth reported about ZrO2 Nano particular dispersion effect on aluminium alloy creating the fine grain structure for hot extrusion process [26]. The Fig. 1(d) indicted that grain start to elongate with agglomeration due to 7.5 wt% TiB2 [10,20]. 3.2. SEM analysis Fig. 2(a) represent the SEM micrographs of AA2219 alloy revealing the network coarse grain boundary with crack and porosity. Fig. 2(b) reveal the uniform dispersion of TiB2 particles in the base matrix created equaxial grains and reduction course grain when compared to base alloy. Fig. 2(c) reveal the homogeneously distribution of grain and good interface between the matrix and reinforcement which has increased the load bearing capability and mechanical properties of the AA2219 alloy. Squeeze pressure load plays a vital role in the heat diffusion and rate of solidification which result in the better refinement of the grain AA2219 alloy [28]. The Fig. 2(d) agglomeration takes place due to 7.5 wt% TiB2 particles were fine grain crushed and elongated [14,15]. 3.3. X-Ray diffraction techniques and energy dispersive X-Ray spectroscopy The Bruker D8 advance X-ray diffraction machine used in analysing AA2219 composites of weight percentage (x = 0, 2.5,5 and 7.5) reinforcement of TiB2 with the scan range and scan speed around 25° to 95° and 1.5 degree per minute respectively. The TiB2 peaked at 28° and 33° in 2H for composites samples and aluminium peaked 38°,44°,65°,78° and 82° respectively. The TiB2 elements were compressed in the AA2219 alloy during the squeeze casting process and dissolution of Al peak shift (1 1 1) with incon-
Please cite this article as: A. Karthik, R. Karunanithi, S. A. Srinivasan et al., Microstructure and mechanical properties of AA 2219-TiB2 composites by squeeze casting technique, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.10.143
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Fig. 1. Show the optical image of (a) AA2219 alloy, (b) AA2219 alloy + 2.5 wt% TiB2 (c) AA2219 alloy + 5 wt% TiB2 (d) AA2219 alloy + 7.5 wt% TiB2.
Fig. 2. Show the SEM image of (a) AA2219 alloy, (b) AA2219 alloy + 2.5 wt% TiB2, (c) AA2219 alloy + 5 wt% TiB2 (d) AA2219 alloy + 7.5 wt% TiB2.
Please cite this article as: A. Karthik, R. Karunanithi, S. A. Srinivasan et al., Microstructure and mechanical properties of AA 2219-TiB2 composites by squeeze casting technique, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.10.143
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Fig. 3. Show the Phase composition of squeeze casted sample (a) X-ray diffraction for weight of TiB2 (x = 0,2.5,5 and 7.5) with AA2219 alloy. show the Phase composition of squeeze casted sample (b) EDS mapping of AA2219 composites.
sistent intensity in the composite materials and peak intensity TiB2 get stronger as matrix reinforcement get thermodynamic stability [21]. Indexing of the XRD peaks has showed the presence of a-Al and TiB2 segments in the composite and there is no formation of intermetallic compound in the composites [28]. The reinforcement of TiB2 further conformed by Quantitative elemental method and elemental mapping of prepared composites represented in Fig. 3 (b). The lithium drift silicon detector used with 20KV voltage at 200x magnification for the detection of aluminium, copper, titanium and born as major peaks of the AA2219 composites which represented in Fig. 3(c). 3.4. Hardness Fig. 4(a) reveals the increase of TiB2 particles which increase the hardness of AA2219 alloy. The 7.5 wt% TiB2 shown the maximum response of hardness number when compared to base alloy. The TiB2 particular decrease the plasticity of alloy which in turn increase the hardness of AA2219 alloy [12,18]. The wettability and surface finishing property has been enhanced by the squeezing casting process capability when compared with other casting process [1]. 3.5. Density A minor variation of the densities found among the sample with the increase in TiB2 content. The difference of density between the base matrix and reinforced TiB2 matrix less than 2.88 g/cm^3 is
negligible. Suspension of particles in molten alumina matrix leads to homogenous distribution over a period of time. The density improvement has results in reduction of porosity due to application squeeze pressure. 3.6. Tensile test The effect of dispersion of the TiB2 particular act as an obstacle to the dislocations movements which contribute towards the enrichment tensile strength of AA2219 alloy. Fig. 4(b) reveals the increase of TiB2 particles with the increase the tensile strength of AA2219 alloy. The maximum response of tensile strength was around 153 N/mm2 for the 7.5 wt% of TiB2 and materials tends behave as a brittle nature. According to Hall–Petch relation the materials yield strength is directly proportionate to the inverse root of the grain size of the particles. The dispersion of TiB2 particles refines grains in the alloy, which leads to higher yield strength [18]. 3.7. Wear mechanism Wear is unwanted, slow mild polishing to rapid and material removal with surface roughness which results in a continuous loss of weight and change in size over a certain time. The TiB2 contribute towards the resistance of wear for the AA2219. Overall composites provided a significant resistance to the micro cutting and the abrasion which leads to less metal removal rate from the surface of AA2219 alloy. The effect of TiB2 reinforcement increase
Please cite this article as: A. Karthik, R. Karunanithi, S. A. Srinivasan et al., Microstructure and mechanical properties of AA 2219-TiB2 composites by squeeze casting technique, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.10.143
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Fig. 4. Mechanical properties of AA2219 alloy and composites (a) Hardness number, (b) Tensile strength.
hardness so that wear performance improved. The wear morphology reveals the abrasives and adhesive wear types along with delamination present. The incorporation of TiB2 reinforcement in AA2219 alloy, restricts the plastic deformation by a protective layer between the abrasive opposing material and counter. The small amount of heat generated and lower shearing effect resulted in fewer metal removal rate from the pin surface at lower frictional load 10 N. Wear tracks obviously show less wear resistance towards the counter-facing disc due to presence of softer aluminium and less wt.% TiB2 particles. Fig. 5(a) and 5(b) represent the wear rate vs wt.% of TiB2 reinforcement for the frictional load 10 N, 20 N, 30 N with the sliding distance 500 m and 1000 m respectively. Gradually decrease of wear rate was observed with increasing percentage on TiB2 reinforcement with the sliding distance and frictional load, this mainly due to the increase of hardness and grain refinement. The AA2219 composites has better wear rate compared to that base alloy [29]. Fig. 5(c) and (d) represent the coefficient of friction vs wt.% of TiB2 reinforcement for friction load 10 N, 20 N, 30 N with respect to sliding distance 500 m and 1000 m respectively. The coefficient of friction decreases with the increasing wt.% TiB2 reinforcement with respect to sliding distance and frictional load. The coefficient of friction varies between 0.34 and 0.16 for sliding distance and frictional load of 500 m and10 N. The AA2219 composites shown less coefficient of friction when compared to base alloy. The formation of Al2O3 oxide on the surface which decrease friction at higher load. The decrease coefficient of friction take place due to the mating between the surfaces which induce plastic deformation which hinder dislocation movement [30]. Fig. 5(e) and (f) represent the weight loss vs wt.% of TiB2 reinforcement for friction load 10 N, 20 N, 30 N with respect to sliding distance 500 m and 1000 m respectively. The weight loss decreases with the increasing wt. % TiB2 reinforcement with respect to sliding distance and frictional load. The reduction of weight loss happens due to strain hardening of the material that happens in any wear process. The weight loss of AA2219 composites less when compared to base alloy [30].
3.8. SEM analysis of worn samples Fig. 6(a) represent the 7.5wt.%TiB2 reinforcement with AA2219 alloy at the frictional load at 30 N and reveal about the substantial scratches and scars. The ploughing phenomenon is commonly observed and deep grooves formation take place due to the plastic
flow of alloy material at higher frictional load. The TiB2 particular shows shearing effect on wear action which causes plastic deformation [31]. Adhesive wear is identified by the plastic deformation and existence of pits and prows. Fig. 6(b) represent the 5wt. %TiB2 with AA2219 alloy at the frictional load 10 N and occurrence of delamination by excessive fracture on the material along with flake. The sequence of minor cracks interconnected due to lower bonding strength of the AA2219 alloy due contamination at the surface and oxidation take place. The formation of loose fragment seen in the middle track because of poor surface bonding and mild ploughing action have been observed [32]. Fig. 6(c) represent the wear morphology of 7.5 wt% TiB2 alloy at 20 N and sliding distance 1000 m. The wear rate of composites decreased due to action of TiB2 particles which provide good interfacial bonding [33]. The alloy gets harder which tend to resist the scratch induced by counter-facing disc. The matrix and reinforcement interaction improved so the formation loose fragment found to be lesser along the wear direction at mild frictional loads. Fig. 6(d) show particles pull out of AA2219 composites at 30 N and the abrasive material increase the metal removal rate from the pin surface due to 7.5 wt. %TiB2 reinforcement. The large flakes had been produced and kept along the wear path for a long time because of heat generation. The flakes had been exposed to intense plastic deformation and spread over the wear surface which causes high metal removal rate at 30 N frictional load and 1000 m sliding distance.
4. Conclusion In order to maximum benefits, the squeeze casting parameter and the component must be in correlation with the alloy chosen. A good design squeeze cast will be able to manufacture the component with excellent mechanical properties due to fine grain structure and a good surface finish to compete with other casting techniques. Squeeze casting process parameter such as squeeze pressure load at 350 MPa, die and melt temperature as 200°C and 650°C respectively used for AA2219 alloy with TiB2 particulate reinforcement. The excellent bond exists between AA2219 alloy and TiB2 particles which results in excellent and homogeneous grain structure. Squeeze pressure provide better solidification rate when compare to other casting process. XRD analysis revealed the presence of TiB2 phases in the composites. Casted composites have significant improvement in the tensile strength, hardness and wear resistance when compared with base AA2219 alloy. The 7.5 wt%
Please cite this article as: A. Karthik, R. Karunanithi, S. A. Srinivasan et al., Microstructure and mechanical properties of AA 2219-TiB2 composites by squeeze casting technique, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.10.143
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Fig. 5. Wear rate vs wt.% of TiB2 reinforcement at constant sliding velocity 2.5 m/s (a) Sliding distance 500 m and (b) Sliding distance 1000 m. Coefficient of friction vs Wt.% of TiB2 reinforcement at constant sliding velocity 2.5 m/s (c) Sliding distance 500 m and (d) Sliding distance 1000 m. Weight loss vs % of TiB2 reinforcement at constant sliding velocity 2.5 m/s (e) Sliding distance 500 m and (d) Sliding distance 1000 m.
Please cite this article as: A. Karthik, R. Karunanithi, S. A. Srinivasan et al., Microstructure and mechanical properties of AA 2219-TiB2 composites by squeeze casting technique, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.10.143
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Fig. 6. Wear morphology of AA2219 alloy and composites (a) Deep groves, (b) Delamination, (c) Ploughing (d) Particular pull out.
TiB2 reinforcement shown the maximum response of hardness 101 and the tensile strength of composites is 153 N/mm2. The AA2219 alloy show better wear resistance with increase of TiB2 under squeeze casting process.
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Declaration of Competing Interest
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The authors declare that they have no known competing financial interests or personal relationships that could have appeared to influence the work reported in this paper. Acknowledgements
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We would like to acknowledge the support of Dr. S.P. Kumareshbabu, Prof, Department of MME, NIT, for their valuable help in carrying out this work and also extend our thankfulness to the Dr. S. Rasool Mohideen Prof. & Dean, School of Mechanical Sciences, Crescent Institute of Science and Technology, B.S. Abdur Rahman University for their valuable suggestions at various stages of the project.
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Please cite this article as: A. Karthik, R. Karunanithi, S. A. Srinivasan et al., Microstructure and mechanical properties of AA 2219-TiB2 composites by squeeze casting technique, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.10.143