Processing, Microstructure and Mechanical Properties of Al2O3 and SiC Reinforced Magnesium Metal Matrix Hybrid Composites

Processing, Microstructure and Mechanical Properties of Al2O3 and SiC Reinforced Magnesium Metal Matrix Hybrid Composites

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Available online at www.sciencedirect.com

ScienceDirect Materials Today: Proceedings 4 (2017) 6750–6756

www.materialstoday.com/proceedings

iMagCon2016

Processing, Microstructure and Mechanical Properties of Al2O3 and SiC Reinforced Magnesium Metal Matrix Hybrid Composites a

b

c

Karthick E , Joel Mathai , Michael Tony J , Senthil Kumar Marikkannan

a,b,c,∗

School of Mechanical and Building Sciences, VIT University, Chennai 600048, Tamilnadu, India [email protected], [email protected]

Abstract Magnesium alloy (AZ31) is used as the base metal matrix. Alumina (Al2O3) with 5 wt%) and silicon carbide (SiC) with varying 0-8 wt% is used as the reinforcing ceramic materials. The compacted green samples were sintered at 450℃ for 20 min. The prepared metal matrix composite hybrid (MMC) samples were subjected to characterization and mechanical studies such as optical microstructure, X-ray diffraction, Scanning electron microscopy (SEM), and hardness. Results showed that magnesium metal matrix composites (MMC) hardness increased from 64.53 to 75.16 HV, which was mainly due to the presence of reinforcements Al2O3 and SiC along with precipitates. Addition of alumina and silicon carbide on magnesium alloy, influenced the hardness of MMC. © 2017 Elsevier Ltd. All rights reserved. Selection and Peer-review under responsibility of the Conference Committee Members of International Conference and Expo on Magnesium (iMagCon2016).

Keywords: Metal–matrix composites (MMC); Particle-reinforced composites; Powder processing; sintering.

1. Introduction Need for lighter materials, made the automotive manufacturers to start looking for material lighter than aluminium. In early 1990’s, automobile industries started to invest in magnesium material. In last years, magnesium and its alloys have attained widespread attention in scientific research and commercial application. It has low density, approximately two-third of that of aluminum [1], and high specific strength [2] as compared to other structural metals. As energy conservation and performance demands are increasing in automotive ∗

Karthick E. Tel.: +91-8148667804; E-mail address: [email protected]

2214-7853 © 2017 Elsevier Ltd. All rights reserved. Selection and Peer-review under responsibility of the Conference Committee Members of International Conference and Expo on Magnesium (iMagCon2016).

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technology. Usage of lightweight materials, will improve fuel economy and reduction of emissions [3]. However, the application of magnesium alloys is restricted due to its poor creep resistance at high temperatures, low strength, low modulus and wear resistance [4, 5]. Most commercial magnesium alloys (AM50, AZ31, AZ91) contains aluminium, manganese and zinc that allows obtaining suitable properties by adding reinforcements [6]. The reinforcements used in MMC are ceramic fiber, whiskers or particulates like SiC, Al2O3, Tic, CNTs etc. [7]. The most common reinforcements studied are Al2O3 and SiC magnesium alloy (AZ31) reinforced with alumina (Al2O3) reported noticeable improvements in hardness and tensile strength prepared by using stir casting technique [8]. Similarly, Addition of SiC increases corrosion rate and cracking. SiC is the best strengthening reinforcement since it is having higher values of Vickers [9, 10]. Mechanical properties and nucleation depends on processing, composition and type of reinforcement [11, 12]. MMCs are manufactured by techniques like powder metallurgy, stir casting process, squeeze casting, In-situ process, ultrasonic cavitation process, spray forming, pressure less infiltration techniques, etc. Cost of fabrication remains a major disadvantage in MMC. The composite materials offer flexibility in selection of reinforcements to tailor the properties. Therefore, cost effective processing of composites plays a crucial role in expanding their applications. Light weight; low cost of processing of hybrid MMCs is yet to attract much attention from researchers by using high strength reinforcements such as Al2O3 and SiC. This research is motivated by the potential benefits of developing MMCs reinforcement with Al2O3 and SiC by using powder metallurgy technique. To study the effects of the addition of particulate reinforcements on the microstructure, physical and mechanical properties of magnesium 2. Experimental Procedure Fig. 1 shows the synthesis and characterization of samples used in this study. Sample preparation was carried out for different compositions with AZ31with 95-87 wt% used as the base metal matrix.

Fig. 1. Methodology of research

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The composition of alumina was fixed at 5% and silicon carbide varied from 0-8 wt% with corresponding composition of magnesium alloy. Green compacts were prepared using stearic acid (CH3 (CH2)16COOH (2 wt%) used as lubricant. Powder metallurgy technique was used for the synthesizing of magnesium metal matrix composites. The reinforcement powders with their weight compositions were mixed in order to ensure uniform distribution of the powder particles. Mixtures were compacted at 200 MPa for 30s different compositions. The compacted samples were subjected to heat treatment in microwave sintering sintered at 450ºC at the rate of 10°C/min for 20 min. Sintered samples are cooled at furnace itself. The density of the sintered samples was determined using Archimedes principle. The phase composition was analysed by diffractometer (SEIFURT) with a graphite monochromatic Cu-kα radiation (λ = 1.54056 Å), operating at 30 kV and 40 mA to study the X-ray powder diffraction (XRD). The XRD patterns were acquired in the 2θ range of 5-70° [11]. SEM (Make: Jeol, Japan; Model: 6410-LV studies were conducted on polished specimens to investigate the presence of reinforcement distribution, and matrix reinforcement grain size and gain morphology. Micro hardness (Make: Shimadzu) was measured on the Vickers superficial Scale using a 1.588 mm (1/16 inch) steel ball indenter with test load of 15 kgf and dwell time of 2 seconds. Microstructures were taken on the polished samples using optical microscope at 100X. 3. Results and discussion 3.1 X-Ray Diffraction Fig. 2 shows XRD result of AZ31 (90 wt%) magnesium alloy reinforced with Al2O3 (5 wt%) and Sic (5 wt%). The sintered magnesium alloy samples were quantified using SEIFURT diffractometer. The diffraction pattern shows the presence of magnesium in higher content from the intensity of peaks compared to Al2O3 and Sic Intensity of peaks for Al2O3 and SiC were very low due to the presence of magnesium content in the sample. XRD patterns from this results confirms the presence of fraction of SiC in the sample. Thus confirms the objective of adding SiC and Al2O3 in this research to improve mechanical properties.

Fig. 2. XRD pattern for MMC AZ31 (90 wt%)

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3.2 Scanning Electron Microscopy Microstructural characterization of the composites showed significant grain refinement, relative uniform reinforcement distribution, and presence of minimal porosity. SEM analysis shows the AZ31 matrix, Al2O3 and SiC particles are well bonded. The presence of precipitates was observed in the matrix or at the interface. Interface has a strong influence to the properties of the composites. A closer observation by SEM showed that the microstructure consisted of primary magnesium, SiC, ß-Mg17-Al12, and Mg2Si precipitates as shown in (Fig 2.) Precipitates were hard and brittle contributing to the hardness of the alloy. SEM images show that reinforcements were distributed in a random and isotropic orientation and no agglomeration was observed. The presence of reinforcements around the boundaries may act as barriers to prevent the grains from growing further (Fig 3). SiC with an average size of grain sizes of 0.320µm showed good strength. As a result of the restriction of this growth, the primary phase would allow the melt to have enough time to form more nuclei. Microstructure showed the interface was sharp and clean without any visible interaction zone. The uniformity of the reinforcement distribution provided great contribution to the mechanical properties of the magnesium matrix composite

Fig. 2. SEM microstructure of AZ31 (87 wt%)

Fig. 3. SEM microstructure of AZ31 (90 wt%)

3.3 Density Measurement From the table 1, the density of magnesium composites increased with respect to increase in the reinforcement wt% (alumina and silicon carbide). The density of SiC is higher than Al2O3 and AZ31 and hence an increase in the SiC content increased the density of the composite. It is observed that by increasing the wt% of SiC from 0 to 8% density increased by 14.66%.

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Table 1. Density Measurement Value for (Mg 95%-87%) Sample

AZ31 %

Density (g/cm3)

1.

87

1.9681

2.

88

1.9534

3.

89

1.9387

4.

90

1.9240

5.

91

1.9093

6.

92

1.8946

7.

93

1.8010

8.

94

1.7980

9.

95

1.7189

3.4 Optical micro structure Microstructural evaluation for different samples of metal matrix hybrid composite is shown in Fig. 4. Observation showed randomly dispersed SiC and Al2O3 particles in AZ31 matrix. In Mg matrix. It is observed that the SiC and Al2O3 particulates are visible and non-homogeneous distribution of SiC and Al2O3 particles was observed at some locations in the magnesium matrix is evident. From Fig. 4c that there is a high volume percent of particulates dispersed in the magnesium matrix for the hybrid composite containing 8 wt% of the SiC in comparison to the reinforcement with 3 and 5 wt% of SiC

Fig.4. Optical microstructure for MMC sample at 100X a) 92 wt% Mg b) 90 wt% Mg c) 87 wt% Mg

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3.5 Hardness Table.2 shows hardness was found to increase with increase in SiC content in the hybrid MMC. In hybrid composites hard SiC particles act as a load bearing member. Hence it enhances the mechanical property of the material. Hardness of the composite increased by 16.47% as the reinforcement content of Al2O3 and SiC particles was varied from 0 to 8 wt%. Silicon particles present along the flow lines and act as barriers to the movement of dislocations within the matrix. The increase in weight fraction of hard particle increased the hardness of the MMC. Our results reported in the table.2 were consistent with the results observed for A356/SiC [13] and Al-Si/SiC by earlier researchers. This observation should be attributed to the presence of the reinforcements Al2O3 and SiC along with presence of precipitates confirmed from the results of SEM with their superior strength and stiffness. Besides, the reduced grain size also had contribution to the increase in hardness. Table 2. Micro Hardness measurement (AZ31 95%-87%)

Sl.NO

AZ31

Hardness

Load

%

HV

Gm

1.

87

75.16

200

2.

88

74.83

200

3.

89

73.25

200

4.

90

72.12

200

5.

91

67.95

200

6.

92

69.42

200

7.

93

69.71

200

8.

94

67.49

200

9.

95

64.53

200

4. Conclusion AZ31 MMC was successfully synthesized using powder metallurgy technique. The microstructure, hardness and density of the samples were evaluated. The obtained results are summarized as follows: 1.

Microstructural investigation showed random dispersion of reinforcing particles SiC and Al2O3 particle in Mg matrix.

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2.

Reinforcing Aluminum alloys with ceramics particles has shown an appreciable increase in its mechanical properties. Hardness of Mg is increased by 16.47% with increase in SiC reinforcement. 3. Density of AZ31-Al2O3-SiC hybrid composites was found to increase with increase in SiC. Hence SiC serve as a complementing reinforcement for the development of low-cost high-performance magnesium hybrid composite.

5.

Acknowledgement

I would like to express my special thanks to Management of VIT University, Dean-SMBS and all those who provided me the support for providing the facilities to carry out this research work.

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