Dr M Prabhakar Presentation Sample to Basha (2)

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EFFECT OF REINFORCEMENT PARTICLE SIZES ON PORE CLOSURE AND WORKABILITY IN SINTERED

Al – SiC POWDER METALLURGY COMPOSITE DURING COLD UPSETTING

ByM. Prabhakar Research ScholarDepartment of Mechanical Engineering

Dr. T. RameshResearch Supervisor,Asst. Professor,Department of Mechanical Engg.,

Dr. R. NarayanasamyResearch Co-Supervisor,Professor,Department of Production Engg.,

NATIONAL INSTITUTE OF TECHNOLOGYTIRUCHIRAPPALLI- 620 015

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CONTENTS INTRODUCTION

LITERATURE REVIEW

STATEMENT OF THE PROBLEM

SCOPE OF THE RESEARCH

FRAME WORK OF THE STUDY

EXPERIMENTAL DESIGN

THEORETICAL DISCUSSION

RESULTS AND DISCUSSION

PUBLICATIONS

REFERENCES

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INTRODUCTION

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METAL MATRIX COMPOSITE

A Metal Matrix Composite (MMC) is a type of composite materials with at

least two constituent parts, one being a metal, the other may be a different

metal or another material, such as a ceramic or organic compound.

When at least three materials are present, it is called a hybrid composite.

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Need for PM Technique

• Structural pieces with complex shapes

• Controlled Porosity

• Controlled performance

• Good performance in stress and absorbing of vibrations

• Special properties such as hardness and wear resistance

• Great precision and good surface finish

• Large series of pieces with narrow tolerances [1]

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[1]

Need for PM Technique

Cost comparison between PM and Forging

PM Structural Component Markets

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Cold Uni-axial Compaction

Widely used in manufacturing of bulk metals

Faster production

Higher strength

Good surface finish

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Sintering

Sintering is a process that consolidates and strengthens loose or

compacted particles into a more dense coherent body.

Sintering generally consists of initial particle bonding, neck growth, pore

channel closure, pore rounding, densification or pore shrinkage and pore

coarsening

During sintering the pores are get closed

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Upset Forging

Upset forging increases the diameter of the work piece when

it is subjected to compressive loading along its axis.

Closing of pores are happened during compaction

Highest densification of the material is achieved.

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Matrix materials

Al Ag Be Co Cu

FeMgNiTi

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Need for Selection of Al as Matrix Material

Widely used

Low weight

Improved strength and stiffness

An attractive balance of fracture properties including ductility, toughness

and fatigue

Higher strength

Good surface finish

Important commercial product for the aerospace and motorsports

industries due to a superior balance of properties, modest cost and

commercial availability

69% of the annual MMC production by mass

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Reinforcement particles SiC NbC Al2O3 B4C BeO C Graphite Mo

NbC TaC TiB TiBl2 TiC W WC

The reinforcement of largest commercial volume is SiC by a significant margin, followed by Al2O3 and TiC

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WORKABILITY Defines as the relative ease with which a metal can be shaped through

plastic deformation. Used interchangeably with the term formability, which is preferred when

referring to the shaping of sheet metal parts. Usually used to refer to the shaping of materials on various bulk

deformation processes like forging, extrusion and rolling. Greater workability of a material allows greater deformation and/or a

more complex shape that can be produced before fracture occurs. Workability depends not only on the fracture resistance (Ductility) of the

material but also on the specific details (Stress state) of the processes such

as Die geometry, work piece geometry, lubrication conditions and

processing conditions.

[2-3]

Pore closure mechanism

• The porosity of sintered powdered metals and of those materials

subsequently deformation processed, may differ in character.

• Some amount of stresses consumed by the material for closing of pores is

called Geometric work hardening

• The work hardening of the matrix material is called Matrix Work

Hardening.

• Total stress required for deformation is the combination of stress required

for closing of pores (Geometric Work Hardening) and stress required for

work hardening of matrix.

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LITERATURE REVIEW

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Literature review- WorkabilityAuthor(s) Journal (S)

Narayanasamy et al., Materials and Design 29 (2008) 1011–1026Materials Science and Engineering A 391 (2005) 418–426

Materials and Design 27 (2006) 640–650Materials Science and Engineering A 394 (2005) 149–160

Proposed constitute relationship for the uniaxial, plane and triaxial stress state conditions.

The instantaneous parameters namely the work hardening exponent, the strength coefficient, the density coefficient and the strain rate sensitivity were evaluated during the cold working of sintered aluminium–iron composite with different iron particle sizes and percent of iron content under various stress state conditions.

For the different percent of iron content and the various sizes of the iron particles, for different initial preform densities and for the different stress state conditions.

The same author have investigated the strain hardening behavior of the composite for various aspect ratios [6] for the same composites (2%).

The same author investigated the instantaneous strain hardening behavior of the same composite where investigated for various iron additions with Al composites [7] Instantaneous strength coefficient and instantaneous strain hardening exponent were also investigated.

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Literature review- WorkabilityAuthor(s) Journal (s)

Narayanasamy et al., Materials and Design 27 (2006) 566–575

studied the workability behaviour of Al-Al2O3 behaviour. [8]

For different aspect ratios and for different initial preform densities at various stress state conditions.

The curves plotted for different components such as axial strain vs. formability stress index, relative density vs. axial strain, fracture strain vs. formability stress index and stress ratio parameters vs. axial strain were analyzed, using the true strains induced during upsetting with the consideration of bulging effect.

Author(s) Journal (s)

C.-C. Huang and J.-H. Cheng Journal of Materials Processing Technology 148 (2004) 382–393.

Investigated the forgeability of sintered iron porous materials under various operational conditions, including the aspect ratio (the height-to-diameter ratio) of billets, the void volume fraction, and the frictional conditions during the deformation and compared with the FEM, Tensile test and frictionless compression test were performed to find porosity, tensile strain, compressive strain, true stress, true strain, yield stress, etc., [9]

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J-O. Park et.al, Materials and Design 27 (2006) 566–575

find the process parameter optimization over the powder forging of the Aluminium piston [10]The Si content, temperature of the sintering and sinering time varied and found the optimum sintering conditions for the forging.As a workability study the density increment during forging with strain loci have been investigated thro upsetting test.Hardness and tensile test were done over the piston after the heat treatment.


M. Abdel-Rahman and M.N. El-Sheikh Journal of Materials Processing Technology 54 (1995) 97-102

investigated the theoretical aspects of the workability of the powder composites. [11]

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A. Rajeshkannan et al. Materials & Design, Volume 29, Issue 9, October 2008, Pages 1862-1867

Investigated the deformation characteristics to evaluate the stress–strain and densification behaviour of Fe–0.8%C–1.0%Si–0.4%Cu steel performs during cold upsetting. [12]


A.J.R. Inigoraj et al. Journal of Materials Processing Technology 84 (1998) 143–148 Journal of Materials Processing Technology 72 (1997) 201-207

Evaluated the strain-hardening phenomenon experienced in sintered aluminium– 3.5% alumina composite preforms during axial compression tests. Powder preforms of three different initial density ratios, namely 0.75, 0.80 and 0.90, with three initial aspect ratios for each density level. [13], [14]


R. Narayanasamy & K.S. Pandey Journal of Materials Processing Technology 100 (2000) 87-94

Investigated the hot forging characteristics over the iron cylindrical compact as well as bulged cylinders geometrical parameter ratio also derived. [15]

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Vijay et al, Scripta Materialia, Vol. 38, No. 10, pp. 1571–1575, 1998

Investigated the cyclic stress response of Al-Cu-Mg alloy mixed with SiC (vol 17.6%) (average sizes of ;1.4 μm, ;16 μm and ;63 μm) and hot extruded billets. Found the higher degree of cyclic hardening for the Finer the size of the SiCp.[16]


K.C. Chan et al. Journal of Materials Processing Technology 74 (1998) 142–148.

Al 2009/20%SiC composite sheet thro hot formation and did uni-axial tensile test and found the parameters and failure phenomenon like elliptical polar failure and also discussed.[17]

Literature review- Al-SiC compositeDEFORMATION STUDIES


J. Li & G. J. Weng International Journal of Plasticity, Vol. 14, Nos. 1-3, pp. 193-208, 1998.

Investigated the concept of transition from elasticity to visco elasticity as well as visco elasaticity to visco plasticity behaviour of the Al-SiC(10 & 20%). The influence of particle concentration, elastic stiffness, and applied strain rate on the overall dilatational and deviatoric stress-strain behaviors are examined.[18]

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K. Sivakumar et al Journal of materials processing technology 62 (1996) 191-198.Journal of material processing technology 73 (1998) 268-275.

investigated explosive compaction of the Al-20%SiC composite and found the process parameters on the densification from the hot rolled specimen’s tensile test and the same examined with various particle sizes of SiC (50 μm and 17 μm). The microstructural analysis were also performed over the formed composites.[19]The same author investigated the same study on 2124Al-20%SiC combination also. (45 μm and 14 μm) [20]



Sridhar and Fleck Acta mater. 48 (2000) 3341-3352

Investigated the yielding behaviour of the Al-40%SiC composites thro the compaction study using triaxial test rig and compared the yielding behaviour of the powder compaction between the isostatic compaction and closed die compaction thro pressure density response. [21]

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Y.X. Lu et al. Journal of materials processing technology 94 (1999) 175-178

studied the tensile and compression behaviour of Al-5Cu/15%SiC composite made thro hot compaction and extrusion route and found that as the strain increases the flow stress increases to a maximum saturation value (440 and 450 MPa for compression and tension, respectively) at relatively low strains. SEM and TEM used for the micro structural examination for the fracture studies. [22]


Author(s) Journal (s)M.F. Zawrah & M.H. Aly Ceramics International 32 (2006) 21–28.

formed Al2O3-SiC-Mullite composite thro P/M route and micro structural studies and X-ray diffraction studies were done with various combination of Mullite. [23]


K. Derrien et al. Materials science and engineering a215 (1996) 67-72.

investigated tensile test on X2080+SiCp (15 and 20%) extruded (Radial as well as longitudinal direction) composite and micro crack investigation were studied and compared the results with the micro-mechanical model.[24]

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T. S. Srivatsan, A. Prakash Composites science and technology 53 (1995) 307-315.

Investigated on same Al alloy with SiC (.5 and .2 volume fraction) 16 μm- extruded green compact. The tensile test were performed and fracture studies were done by them thro microstructural studies. [25]



Y.B.Pan et al, Material research bulletin, vol. 33, No. 1, pp. 133-139, 1998.

studied the microhardness test analysis over AlN + SiC (85%) at different temperature to test the oxidization behaviour of the composite. [26]

Author(s) Journal (s)S. Szczepanik, W. Lehnert Journal of materials processing technology 60 (1996) 703-709.

did the compression deformation test on Al + SiC(5%) at different strain rate and micrographic examination also performed. The composite prepared by hot forming technique.[27]

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Barker et.al., The Engineering of sport, Steve Haake, 1996, Taylor & Francis

Studied 6061 Al alloy + 10 and 25% SiC analysed for the sports and leisure applications- tensile test and microstructure studies have been conducted and analyzed. Here sintering temperature selected as 615oC for 5 hours and then solution heat treated at 530˚C for 40 minutes, cold water quenched and artificially aged at 160˚C for 16 hours [28]


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Sljapic et al., Journal of materials processing technology 125-126(2002) 267-274.

Studied the deformation studies on brass with flange collar specimen as well as hexagon to study the ductile fracture and simulated. [29]

DEFORMATION STUDIES

Literature review- Deformation studies


J. Landre et al. Journal of materials processing technology 39(2003)175-186.

Studied the formability experiments were performed for an AISI 1040 carbon steel (annealed condition). The stress–strain curve for the material was obtained from the frictionless, slow speed compression test at room temperature of cylindrical, tapered and flange components and FE simulation also had been performed. [30]


Z.Y.Zhou et al. Journal of materials processing technology 129(2002)385-388.

compared the iron powder cylindrical component deformation with the FE results. [31]

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STATEMENT OF THE PROBLEM

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Statement of the problem Many authors have contributed their work on Al-SiC powder composite’s

on yielding behaviour, tensile test, micro-hardness test, cyclic hardening effect

etc.

Few authors have investigated the tensile and deformation tests on Al-SiC

composites which produced thro hot compaction and extrusion route.

Narayanasamy et al. investigated on workability studies on Al-Al2O3, Al-Fe,

Fe, Fe-TiC etc.,

Only few works have been identified in the field of studying the Workability

behaviour on Al- SiC composites in the past.

Pore closure rate verification of Al-SiC composite is an interesting area

where the large scope for conducting research works.

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SCOPE OF THE RESEARCH

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Scope of the Research To reveal the effect of the percent of second phase particle Content and its

particle sizes on various stresses under Triaxial stress state condition

To reveal the effect of the percent of second phase particle Content and its

particle sizes on the effect of relative density and the strain parameters.

To reveal the effect of the percent of second phase particle Content and its

particle sizes on the stress ratio parameters on the above said composite.

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To study the effect of various percent addition of second phase particle

content and its particle sizes in exploring

the Instantaneous strain hardening index (ni),

the Instantaneous density coefficient (Ai),

the Instantaneous strain rate sensitivity (mi) and

the Instantaneous strength coefficient (Ki) of the composites during

cold upsetting.

Scope of the Research

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To study the workability behaviour of Al-SiC composite

To study the pore closure rate for different percent of second phase particle Content and its particle sizes of the composites.

To study on the stress based pore closure rate verification for different percent of second phase particle Content and its particle sizes of the composites.

To study on the strain based pore closure rate verification for different percent of second phase particle Content and its particle sizes of the composites.

Scope of the Research

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MATERIAL SELECTION

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Dr M Prabhakar Presentation Sample to Basha (2)