PRODUCTION AND MECHANICAL … reinforcement aluminium composites ... which are lightweight materials used ... industry. Before mixing the fly ash it is pre heated at

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International Journal of Mechanical Engineering and Technology (IJMET) Volume 7, Issue 6, November–December 2016, pp.225–235, Article ID: IJMET_07_06_023

Available online at

http://www.iaeme.com/ijmet/issues.asp?JType=IJMET&VType=7&IType=6

ISSN Print: 0976-6340 and ISSN Online: 0976-6359

© IAEME Publication

PRODUCTION AND MECHANICAL

CHARACTERIZATION OF AL-7075-T6 AND FLY ASH

COMPOSITE BY STIR CASTING HOT DIE PROCESS

F. Anand Raju

Assistant Professor, Siddharth Institute of Engineering & Technology, Puttur, A.P, India.

Dr. M.L.S. Deva Kumar

Professor & Vice Principal, JNT University College of Engineering, Anthapuramu, A.P, India.

ABSTRACT

Today the engineering metals are mutable their properties with high mechanical properties by

the combination of different metals and other process. One of the most recent developments in the

field of metals improves mechanical properties and reduce the weight density to utilize day- today

life is composite materials. In this Aluminum metal matrix composite (AMMC) has gain more

predominate role in metal matrix composite. After the usage of iron the second largest metal that

use in the engineering, industrial, domestic works is aluminum. Fly ash (15%, 20% and 25%)

particles are added in the Al-7075-T6 to produce Aluminum metal matrix composite by hot die

casting process. Fly ash act as the reinforce metal in the aluminum metal matrix. This is added in

the molten metal by stirring the ash particles to mix thoroughly and spared in the aluminum metal.

Fly ash is the industrial waste by product converted in to usable metal so it reduce the storage

problem and reduce the weight ratio of the AMMC. In this work the composition of the fly ash is

varied to get the best mechanical properties and reduce the weight density of the AMMC. This type

of AMMC is widely used in light weight vehicles, building elevation materials and aerospace

application.

Key words: Aluminum 7075-T6, Fly Ash, Mechanical Properties, Stir Casting, Chemical analysis

of Aluminum and Fly Ash.

Cite this Article: F. Anand Raju and Dr. M.L.S. Deva Kumar, Production and Mechanical

Characterization of Al-7075-T6 and Fly Ash Composite by Stir Casting Hot Die Process.

International Journal of Mechanical Engineering and Technology, 7(6), 2016, pp. 225–235.

http://www.iaeme.com/ijmet/issues.asp?JType=IJMET&VType=7&IType=6

1. INTRODUCTION

Aluminum is the second largest metal in the engineering materials. This is the oldest metal and most usable

metal from house hold to aerospace. Aluminum fly ash metal matrix composite is strengthen composite in

which soft and ductile aluminium matrix is strengthen by the hard and brittle fly ash particles.

Discontinuously reinforced aluminium based metal matrix composites are improving their high strength,

high isotropic and goodwear resistance. Discontinuously reinforcement aluminium composites have been

developed in the various fields like aerospace, automotive and many other engineering applications [1].

F. Anand Raju and Dr. M.L.S. Deva Kumar


Fly ash particles are potential discontinuous dispersoids used in metal matrix composites due to their

low cost and low density reinforcement which are available in large quantities as a waste by productin

thermal power plants [2].

MMCs offer a unique balance of physical and mechanical properties. Aluminium MMCs have received

increasing attention in recent years as engineering materials with improved strength, hardness and impact

resistance. The stair casting method is widely used among the different process.

Fly ash is a naturally-cementatious coal combustion by-product. About 130 coal based thermal power

plants that available in India are producing about 120 million tonne fly ash per year. Fly ash has been

considered as an “Industrial waste” and was being disposed of in ash ponds. In Indian coal has high ash

content and low calorific value as result huge amount of fly ash is generated. According to ASTM C-618

Fly ash is broadly classified into two major categories: Class F and Class C fly ash. The chemical content

of the ash differ the type of ash i.e., the amount of calcium, silica, alumina and iron [4].Fly ash utilization

improved and reduces the pollution in environment, now in present day’s fly ash is focusing and improving

their investigation in various fields like AMMC’s, brick, roads, agriculture and etc.

Production of AMMC’s has nemours advantages which are lightweight materials used in aerospace and

automobile industry. The production of AMMC’s gives good mechanical characteristics and less in cost.

2. EXPERIMENTAL WORK

2.1. Raw Material

In this work, aluminum 7075-T6 alloy has been used as matrix and fly ash particle with average size of (1-

53µm) were used as reinforcement material and its chemical composition was shown in the table 1. The fly

ash is collected from Lanco Industry at Srikalahasti.

Figure 2.1 Fly Ash Figure 2.2 Aluminum 7075-T651 plate

2.2. Dimensions of the Die

The die is prepared by mild steel plate and square rods. The bottom plate is of 300×150×25mm and the top

plate of 300×150×10 mm, the side bars on four side of different length, and two are 250×25×25 mm and

the two short length of 150×25×25 mm is machined and polished to avoid the sticking of the cast. The bars

were firmly bolted to the bottom and top plates to form as a rectangular cavity of size 250×100×15 mm. At

the center of the top plate a 30mm diameter hole is drilled to pour the molten metal into the cavity. The one

Production and Mechanical Characterization of Al-7075-T6 and Fly Ash Composite by Stir Casting Hot Die Process


side of the top plate a 10mm hole is drilled to form as a riser and escape the molten hot gases evolved in

the casting.

Figure 2.3 Open Die Figure 2.4 Closed Die

2.3. Preparation of Specimen by Stir Casting Process

In this, the electric induction titling furnace is chosen to produce the specimens. The furnace is fully

equipped with a stirrer and a DC motor to move the stirrer up and down. The motor movement is operated

by pneumatic system. The control of temperature is done by digital control system. The speed of motor is

controlled by DC regulator.

Figure 2.5 Tilting Induction furnace Figure 2.6 Stirrer

The aluminum of 7075-T6 was melted at the temperature of 800°C then the stirrer is start to stir the

molten aluminium. Fly ash particles were added to the melt at the time of vortex formation (15%,20%,and

25%) by weight %.The fly ash particles average size of (1-52µm) is obtained by sieving the collected ash

from the industry. Before mixing the fly ash it is pre heated at the temperature of 600°C to remove the

wettability in the muffle furnace. The melt temperature is maintained 800°C to 1000°C during the addition

of the fly ash particles. The mixed AMMC is poured in the metal die which is maintained at hot condition.

Then the die is allowed to solidification to produce the given specimen.



Figure 2.7 Digital Temperature Control Figure 2.8 Digital DC speed control

(a) 15% Fly ash (b) 20% Fly ash (c) 25% Fly ash

Figure 2.9 Cast specimen of Al7075-T6 and Fly ash.

The cast specimens were prepared for mechanical test

3. MECHANICAL TEST ON SPECIMEN

3.1. Tensile Test

The Al-7075-T6is preparing according to the ASTM C-618and also AMMC. The plate size of aluminum

prepared in the die of 250×150×15mm plate is cut to 250× 25×12.5 mm to test tensile strength of the

specimen at different composition with parent material.



Figure 3.1 Cutting of parent plate Figure 3.2 Universal testing machine with specimen

Figure 3.3 Tensile Test specimen with Dimensions

Figure 3.4 Test Specimen before Test Figure 3.5 Test specimen after test



Figure 3.6 Load VS Displacement

3.2. Hardness Test

Hardness is the property of a material that enables it to resist plastic deformation, usually by penetration.

However, the term hardness may also refer to resistance to bending, scratching, abrasion or cutting. The

hardness test was conducted on the Brinell hardness testing machine for all the samples with composite

specimens.

Figure 3.7 Specimen under test

3.3. Impact Strength

The toughness is the energy requires breaking the material. The energy is calculated in jouls. The energy

consumed is calculated by the difference between total energy supplied to the energy available at the end.

The measure of toughness can be found with the help of Charpy and Izod impact tests. The standard

specimen size for Charpy impact testing is 10mm×10mm×55mm.

Figure 3.8 Test specimen before testing Figure 3.9 Test specimen after testing

0

3

6

9

12

15

18

21

24

27

30

0 2 4 6 8 10 12 14 16

Load

kN

Displacement mm

Load Vs Displacement

Production and Mechanical Characterization of Al

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Impact test was carried out at room temperature using Impact tester to calculate toughness. The

specimen is supported at two end like a

breaking the specimen due to the impact of the pendulum.

Figure 3.10

4. RESULT AND DISCUSSIO

4.1. Chemical Analysis of Al7075

The chemical analysis of the parent

Spark or arc atomic emission spectroscopy is used for the analysis of metallic elements in solid samples.

The parent aluminum piece is ground up and

through the sample, heating it to a high temperature to excite the atoms within it.

atoms emit light at characteristic wavelengths that can be dispersed with a monochromator and detected.

The detected elements are tabulated

Table 4.1

Element Silicon

Si

Iron

Fe

Copper

Cu

Required 0.4 0.5 1.2

Content 0.35 0.164 2.02

Element Zirconium

Zr

Na Tin

Sn

Required - -

Content - -


IJMET/index.asp 231


end like a simply supported beam in the test and reading was taken by

breaking the specimen due to the impact of the pendulum.

3.10 Charpy Impact test specimen with dimensions

RESULT AND DISCUSSIONS

nalysis of Al7075-T6

The chemical analysis of the parent Aluminum is tested by Spark or arc atomic emission spectroscopy


ground up and burned during analysis. An electric arc or spa

through the sample, heating it to a high temperature to excite the atoms within it.

characteristic wavelengths that can be dispersed with a monochromator and detected.

The detected elements are tabulated below.

Table 4.1 Chemical Composition of Al 7075-T6

Copper

Cu

Manganese

Mn

Magnesiu

m

Mg

Chromiu

m

Cr

1.2-2.0 0.3 2.1-2.9 0.18-0.28

2.02 0.015 2.06 0.15

Tin

Sn

Bismut

h

Bi

Plambu

m

Pb

Co Other Element

Each

- - - - 0.05

- - 0.01 <0.002 0.05

T6 and Fly Ash Composite by Stir Casting Hot Die Process

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beam in the test and reading was taken by

specimen with dimensions

Spark or arc atomic emission spectroscopy.


An electric arc or spark is passed

through the sample, heating it to a high temperature to excite the atoms within it. The excited analyte

characteristic wavelengths that can be dispersed with a monochromator and detected.

Nicke

l

Ni

Zinc

Zn

Titaniu

m

Ti

- 5.1-6.1 0.2

<0.01 5.989 0.05

Other Element Al

Total

0.15 Remainder

0.15 Remainder



4.2. Mechanical Properties

Table 4 2Al 7075-T6 Metal matrix samples with different compositions by weight ratio.

Sample Weight % of aluminum Weight % of fly ash

Sample-1 100 0

Sample-2 85 15

Sample-3 80 20

Sample-4 75 25

Table 4.3 Mechanical properties of the samples.

Sample Tensile

strength

(N/sq mm)

Yield

strength

(N/sq mm)

Elongation on

50mm G.L

(%)

Impact Test

‘V’ notch(J)

Size

10×10×55mm

Hardness

[ HBW /10 mm ball

dia / 3000 kgf load]

Density

g/cc

Sample-1 586 543 15 9 58 2.89

Sample-2 150 141 6 7 66 2.73

Sample-3 60 55 2 4 78 2.58

Sample-4 73 66 5 6 64 2.75

Figure 4.1 Samples Vs Tensile Strength

Figure 4.2 Samples Vs Yield Strength

0

100

200

300

400

500

600

700

Sample 1 Sample 2 Sample 3 Sample 4

Te

nsi

le S

tre

ng

th (

N/

sq m

m)

Samples

0

100

200

300

400

500

600


Yei

ld s

tren

gth

(N /

sq

mm

)

Samples



Figure 4.3 Samples Vs Elongation

Figure 4.4 Samples Vs Impact Strength

Figure 4.5 Samples Vs Brinell Hardness (BHN)

0

2

4

6

8

10

12

14

16

Sampe 1 Sample 2 Sample 3 Sample 4

Elo

ng

ati

on

%

Samples

0

1

2

3

4

5

6

7

8

9

10


Imp

act

Str

en

gth

(J)

Samples

0

10

20

30

40

50

60

70

80

90


Bri

ne

ll H

ard

ne

ss (

BH

N)

Samples



5. CONCLUSION

The investigation conducted, leads to the following conclusions:

Fly ash is added in the molten aluminum up to 25% by weight ratio by stir casting process for

production of composite material. So the industrial waste turns into industrial wealth. Addition of fly ash

as 15%, 20% and 25% by weight % the tensile strength of the samples reduces and hardness of the samples

is increased. By comparing the four samples, the sample3 with 20% fly ash has highest hardness BHN

78.The weight density of the material is decreased by 20% fly ash addition. By increasing of the hardness,

ware rates significantly reduced.

The study gives the further addition of fly ash and study of microstructure and tribological studies.

Casting the materials in to blooms and slabs to be rolled and extruded as different components for all

applications.

REFERENCE

[1] Mahendra.K.V and Radhakrishna. K, Castable composites and their application in automobiles, Proc.

IMechE Vol. 221 Part D: J. Automobile Engineering, (2007): pp. 135-140

[2] B.VijayaRamnath et al “Aluminium Metal Matrix Composite –A Review” published in Advanced

material science, 38(2014) pp 55-60.

[3] P. Shanmughasundaram1, R. Subramanian2 “Some Studies on Aluminium-Fly Ash Composites

Fabricated by Two Step Stir Casting Method”, European Journal of Scientific Research ISSN 1450-

216X Vol.63 No.2 (2011), pp.204-218.

[4] J.Alam and MN Akhtar “Fly ash Utilisation in different sector in india scenario” published in Internation

journal of emerging trends in Engineering and Development, vol-1 Augest 2011, pp1-14.

[5] P. K. Rohatgi and R. Q. Guo, “Low Cost Cast Aluminium – Fly Ash Composites for Ultra-light

Automotive Application”, TMS Annual Meeting, Automotive Alloys, (1997)

[6] Deepak singla1, S.R. Mediratta2, “Evaluation of Mechanical Properties of Al 7075-Fly Ash Composite

Material”, International Journal of Innovative Research in Science, Engineering and Technology ISSN:

2319-8753 Vol. 2, Issue 4, April 2013

[7] H.C. Anilkumar1, H.S. Hebbar2 and K.S. Ravishankar3 “Mechanical Properties of Fly Ash Reinforced

Aluminium Alloy (Al6061) Composites”, International Journal of Mechanical and Materials

Engineering (IJMME), Vol.6 (2011), No.1, 41-45

[8] sankar.L1, Srinivasan.R2, Viswanathan.P3 and Subramanian.R4, “Comparison Study of Al-Fly Ash

Composites In Automobile Clutch Plates”, from internet

[9] Vivekananthan1 M. and Senthamarai2 k., “Experimental Evaluation of Aluminium-Fly Ash Composite

Material to Increase the Mechanical &Wear Behaviour by Stir Casting Method”,CARE Journal of

Applied Research (ISSN 2321-4090)

[10] K.V. MAHENDRA1, K. R ADHAKRISHNA2, “Fabrication of Al–4.5% Cu Alloy with Fly Ash Metal

Matrix Composites and Its Characterization”, material science-poland, Vol.25, No.1 2007

[11] Hull D, Clyne T W, “An Introduction to Composite Materials, Cambridge”, UK: Cambridge Univ.

Press, 1996

[12] Matthews F.L., Ralwlings R.D, “Composite materials engineering and science”, Glasgow, UK,

Champaman and hall, 1994



[13] DRDO “Composite Materials”, Popular Science & Technology (PST) series is being published by

DESIDOC, was published in the year 1990

[14] Rohatgi P.K, Metal-matrix Composites, Defence Science Journal, Vol 43, No 4, (1993): pp 323-349.

[15] R.Maguteeswarana, Dr. R.Sivasubramanian and V.Suresh, “Study and Investigation of Analysis of

Metal Matrix Composite”, International Journal of Mechanical Engineering & Technology (IJMET),

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[16] R.Maguteeswarana, Dr. R.Sivasubramanian and V.Suresh, “Methodology Study and Analysis of

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PRODUCTION AND MECHANICAL … reinforcement aluminium composites ... which are lightweight materials used ... industry. Before mixing the fly ash it is pre heated at