Mechanical and Machining Properties Analysis of Al6061-Cu-Reinforced SiC<sub>P</sub> Metal Matrix Composite

Abstract

The metal matrix composite (MMC), despite of its high stiffness, strength, corrosion resistance, wear resistance, non-react with chemicals and so many other tailored qualities which are never obtained in alloy of metals, has limited utilization due to the high cost of fabrication. In this study, a modest attempt has been made to find out the process parameters at which best mechanical properties of Al6061, 4% Cu and reinforced 5% SiC p ceramic MMC can be obtained. The addition of 4% Cu in Al6061 is more or less comparable to the composition duralumin, which are widely used in aerospace applications. SiC p is hard and has linear thermal expansion at high temperature. With reinforcement of SiC p in Al6061-Cu alloy, it can be postulated that hardness of MMC retains at high temperature applications. An analysis of Variance (ANOVA) and linear regression was used for analysis of data with the help of SPSS (Version-17.0). Independent parameters are five levels of pouring rates (1.5 cm/s, 2.0 cm/s, 2.5 cm/s, 3.0 cm/s and 3.5 cm/s), and material type (Al6061 + 4% Cu alloy and Al6061 + 4% Cu, reinforced 5% SiC p MMC processed using stir casting technique) and dependent parameters are hardness and impact strength material removal rates of workpiece. It is found that at different pouring rates material hardness and impact strength of workpiece are highly significant but the material removal rate of workpiece is having no significance value. At pouring rate of 2.5 cm/s and 700˚C ± 5˚C pouring temperature, optimum values of hardness and impact strength are observed as compared to other values of pouring rates (1.5 cm/s, 2.0 cm/s, 3.0 cm/s and 3.5 cm/s). Material Removal rate for work pieces of Al6061 + 4% Cu alloy is less as compared to MMC. So it can be concluded that MMC has better machining ability compared to Al6061 + 4% Cu alloy. Material removal rate of Al6061 + 4% Cu, reinforced 5% SiC p MMC has maximum values at 1.5 cm/s pouring rate compared to 2.0 cm/s, 2.5 cm/s, 3.0 cm/s and 3.5 cm/s pouring rates. With reinforcement of 5% SiC trend of mechanical properties is same, but the hardness and impact strength of MMCs are increased by 25% and 20% respectively. Also it is observed from scanning electron microscopy (SEM) that at pouring rate 2.5 cm/s a better homogeneity can be obtained.

Effect of machining parameters on deformation behaviour of Al-based metal matrix composites under tension

“…6 A number of studies have been conducted addressing the effect of machining parameters on surface integrity of the machined MMCs parts as well as the effect of ‘surface defect minimisation process’. 7–11 However, application of ‘surface defect minimisation processes’ for parts used in practical applications is very expensive and not realistic from commercial point of view. In literature, enough information is not available on the behaviour of MMCs with imperfect surface integrity generated by different machining processes.…”

Effect of Pouring Temperature and Stirring Speed on Mechanical, Microstructure and Machining Properties of Al6061-Cu Reinforced Sicp Metal Matrix Composites

“…Mechanical properties are improved with increase in weight % of ceramics, stirring time and decrease with particle size of the reinforced ceramics [1,2]. The pouring speed (rate) influencing the mmcs mechanical properties of Al 6061-Cu reinforced SiC metal matrix composites [4]. The process parameters are influencing the mechanical and machining properties of metal matrix composites [3,4,5].…”

“…The pouring speed (rate) influencing the mmcs mechanical properties of Al 6061-Cu reinforced SiC metal matrix composites [4]. The process parameters are influencing the mechanical and machining properties of metal matrix composites [3,4,5]. A. Chennakesava Reddy and Essa Zitoun, in their rigorous experimentation, investigated the mechanical properties for different metal matrix composites produced from Al 6061, Al 6063 and Al 7072 matrices alloys reinforced with silicon carbide particulates [6].…”