CHAPTER 4

TEST RESULTS AND ANALYSIS FOR PHYSICAL,

CHEMICAL AND MECHANICAL PROPERTIES OF STIR
CAST SAMPLES

4.1 SCHEME OF TESTING AND ANALYSIS

A set of tests has been earned out in a pre-planned way to investigate the various
properties of the prepared Al/5 vol%, Al/10 vol%, Al/15 vol% SiCP-MMC,s; Al/5
vol%, Al/10 vol%,Al/15 vol% A1203-MMC,s and Al/5 vol%, Al/10 vol%, Al/15 vol%
Grp-MMC,s samples by stair cast technique. The casting experiments are performed
for evalution of the physical properties e.g. appearance and density of stir cast
samples. The casting tests are also performed for chemical composition analysis of
the various stir cast samples and reported the results thereafter. The various tests are
also performed on the prepared stir cast samples to evaluate the micro hardness and
tensile strength which are very much important for further utilization of the prepared
samples in various engineering applications. Therefore, main objective and scheme of
this chapter is to conduct the various tests utilizing different test setups and machines
to evaluate the different properties and thereafter analyze the test results for suitability
of the prepared samples made of different hard reinforced particulates e.g. SiCp, AI2O3
and Grp with AA6061-A1 metal matrix composites as mentioned above. Different
optical micro graphs and SEM photographs of the prepared samples are also reported
in the chapter to understand the actual distributions of the hard reinforced particulates
in the prepared metal matrix composites.

4.2 PLANNING FOR PROPERTY TESTING

Prepared stir cast metal matrix composite samples are tested for physical, mechanical
and microstructiural properties. Density of the specimen is measured using
Archimedes principle. Quantitative assessment of particulates in stir cast metal matrix
composites is done with image analyzer Microstructural characterization of the
prepared Al/5 vol%, Al/10 vol%, Al/15 vol% SiC-MMC,s; Al/5 vol%, Al/10

48
 vol%,Al/15 vol% A1203-MMC,s and Al/5 vol%, Al/10 vol%, Al/15 vol% GrP-MMC,s
samples is earned out using optical microscope and Scanning Electron Microscope on
the metallographically polished as processed specimen so as to investigate distribution
of reinforced particulates ,to study interfacial bonding and to check presence of
porosity.Micro hardness and ultimate tensile strength of the specimen is also
determined

4.3 PHYSICAL TEST RESULTS AND ANALYSIS

4.3.1. Density of the prepared cast composite

The Archimedes principle was applied to measure the densities of the cast Al/5 vol% SiC,

Al/10 vol% SiC, Al/15 vol% SiC-MMC,s; Al/5 vol% A1203, Al/10 vol% A1203, Al/15

vol% Al203-MMC,s and Al/5 vol% GrP, Al/10 vol% GrP, Al/15 vol% GrP-MMC,s

samples and presented the results in this chapter.

Table 4.1 Densities of prepared Al/SiC-MMC samples

Property Aluminium Titanium Steel Composite particle(SiC) volume
j

(6061-T6) (6A1-4V) (4340) fraction

5% 10% 15%
Density, g/cm 2.75 4.43 7.76 2.81 0.03 2.82 0.02 2.85 0.03

Table 4.2 Densities of prepared A1/A1203-MMC samples

Property Aluminium Titanium Steel Composite particle(Al203 )volume
(6061-T6) (6A1-4V) (4340) fraction
5% 10% 15%
Density, g/cm3 2.75 4.43 7.76 2.79 0.04 2.80 0.03 2.82 0.04

49
Table 4.3 Densities of prepared Al/Grp-MMC samples
Property Aluminium Titanium Steel Composite particle volume
(6061-T6) (6A1-4V) (4340) fraction
5% 10% 15%
Density, g/cm3 2.75 4.43 7.76 2.580.02 2.610.04 2.640.03

The densities of all the prepared composites have been found to be less than that of
the matrix. Density of Al/5 vol% SiC-MMC is 2.81 0.03 while that of Al/15 vol%
SiC-mmc is 2.85 0.03. With the increase in the reinforcement content the density of
the stir cast is found to increase. The rule of mixtures for density is as follows:

pc=pfVf+pcVm ............................................................. Eqn 4.1

Where, pc is density of composite, pf is density of reinforcement and pm is density

of matrix ;Vf and Vm are the corresponding volume fractions of reinforced particles
and matrix respectively.

Theoretically, as per Eqn.4.1, the density increases as the reinforcement content

increases. Density of Al/5 vol% AI2O3-MMC is 2.79 + 0.04 and that of Al/10 vol%
AI2O3-MMC is 2.80 +_0.03m which is comply with the experimental results. The
density of Al/ AI2O3-MMC is lesser than that of Al/ SiCp-MMC. This is because
density of alumina particulate is slightly lesser than silicon carbide particulate.
Density of Al/GrP-MMC is least as compared to the all other cast samples.

4.4 QUANTITATIVE MICROSTRUCTURE AND REINFORCED VOLUME

FRACTION

Quantitative assessment of reinforcement particles with their volume fraction are also
analyzed through various images utilizing eM Power image analyzer (version 3.0.0.9)
and the results of the test samples are shown in figures 4.1 to 4.4.

50
 A1203
Particle

SID:Alumina 10 % Frame Area(mrtf) Alumina(%) Al Matrix(^)

Frame 1 0.2272 9.282 90.718
Average 0.2272 9.282 90.718

Fig 4.1 Microstructure and reinforcement vol. fraction of AA 6061/10 vol% A1203-
MMC

51
 ai2o3
Particle

SID: Alumina Frame Area(mrrf) Alumina!*) Al Matrix()

Frame -1 0.2272 14.911 85.089
Average 0.2272 14.911 85.089

Fig 4.2 Micro structure and reinforcement vol. fraction of AA 6061/ 15 vol% AI2O3-
MMC

52
 100

80

A 60

F
% 40

20

SID:Graphite 10 X Frame Area(mrrf) Graphite(%) Al Matrix(%)

Frame * 1 0.2272 9.95G 90.044
Average 0.2272 9.956 90.044

Fig 4.3 Microstructure and reinforcement vol. fraction of AA 6061/ 10 vol% Grp
MMC

53
 A
F
%

SID:SiC10* Frame Aieajmnf) SiC(*) Al Matrix!*)

Frame 1 0.2272 9.452 90.548
Average 0.2272 9.452 90.548

Fig 4.4 Microstructure and reinforcement vol. fraction of AA 6061/ 10 vol% SiC
MMC

54
Image analysis of the prepared stir cast metal matrix composites shows the percentage
of volume fraction of particulates. In almost all the prepared samples, the percentage
of volume fraction was found to be less than the actual particulates added. In AA
6061/10 vol% AI2O3-MMC the actual volume fraction is 9.282 5 instead of 10%.
Similarly for AA 6061/ 10 vol% SiC-MMC and AA 6061/ 10 vol% Grp-MMC the
volume fraction is respectively 9.452 and 9.956 %.Some loss of particulate is
inevitable in processing composite via stir cast route. The loss occurs when
particulates are added in molten aluminium matrix.

4.5 MECHANICAL PROPERTIES TEST, RESULTS AND ANALYSIS

Ultimate tensile strength and microhardness tests were carried out to evaluate the
mechanical properties of the prepared stir cast specimens and test results presented in
this article.

4.5.1 Micro Hardness Test

Polished cubes of the Al/5 vol%, Al/10 vol%, Al/15 vol% SiCp-MMC,s; Al/5 vol%, Al/10
vol%,Al/15 vol% A1203-MMC,s and Al/5 vol%, Al/10 vol%, Al/15 vol% GrP-MMC,s were
prepared and subjected for micro hardness tests. Micro hardness tests were preferred over
other hardness tests because in case of agglomeration of particulates, other tests tend to give
values on higher side. In the present work the Vickers Hardness test was carried out on the
HMV Micro Hardness Tester using a diamond pyramid indenter. During the testing 50gmload
was applied for 20 second and the average of readings have been reported in the results. The
specification of the microhardness tester used for testing the microhamess of the prepared
composites as given below:

Test force: 10, 20, 50, 100, 200, 300, 500, 1000 gms;

Automatic loading and unloading test force,

Amplification 100X, 400X; Holding time for test force: 65-60 secs:

Maximum height of specimen: 65mm; maximum width of specimen: 85mm

Power supply: AC 230V/50Hz

Dimensions: 405X290X480mm

55
 Fig 4.5 Specimen mounted for microhardness testing

Fig 4.6 Indentor at load 50gm and time 20s for microhardness

56
 Fig 4.7 Impression of diamond indentor on Prepared Al/10 vol%Grp MMC

For measuring the microhardness distance between the diagonals of the rhombus is
measured

4.5.2 Tensile Strength Test

Smooth bar ultimate tensile strength of as processed samples were determined in

accordance with ASTM test method E8M-91. Tests were conducted on round tension
test specimen of diameter 40mm and gauge length 200 mm using UNIVERSAL
TESTING MACHINE HT-2107 A (HUNGTA) having 300T capacity at room
temperature and the test speed was kept 0.5 mm/min

The results of microhardness and ultimate tensile strength tests are reported in various
Table 4.5 to Table 4.13.

57
 Table 4.5 Test results of Micro Hardness (VHN) and Tensile Strength (MPa) of prepared Al/ 5%
vol SiC-MMC

Expt Pouring Shear Stirring Micro Hardness (VHN) Tensile Strength (MPa)
No Temp rate Time
(C) Y1 Y2 Y3 Average Z1 Z2 Z3 Average
(r.p.m) (min)
1 750 150 3 155.7 156.4 156.8 156.3 289.36 289.58 289.63 289.52
2 750 150 6 156.5 156.2 156.3 156.33 290.48 290.83 290.54 290.61
3 750 150 9 156.7 156.9 156.8 156.8 292.13 292.38 292.28 292.26
4 825 225 3 159.2 159.6 159.8 159.5 294.63 294.27 294.42 294.44
5 825 225 6 160.4 160.3 160.0 160.2 295.61 295.28 295.36 295.41
6 825 225 9 160.7 160.2 160.9 160.6 297.23 297.46 297.17 297.28
7 900 300 3 161.1 161.3 161.0 161.1 297.58 297.71 297.62 297.64
8 900 300 6 160.2 160.4 160.8 160.5 298.34 298.17 298.68 298.39
9 900 300 9 162.1 162.4 162.6 162.4 298.48 298.66 298.71 298.62
10 825 300 3 153.8 153.1 153.0 153.3 287.23 287.45 287.63 287.44

11 825 300 6 154.7 154.5 154.8 154.7 288.45 288.61 288.53 288.53

12 825 300 9 152.1 152.4 152.7 152.4 286.16 286.78 286.94 286.63

13 900 150 3 158.8 158.9 158.6 158.8 292.58 292.79 292.98 292.78

14 900 150 6 159.4 159.3 159.0 159.2 293.19 293.36 293.48 293.34

15 900 150 9 157.7 157.8 157.5 157.7 292.17 292.39 292.43 292.33
16 750 225 3 159.8 159.7 159.9 159.8 293.12 293.43 293.26 293.27

17 750 225 6 160.2 160.5 160.8 160.5 295.73 295.77 295.64 295.71

18 750 225 9 159.2 159.4 159.0 159.2 293.28 293.46 293.73 293.49

19 900 225 3 152.1 152.8 152.3 152.4 286.35 286.72 286.47 286.51

20 900 225 6 151.2 151.0 151.9 151.4 285.92 285.86 285.71 285.83

21 900 225 9 151.1 151.4 151.6 151.3 285.48 285.64 285.59 285.57

22 750 300 3 155.4 155.2 155.7 155.4 288.70 288.75 288.83 288.76

23 750 300 6 153.9 153.4 153.7 153.7 287.91 287.48 287.32 287.57

24 750 300 9 154.3 154.0 154.1 154.1 288.13 288.26 288.32 288.24

25 825 150 3 158.3 158.4 158.0 158.2 292.27 292.81 292.33 292.47

26 825 150 6 157.3 157.0 157.9 157.4 289.71 289.84 289.69 289.74

27 825 150 9 157.1 157.4 157.2 157.2 290.61 290.64 290.92 290.72

58
 Table 4.6 Test results of Micro Hardness (VHN) and Tensile Strength (MPa) of
prepared Al/ 10% vol SiC-MMC

Expt Pouring Shear Stirring Micro Hardness (VHN) Tensile Strength (MPa)
No Temp rate Time
Y1 Y2 Y3 Average Z1 Z2 Z3 Average
(C) (r.p.m) (min)
1 750 150 3 167.9 168.0 168.1 168.0 303.78 303.86 303.93 303.86

2 750 150 6 168.5 168.2 168.3 168.3 304.47 304.58 304.69 304.58

3 750 150 9 168.9 168.7 168.8 168.8 306.18 306.37 306.23 306.26

4 825 225 3 172.2 172.6 172.8 172.5 308.28 308.36 308.41 308.35

5 825 225 6 173.1 173.0 173.3 173.1 308.78 308.83 308.92 308.84

6 825 225 9 173.9 173.2 173.7 173.6 309.59 309.48 309.70 309.59

7 900 300 3 174.0 174.1 174.3 174.1 310.82 310.36 310.54 310.57

8 900 300 6 174.2 174.8 174.4 174.5 311.07 311.27 311.42 311.25

9 900 300 9 175.1 175.4 175.6 175.4 311.83 311.93 311.77 311.84

10 825 300 3 165.0 165.1 165.3 165.1 302.33 302.17 302.24 302.25

11 825 300 6 166.5 166.7 166.8 166.7 303.19 303.26 303.34 303.26

12 825 300 9 164.4 164.7 164.9 164.7 301.87 301.92 301.98 301.92

13 900 150 3 171.8 171.6 171.9 171.8 307.21 307.33 307.41 307.32
14 900 150 6 172.0 172.3 172.4 172.2 307.78 307.82 307.93 307.84
15 900 150 9 170.5 170.7 170.8 170.7 306.42 306.51 306.59 306.51
16 750 225 3 172.9 172.7 172.8 172.8 307.48 307.62 307.71 307.60
17 750 225 6 173.2 173.5 173.8 173.5 309.13 309.27 309.36 309.25

18 750 225 9 172.0 172.2 172.4 172.2 308.06 308.12 308.21 308.13

19 900 225 3 164.2 164.0 164.3 164.2 301.61 301.78 301.81 301.73
20 900 225 6 163.9 163.2 163.0 163.4 301.34 301.41 301.52 301.42
21 900 225 9 163.1 163.4 163.6 163.3 301.24 301.16 301.29 301.23
22 750 300 3 167.0 167.7 167.2 167.3 303.45 303.52 303.67 303.55
23 750 300 6 165.7 165.9 165.4 165.7 302.38 302.49 302.58 302.48
24 750 300 9 166.3 166.0 166.1 166.1 302.67 302.89 302.83 302.79
25 825 150 3 171.4 171.3 171.0 171.2 306.63 306.71 306.82 306.72
26 825 150 6 169.0 169.3 169.9 169.4 304.17 304.23 304.36 304.25
27 825 150 9 169.1 169.4 169.2 169.2 304.81 304.89 304.97 304.89

59
 Table 4.7 Test results of Micro Hardness (VHN) and Tensile Strength (MPa) of
prepared Al/15% vol SiC-MMC

Expt Pouring Shear Stirring Micro Hardness (VHN) Tensile Strength (MPa)
No Temp rate Time
(C) Y1 Y2 Y3 Average Z1 Z2 Z3 Average
(r.p.m) (min)
1 750 150 3 177.9 178.1 178.0 178.0 315.64 315.51 315.86 315.67
2 750 150 6 178.2 178.3 178.5 178.3 316.26 316.48 316.35 316.36
3 750 150 9 178.8 178.9 178.7 178.8 318.17 318.25 318.46 318.29
4 825 225 3 182.2 182.6 182.8 182.5 320.81 320.64 320.72 320.72
5 825 225 6 183.3 183.0 183.1 183.1 321.14 321.26 321.38 321.26
6 825 225 9 183.9 183.2 183.7 183.6 322.27 322.19 322.36 322.27
7 900 300 3 184.1 184.0 184.3 184.1 322.41 322.52 322.64 322.52
8 900 300 6 184.8 184.2 184.4 184.5 323.81 323.78 323.94 323.84
9 900 300 9 185.1 185.6 185.4 185.4 324.17 324.22 324.44 324.28
10 825 300 3 175.3 175.1 175.0 175.1 313.48 313.67 313.59 313.58
11 825 300 6 176.7 176.8 176.5 176.7 314.51 314.63 314.71 314.62
12 825 300 9 174.9 174.7 174.4 174.7 313.07 313.24 313.36 313.22
13 900 150 3 181.6 181.9 181.8 181.8 319.42 319.58 319.64 319.55
14 900 150 6 182.0 182.4 182.3 182.2 320.08 320.17 320.24 320.16
15 900 150 9 180.8 180.5 180.7 180.7 318.84 318.89 318.94 318.89
16 750 225 3 182.8 182.7 182.9 182.8 319.71 319.77 319.83 319.77
17 750 225 6 183.5 183.2 183.8 183.5 321.44 321.58 321.62 321.55
18 750 225 9 182.2 182.4 182.0 182.2 320.36 320.48 320.57 320.47
19 900 225 3 174.3 174.2 174.8 174.4 312.91 312.73 312.82 312.82
20 900 225 6 173.2 173.9 173.0 173.4 312.69 312.52 312.63 312.61
21 900 225 9 173.4 173.6 173.1 173.3 312.14 312.27 312.44 312.28

22 750 300 3 177.7 177.2 177.4 177.4 314.78 314.81 314.89 314.83

23 750 300 6 175.7 175.4 175.9 175.7 313.72 313.81 313.92 313.82

24 750 300 9 176.0 176.3 176.1 176.1 314.24 314.36 314.42 314.34
25 825 150 3 181.4 181.0 181.3 181.2 319.13 319.26 319.34 319.24
26 825 150 6 179.0 179.3 179.9 179.4 315.21 315.11 315.36 315.23

27 825 150 9 179.2 179.1 179.4 179.2 316.47 316.58 316.72 316.59

60
 Table 4.8 Test results of Micro Hardness (VHN) and Tensile Strength (MPa) of
prepared Al/ 5% vol AI2O3-MMC

Expt Pouring Shear Stirring Micro Hardness(VHN) Tensile Strength(MPa)

No Temp rate Time Z2 Z3 Average
Y1 Y2 Y3 Average Z1
(C) (r.p.m) (min)
1 750 150 3 135.1 135.2 135.0 135.1 274.31 274.28 274.17 274.25

2 750 150 6 137.6 137.1 137.2 137.3 275.47 275.57 275.64 275.56

3 750 150 9 136.3 136.1 136.8 136.4 276.25 276.10 276.38 276.24

4 825 225 3 138.7 138.4 138.0 138.3 278.21 278.36 278.41 278.33

5 825 225 6 139.3 139.6 139.8 139.6 278.47 278.65 278.72 278.61

6 825 225 9 137.3 137.5 137.4 137.4 279.43 279.54 279.65 279.54

7 900 300 3 135.3 135.5 135.8 135.5 279.82 279.71 279.91 279.81

8 900 300 6 136.4 136.9 136.0 136.4 280.24 280.31 280.42 280.32

9 900 300 9 135.6 135.4 136.2 135.7 281.51 281.82 281.91 281.75

10 825 300 3 137.4 137.3 137.1 137.3 272.45 272.57 272.64 272.55

11 825 300 6 138.9 138.1 138.5 138.5 273.45 273.61 273.75 273.60

12 825 300 9 139.1 139.2 139.4 139.2 272.14 272.28 272.37 272.26

13 900 150 3 134.2 134.7 134.6 134.5 277.14 277.26 277.35 277.25

14 900 150 6 133.8 133.7 133.6 133.7 277.69 277.34 277.83 277.62
15 900 150 9 132.1 132.5 132.9 132.5 276.41 276.54 276.67 276.54

16 750 225 3 139.7 140.6 139.5 139.9 277.39 277.48 277.53 277.47
17 750 225 6 141.9 141.4 141.3 141.4 278.79 278.84 278.94 278.86
18 750 225 9 136.5 136.7 136.9 136.7 278.08 278.15 278.24 278.16
19 900 225 3 139.8 138.1 140.9 139.6 271.73 271.82 271.91 271.82
20 900 225 6 141.3 142.8 141.7 141.9 271.43 271.51 271.64 271.53
21 900 225 9 136.1 136.2 136.6 136.3 271.14 271.38 271.26 271.26
22 750 300 3 139.0 138.9 140.8 139.6 273.84 273.92 273.98 273.91
23 750 300 6 142.7 141.4 142.5 142.2 272.74 272.81 272.89 272.81
24 750 300 9 136.4 136.6 136.7 136.6 273.13 273.28 273.37 273.26
25 825 150 3 136.1 137.8 136.0 136.6 276.78 276.84 276.92 276.85
26 825 150 6 141.9 141.5 141.0 141.5 274.58 274.78 274.82 274.73
27 825 150 9 136.8 135.8 135.9 136.2 275.74 275.86 275.95 275.85

61
 Table 4.9 Test results ot Micro Hardness (VHN) and Tensile Strength (MPa) of
prepared Al/10 % vol A1203-MMC

Expt Pouring Shear Stirring Micro Hardness (VHN) Tensile Strength (MPa)
No Temp rate Time
(C) Y1 Y2 Y3 Average Z1 Z2 Z3 Average
(r.p.m) (min)
1 750 150 3 151.5 151.8 151.6 151.6 289.36 289.48 289.56 202.47
2 750 150 6 160.3 160.5 160.6 160.5 290.13 290.29 290.36 290.26
3 750 150 9 161.0 161.3 161.2 161.2 290.89 290.78 290.64 290.77
4 825 225 3 163.7 163.6 163.3 163.5 293.17 293.48 293.61 293.42
a

5 825 225 6 163.9 164.5 164.2 164.2 293.77 293.89 293.94 293.87

6 825 225 9 165.8 165.6 165.0 165.5 294.58 294.69 294.78 294.68
7 900 300 3 166.3 166.1 166.4 166.3 295.46 295.71 295.89 295.69
8 900 300 6 166.9 166.6 166.8 166.8 296.17 296.43 296.78 296.46

9 900 300 9 167.6 167.0 167.3 167.3 297.81 297.98 297.45 ?97
M f IS
f %/

10 825 300 3 148.9 149.0 149.2 149.0 288.17 288.34 288.29 288.27
11 825 300 6 150.5 150.7 150.4 150.5 288.84 288.91 288.98 288.91
12 825 300 9 148.4 148.7 148.8 148.6 287.81 287.89 287.97 287.89
13 900 150 3 161.9 162.0 162.2 162.0 291.73 291.82 291.87 291.81
14 900 150 6 162.8 162.9 163.1 162.9 292.38 292.46 292.54 292.46
15 900 150 9 161.4 161.1 161.5 161.3 291.14 291.27 291.36 291.26
16 750 225 3 162.5 162.3 162.6 162.5 292.19 292.32 292 27 292.26

17 750 225 6 164.3 164.9 164.4 164.5 294.19 294.28 294.46 294.31
18 750 225 9 163.5 163.2 163.4 163.4 292.65 292.74 292.89 292.76
19 900 225 3 148.0 148.3 148.1 148.1 287.58 287.64 287.78 287.66

20 900 225 6 147.8 147.4 147.9 147.7 287.48 287.42 287.34 287.41
: 21 900 225 9 147.3 147.0 147.2 147.2 287.09 287.17 287.21 287.16
22 750 300 3 150.9 150.8 151.2 151.0 289.08 289.14 289.23 289.15

23 750 300 6 149.4 149.7 149.5 149.5 288.41 288.52 288.60 288.51

24 750 300 9 149.9 150.3 150.0 150.1 288.81 288.74 288.68 288.74
25 825 150 3 161.6 161.8 161.7 161.7 291.44 291.56 291.62 291.54
one
26 5 Lj 150 6 151.9 160.0 160.2 157.4 289.61 289.73 289.81 289.72
27 825 150 9 160.7 160.9 160.8 160.8 290.41 290.47 290.57 290.48

62
Table 4.10 Test results of Micro Hardness (VHN) and Tensile Strength (MPa) of
prepared AM 15% vol AI2O3-MMC

Expt Pouring Shear Stirrin Micro Hardness (VHN) Tensile Strength (MPa)
No Temp rate g Y1 Y2 Y3 Average Z1 Z2 Z3 Avera;
(C) (r.p.m) Time
(min)
1 750 150 3 161.7 161.4 161.0 161.4 305.21 305.63 305.48 305.4^
2 750 150 6 161.9 161.8 161.2 161.6 306.45 306.51 306.32 306.4:
5' 750 150 9 162.5 162.4 162.7 162.5 307.41 307.23 307.08 307.2Z
4 825 225 3 164.3 164.8 164.7 164.6 309.28 309.47 309.54 309.42
5 825 225 6 165.1 165.5 165.2 165.3 309.72 309.63 309.87 309.7^
6 825 225 9 165.6 165.3 165.4 165.4 310.32 310.06 310.24 310.2]
7 900 300 3 166.2 166.5 166.4 166.4 310.87 310.73 310.92 310.8Z
8 900 300 6 166.9 166.3 166.6 166.6 311.41 311.28 311.62 311.4^
9 900 300 9 166.0 166.8 166.7 166.5 311.93 311.71 311.86 311.82
10 825 300 3 159.9 159.0 159.6 159.5 303.41 303.52 303.64 303.52
11 825 300 6 160.7 160.1 160.3 160.4 304.42 304.51 304.62 304.52
12 825 300 9 159.3 159.4 159.2 159.3 303.36 303.07 303.21 303.21
13 900 150 3 163.2 163.7 163.4 163.4 308.14 308.29 308.34 308.26
14 900 150 6 164.0 164.3 164.5 164.3 308.63 308.68 308.74 308.68
15 900 150 9 162.8 162.9 162.1 162.6 307.48 307.56 307.62 307.55
16 750 225 3 163.9 163.5 163.8 163.7 308.46 308.38 308.54 308.46
17 750 225 6 165.0 165.9 165.8 165.6 309.91 309.88 309.98 309.92
18 750 225 9 164.4 164.6 164.1 164.4 308.84 308.96 308.76 308.85
19 900 225 3 158.7 158.9 158.2 158.6 302.82 302.88 302.74 302.81
20 900 225 6 158.5 158.6 158.1 158.4 302.44 302.52 302.61 302.52
21 900 225 9 158.4 158.0 158.3 158.2 302.26 302.14 302.38 302.26
22 750 300 3 160.9 160.2 160.7 160.6 304.68 304.86 304.79 304.78
23 750 300 6 159.1 159.7 159.8 159.5 303.78 303.92 303.81 303.84
24 750 300 9 160.6 160.0 160.4 160.3 304.29 304.18 304.36 304.28
25 825 150 3 163.3 163.1 163.6 163.3 307.86 307.74 307.67 307.76
26 825 150 6 161.5 161.3 161.4 161.4 305.84 305.79 305.68 305.72
27 825 150 9 162.6 163.0 163.3 162.9 306.58 306.68 306.83 306.74

63
 Table 4.11 Test results of Micro Hardness (VHN) and Tensile Strength (MPa) of
prepared Al/ 5% vol Grp-MMC

Expt Pouring Shear Stirring M i ero H ardness (V HN) Tensile Strength (MPa)
No Temp rate Time
(C) Y1 Y2 Y3 Average Z1 Z2 Z3 Average
(r.p.m) (min)
1 750 150 3 67.6 67.0 67.3 67.3 191.54 191.21 191.38 191.38
2 750 150 6 67,2 67.9 67.7 67.6 192.43 192.68 192.71 192.61
3 750 150 9 68.2 68.9 68.1 68.4 193.26 193.08 193.19 193.18
4 825 225 3 70.7' 70.8 70.5 70.7 195.04 195.26 195.18 195.16
5 825 225 6 71.2 71.0 71.4 71.2 195.47 195.62 195.39 195.50
6 825 225 9 71.7 71.5 71.3 71.5 196.48 196.67 196.59 196.58
7 900 300 3 72.2 72.5 72.4 72.4 196.71 196.84 196.92 196.82
8 900 300 6 72.1 72.6 72.7 72.5 198.32 198.48 198.74 198.51
9 900 300 9 72.9 72.0 72.8 72.6 198.86 198.94 198.81 198.87
10 825 300 3 65.4 65.6 65.3 65.4 189.62 189.57 189.73 189.64
11 825 300 6 66.2 66.8 66.4 66.5 190.34 190.41 190.52 190.42

12 825 300 9 65.2 65.0 65.1 65.1 189.36 189.42 189.21 189.33

13 900 150 3 69.2 69.5 69.6 69.4 193.69 193.79 193.74 193.74
14 900 150 6 70.2 70.0 70.3 70.2 194.64 194.78 194.21 194.54

15 900 150 9 68.8 68.6 68.7 68.7 195.78 195.84 195.91 195.84

16 750 225 3 69.7 69.8 69.3 69.6 194.89 194.96 194.82 194.89

17 750 6 71.6 71.4 71.3 71.4 188.79 188.94 188.86 188.86

18 750 225 9 70.4 70.6 70.3 70.4 188.57 188.73 188.61 188.64
19 900 225 3 64.8 64.9 64.6 64.8 188.31 188.42 188.53 188.42

20 900 225 6 64.1 64.5 64.4 64.3 190.73 190.62 190.54 190.63

21 900 225 9 64.2 64.0 64.3 64.2 189.84 189.78 189.92 189.85

22 750 300 3 66.9 66.7 66.3 66.6 190.54 190.78 190.62 190.64

23 750 300 6 65.9 65.7 65.5 65.7 189.78 189.92 189.84 189.84

24 750 300 9 66.0 66.5 66.1 66.2 190.08 190.26 190.17 190.17

25 825 150 3 69.4 69.3 69.1 69.3 193.44 193.65 193.58 193.56

26 825 150 6 67.1 67.5 67.4 67.3 191.84 191.92 191.67 191.81

27 825 150 9 68.4 68.0 68.5 68.3 192.79 192.84 192.93 192.85

64
 Table 4.12 Test results of Micro Hardness (VHN) and Tensile Strength (MPa) of
prepared AM 10% vol Grp-MMC

Expt Pouring Shear Stirring Micro Hardness (VHN) Tensile Strength (MPa)
No Temp rate Time Z2 Z3 Average
Y1 Y2 Y3 Average Z1
(C) (r.p.m) (min)
1 750 150 3 78.1 78.5 78.2 78.3 215.52 215.41 215.65 215.53

2 750 150 6 78.6 78.4 78.9 78.6 216.28 216.63 216.47 216.46

3 750 150 9 79.2 79.6 79.8 79.5 217.32 217.18 217.21 217.24

4 825 225 3 81.9 81.4 81.6 81.6 219.88 219.76 219.91 219.85

5 825 225 6 82.2 82.0 82.5 82.2 220.46 220.54 220.35 220.45

6 825 225 9 82.4 82.9 82.6 82.6 220.62 220.71 220.89 220.74

7 900 300 3 83.3 83.0 83.4 83.2 221.58 221.87 221.97 221.80

8 900 300 6 83.2 83.6 83.5 83.4 222.26 222.14 222.39 222.26

9 900 300 9 83.7 83.1 83.8 83.5 222.74 222.52 222.86 222.70

10 825 300 3 77.8 77.7 77.3 77.6 214.32 214.58 214.41 214.44

11 825 300 6 78.1 78.5 78.6 78.4 215.16 215.08 215.12 215.12

12 825 300 9 77.5 77.0 77.1 77.2 214.24 214.09 214.17 214.17

13 900 150 3 80.1 80.6 80.4 80.4 218.35 218.14 218.27 218.25

14 900 150 6 81.3 81.0 81.5 81.3 218.74 218.82 218.96 218.84

15 900 150 9 79.9 79.5 79.7 79.7 217.41 217.63 217.54 217.53

16 750 225 3 80.2 80.8 80.7 80.6 218.52 218.41 218.69 218.54

17 750 225 6 82.7 82.1 82.3 82.4 220.19 220.12 220.26 220.19
18 750 225 9 81.8 81.1 81.2 81.4 219.22 219.41 219.68 219.44

19 900 225 3 76.7 76.9 76.5 76.7 213.84 213.97 213.79 213.87

20 900 225 6 76.6 76.0 76.2 76.3 213.53 213.61 213.72 213.62
21 900 225 9 76.3 76.1 76.4 76.2 213.38 213.24 213.46 213.36

22 750 300 3 78.6 78.9 78.8 78.8 215.28 215.21 215.34 215.28

23 750 300 6 77.9 77.6 77.4 77.6 214.64 214.81 214.72 214.72
24 750 300 9 73.3 78.4 78.0 78.2 214.94 214.87 214.98 214.93

25 825 150 3 80.0 80.2 80.3 80.2 217.83 217.71 217.96 217.83
26 825 150 6 78.3 78.6 78.0 78.3 215.82 215.91 215.74 215.82
27 825 150 9 79.3 79.1 79.4 79.3 216.89 216.74 216.91 216.85

65
 Table 4.13 Test results of Micro Hardness (VHN) and Tensile Strength (MPa) of
prepared Al/ 15% vol Grp-MMC

Expt Pouring Shear Stirring Micro Hardness (VHN) Tensile Strength (MPa)
No Temp rate Time
(C) Y1 Y2 Y3 Average Z1 Z2 Z3 Average
(r.p.m) (min)
1 750 150 3 90.4 90.2 90.3 90.3 230.09 230.26 230.45 230.27
2 750 150 6 90.7 90.5 90.8 90.7 231.12 231.52 231.27 231.30
3 750 150 9 91.0 91.9 91.1 91.3 232.23 232.45 232.37 232.35
4 825 225 3 93.7 93.3 93.8 93.6 233.87 233.94 233.98 233.93
5 825 225 6 94 4 94.0 94.3 94.2 234.04 234.26 234.18 234.16
6 825 225 9 94.8 94.2 94.7 94.6 234.62 234.71 234.89 234.74
7 900 300 3 95.2 95.5 95.1 95.3 235.28 235.41 235.62 235.44
8 900 300 6 95.4 95.7 95.0 95.4 235.91 235.72 235.87 235.83
9 900 300 9 95.6 95.3 95.9 95.6 236.20 236.71 236.43 236.45
10 825 300 3 88.8 88.6 88.5 88.6 228.47 228.62 228.56 228.55
11 825 300 6 89.2 89.6 89.7 89.5 229.43 229.72 229.57 229.57

12 825 300 9 88.1 88.0 88.3 88.1 228.36 228.11 228.27 228.25
13 900 150 '3 92.6 92.8 92.7 92.7 233.08 233.21 233.14 233.14
14 900 150 6 93.0 93.2 93.1 93.1 233.43 233.51 233.59 233.51
15 900 150 9 91.8 91.4 91.7 91.6 232.52 232.72 232.61 232.62
16 750 225 3 92.5 92.1 92.9 92.5 233.24 233.31 233.38 233.31
17 750 225 6 94.3 94.5 94.1 94.3 234.14 234.42 234.51 235.36
18 750 225 9 93.8 93.1 93.2 93.4 233.62 233.71 233.84 233.72
rj r"j
19 900 225 3 87.9 87.6 87.7 227.84 227.93 227.71 227.83

20 900 225 6 87.3 87.8 87.7 87.6 227.43 227.62 227.51 227.52

21 900 225 9 87.4 87.0 87.5 87.3 227.12 227.28 227.37 227.26

22 750 300 3 89.9 89.6 89.8 89.8 229.89 229.82 229.94 229.89

23 750 300 6 88.9 88.7 88.4 88.7 228.71 228.83 228.94 228.83
24 750 300 9 89.0 89.4 89.3 89.2 229.16 229.36 229.27 229.26

25 825 150 3 92.2 92.0 92.4 92.2 232.97 232.89 232.81 232.89

26 825 150 6 90.4 90.6 90.1 90.4 230.54 230.84 230.69 230.69

27 825 150 9 91.2 91.4 91.3 91.3 231.84 231.67 231.98 231.83

66
4.6 MICROSTRUCTURAL CHARACTERIZATION
Microstructural characterization of the as processed specimens was carried out using
optica] microscope and JSM 6100 (JEOL) Scanning Electron Microscope on the
metallographically polished as processed samples so as to study the distribution of
SiC, AEO3 and Grp and interfacial bonding. Specifications of SEM used are given in
table 4.14. Microstructural investigation was conducted on etched specimens and the
etchent used was Kellers reagent (0.5 HF-1.5 HC1-2.5 HNO-95.5 H20)

Table 4.14 Features of the scanning Electron Microscope

Resolution 4.0 nm at 8mm working distance

Working distance 6 to 48 mm
Accelerating Voltage 0.3 to 30 KV
Magnification XI0 to x300,000
Image Recording 120 B&W Roll Film (100 ASA) or 35mm B&W roll (25 ASA)
Instant Print Instant print is also possible on a Thermal Video Printer (8x10.5)

4.6.1 Microstructure Testing

Preliminary preparations for microstructural investigation was carried out as given
below

1. 213 samples were cut from different metal matrix composites specimens as
obtained from different parametric settings(pouring temperature, stirring
speed, stirring time)
2. Samples were first polished with 1200 grade emery paper
3. Each sample was then polished using auto polishing machine and using
Kellers reagent as etchent.
4. Samples were then observed under metallurgical microscope and SEM.

67
Fig 4.8 Prepared Composite Samples

68
 Fig : 4.9 Specimen mounted for Autopolishing

Fig 4.10 Autopolishing of MMC specimens by electrolyte

4.6.2 Testing Results and discussion

The results of the optical micrograph together with SEM studies of some of prepared
samples of Al/5 vol%, Al/10 vol%, Al/15 vol% SiC-MMC,s; Al/5 vol%, Al/10
vol%,Al/15 vol% Al203-MMC,s and Al/5 vol%, Al/10 vol%, Al/15 vol% Grp-MMC,s
are shown in different figures given below.

69
Fig.4.11 Optical micrograph AI2O3 Vol. fraction 15%, At pouring temp 850C, 225
rpm, 6min

Fig.4.12 Optical graph AI2O3 15%, shear rate 225 r.p.m, pouring temp 900C,
time 6min

70
Fig.4.13 Optical micrograph 10% vol.Grp ,shear rate 225 r.p.m, pouring temp 750C,
time 6min

Fig.4.14 Optical micrograph 5% vol. Grp, shear rate 150 r.p.m, pouring temp 825C,
time 9min

71
Fig.4.15 Optical micrograph 10%vol Grp,shear rate 225 r.p.m, pouring temp 750C

72
Fig 4.17 Pouring Temp. 825C, stirring speed (300 r.p.m) and 15%vol.Grp, stirring
time 6 min

Fig 4.18 Pouring Temp. 825C, stirring speed 300 r.p.m, 5%vol Grp, stirring time 6
min

73
Fig 4.20 Pouring Temp. 900C, stirring speed 300 r.p.m, 5%vol Grp, stirring time 9

min

74
Fig 4.21 Pouring Temp. 900C, stirring speed 300 r.p.m, 10%vol Grp, stirring time 3
min

Fig 4.22 Pouring Temp, 750C, stirring speed 150 r.p.m, 15%vol Grp, stirring time 9
min

75
Fig 4.23 Poring Temp 825C, stirring speed 225 r.p.m, 10%vol Grp, stirring time 6
min

Fig 4.24 PouringTemp 900C, stirring speed 300 r.p.m, 10%vol Grp, stirring time
9min

76
Fig 4.25 SEM of unetched Al/SiCp Fig 4.26 SEM of unetched Al/SiCp 10
5vol% MMC vol% MMC

Fig 4.27 SEM of etched Al/SiCp 5 vol% MMC Fig 4.28 SEM of etched Al/SiCp
(825C,225 r.p.m,6min) 10 Vol% MMC (825C,225 r.p.m,6min)

Optical micrograph and SEM studies earned out on the stir cast composite samples in
unetched and etched conditions reveal the distribution of reinforcement particulate in
the aluminum matrix.Different parametric settings produce different distribution of
reinforcement as is clearly seen in optical micrographs.In addition at higher pouring
temperature and at low stirring speed and low stirring time there is a strong tendency
of the particulte to aggloromate in all stir cast metal matrix composites.Interfacial
integrity is seen to improve at (825C,225 r.p.m,6min) as can be observed from Fig
4.28 and 4.29.SEM picture shows a very uniform distribution of SiC particultaes in
5% and 10 vol % MMC.Moreover this uniform distribution indicates isotropic
behaviour of prepared composite. Through the experimentation and property
evaluation, optimisation of casting parameters is carried out in next chapter i.e chapter
5.

77