EXPERIMENTAL ANALYSIS AND

MECHANICAL CHARACTERISATION
OF A356 ALLOY METAL MATRIX
WITH ALUMINA OXIDE&GRAPHITE
BY:
R.EBENEZER SINGARAYAN 961315410004

GUIDED BY: Mr. P.NAVEEN JASS ME.,

ASSISTANT PROFESSOR,
DEPARTMENT OF MECHANICAL ENGINEERING,
M.E.T ENGINEERING COLLEGE.
 INTRODUCTION

• A materials system composed of two or more physically

distinct phases whose combination produces aggregate
properties that are different from those of its constituents
• Examples:
– Cemented carbides (WC with Co binder)
– Plastic molding compounds containing fillers
– Rubber mixed with carbon black
– Wood (a natural composite as distinguished from a
synthesized composite)
 SPECIAL PROPERTIES OF COMPOSITE

• Composites can be very strong and stiff, yet very light in

weight, so ratios of strength-to-weight and stiffness-to-weight
are several times greater than steel or aluminum
• Fatigue properties are generally better than for common
engineering metals
• Toughness is often greater too
• Composites can be designed that do not corrode like steel
• Possible to achieve combinations of properties not attainable
with metals, ceramics, or polymers alone
 OBJECTIVE
In this project various mechanical
characterization have been conducted by varying mass fraction
of aluminium and graphite to attain maximum tensile strength.
The Hardness strength will also be taken into consideration. In
this work a composite is developed by adding Al2O3 in
Aluminum metal by volume ratio 5%, 8% and 10% with
3%.5%,&7% of graphite. The composite has to be prepared by
crucible casting technique and has to be analyzed various
machining properties. The composite has to be prepared by
crucible casting technique and has to be analyzed various
machining properties. Various mechanical properties alloys are
also to be investigated.
 PROBLEM IDENTIFICATION

Conventional materials like Steel, Brass, Aluminium etc will

fail without any indication. Cracks initiation, propagation will
takes place with in a short span. Now a day to overcome this
problem, conventional materials are replaced by Aluminium
alloy materials. Aluminium alloy materials found to the best
alternative with its unique capacity of designing the materials
to give required properties.
PRIMARY PHASE&SECONDARY PHASE

– Primary phase - forms the matrix within which the

secondary phase is embedded
– Al 6063
– Secondary phase - imbedded phase sometimes referred to
as a reinforcing agent, because it usually serves to
strengthen the composite
– Graphite
A356Aluminium Alloy Mechanical Properties

0.2 % proof stress (N/mmo) 185

Tensile stress(N/mm_) 230
Elongation(%) 2
Impact -
Brinell hardness 75
Endurance limit 56
Modulus of elasticity 71
Shear strength 120
 Chemical Composition of A356 Aluminium
.

ELEMENT PERCENTAGE
Si 6.5 – 7.5

Fe 0.6

Cu 0.25

Mn 0.35

Mg 0.20 – 0.45

Zn 0.35

Ti 0.25
• Thermal Properties
• Liquidus temperature. 615ºC (1135ºF)
• Solidus temperature. 555ºC (1035ºF)
 GRAPHITE
• Natural Graphite is a mineral consisting of graphitic carbon.
• Most commercial (natural) graphites are mined and often
contain other minerals.
• Natural graphite is an excellent conductor of heat and
electricity.
• It is stable over a wide range of temperatures. Graphite is a
highly refractory material with a high melting point (3650°C.)
• Natural graphite is subdivided into three types of material:
• • Amorphous
• • Flake
• • High Crystalline
 PROPERTIES OF GRAPHITE
PROPERTIES COMMERCIAL GRAPHITE

MODULUS OF ELASTICITY(Gpa) 8 - 15

COMPRESSIVE STRENGTH(Mpa) 20 - 200

THERMAL CONDUCTIVITY(w/m.k) 25 - 470

SPECIFIC HEAT CAPACITY(J/kg.k) 710 -830

POROSITY(%) 0.7 - 53
 MATRIX (PRIMARY PHASE)

1. Aluminium Alloy is used for Light weight Composites.

2.The matrix is the monolithic material into which the
reinforcement is embedded, and is completely continuous.
This means that there is a path through the matrix to any
point in the material, unlike two materials sandwiched
together.
3. In structural applications, the matrix is usually a lighter metal
such as Aluminium, magnesium, and titanium, and provides a
compliant support for the reinforcement. In high temperature
applications, cobalt and cobalt-nickel alloy matrices are
common.
 REINFORCEMENT MATERIALS

• The reinforcement material is embedded into the matrix. The

reinforcement does not always serve a purely structural task
(reinforcing the compound), but is also used to change
physical properties such as wear resistance, friction
coefficient, or thermal conductivity The reinforcement can be
either continuous, or discontinuous.
• In this experimental we have used discontinuous
Reinforcement
• Common secondary phase is alumina and sic.
CASTING PROCEDURE
For the preparation of the Aluminium graphite alloy by
using mass basis ratio
MIXING RATIO
In this project Aluminum and graphite mixed below
mentioned categories
Sample1: Al90%, AL203,5% &Graphite 5%
Sample2: Al85%, AL203, 12 % &Graphite 3%
Sample3: Al90%, AL203,8% &Graphite 7%
 MATERIAL REQUIREMENT CALCULATION

SAMPLE : 1 (Dia-25mm&Legth 300mm)

MATERIAL REQUIREMENT FINDING METHOD

Specimen size-25 mm dia-
Length-250 mm
Volume-3.14/4*252*300*percentage of composite*density*percentage of excess of
material

Sample1: Al90%, AL203,5% &Graphite 5%

Excess for Runner,Riser & Slag
Aluminium -562gm
Graphite -20 gm
AL203 -36.3gm
 MATERIAL REQUIREMENT CALCULATION

SAMPLE : 2
Al85%, AL203, 12 % &Graphite 3%
Excess for Runner, Riser & Slag
Aluminium-525gm
AL203 -61.5gm
Graphite -21gm
SAMPLE : 3
Al90%, AL2038% &Graphite 7%
Excess for Runner,Riser&Slag
Aluminium-438gm
AL203 -89gm
Graphite -71.69gm
 CUTTING TOOL MATERIAL

 CERMET cutting tools have traditionally been employed in hard part machining for
ferrous based work piece materials with hardness of 50-70HRC, and are capable of
generating surface roughness of ~0.2μm Ra using standard machine tools.
• Increased productivity can be achieved with PCBN tools through:
• Higher cutting speeds.
• Higher feed rates.
• Longer tool life.
• Less machine downtime.
• Solid Inserts
• Inserts are made only from PCBN.
• No material joint.
• Best heat absorption capacity.
• Can work at highest temperatures.

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 Conclusion &Future works
• In Phase I the material and the casting ratio were selected,
based on the literature survey and getting some idea from the
experts. Materials requirement calculation were prepared,
according to the standards, and material has to be planed to
be casted as per the dimension. In Phase II the following test
are going to do to check the mechanical characteristics and
machining behavior of the material.
• 1. Crucible casting
• 2. Various destructive Test
• 3. Out Response verification and Investigation
• 4. Evaluation
REFERENCE