INTRODUCTION
Optimization and Prediction of Stir casting is a forming
Al(7075) metal matrix with and fabrication technique. Aluminium has
played a key role in the development of
Silicon Carbide, Fly Ash and E- metal matrix composites (MMCs)
glass Fibre reinforced with Bi and fly ash. The
combination of light weight, environmental
resistance and useful mechanical properties
[Link] and [Link] and such as modulus, strength, toughness and
[Link] and [Link] and impact resistance has made aluminium
[Link] alloys well suited for use as matrix
a
Assistant Professor, Department of Mechanical
materials. Moreover, the melting point of
Engineering, KSRCE Tiruchengode, 637215, aluminium is high enough to satisfy many
India. application requirements. Bismuth is
b,c,d & e
widely used because of its high modulus
UG students, Department of Mechanical
and strengths, excellent thermal resistance,
Engineering, KSRCE Tiruchengode, 637215,
India. good corrosion resistance, good
compatibility with the aluminium matrix,
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low cost and ready availability.
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Abstract MATERIAL SELECTION
In the present scenario E- ALUMINIUM:
Waste is an important subject to solve and Aluminium hybrid composites
to utilize in a better way for the betterment
of the human society. E-Waste mainly are a new generation of metal matrix
contains many useful materials such as composites that have the potentials of
aluminium, copper, lead, gold, etc. These
satisfying the recent demands of advanced
materials are recyclable and can be utilized
in making a better material composite by engineering applications. This demand is
using a suitable reinforcement. Here study met due to improved mechanical properties
focused on the E-Waste like printed circuit
boards which contains aluminium in its as discussed above. Current engineering
heat sinks. These heat sinks are made up of application requiresmaterial that is
aluminium alloy specially from Al7075.
stronger, lighter and less expensive.
Our study basically focused on Al7075 is
taken as matrix material and reinforcement AlsoAluminium strength to weight ratio
as fly ash and E-Waste. Here fly ash is which is best suitable for automobile
varied with respect to weight percentage
and E-Waste is kept constant with some application.
weight%. After that the sample composite
will be prepared by the stir casting method.
ALUMI Fly ash is considered as one of the
NIUM(7075) most important and advantageous waste
material in construction [Link] ash
(FA) is one of the cheapest available
reinforcement. The advantages of using FA
is the reinforcement due to its low density
paves way for the development of effective
AMCs.
FLY ASH
BISMUTH:
It is a brittle metal with a silvery-
white color when freshly produced, but
surface oxidation can give it
an iridescent tinge in numerous colours.
Bismuth is the most
naturally diamagnetic element and has one
of the lowest values of thermal E-WASTE:
conductivity among [Link] If the aluminium scrap is properly
particles when reinforced metal matrix recycled and purified it should be nearly
composites have been considered as an 100% pure aluminium.
excellent structural property in the
automotive industry, because of their
excellent combination of low density and E-WASTE (Al SCRAP)
high thermal conductivity
BISMUTH
EXPERIMENTAL PROCEDURE:
FLYASH:
We selected our materials first which
is aluminium 7 series, bismuth, fly ash and
E-Waste. In the help of materials stir
casting process is used to find composite
material and then got work piece it is used
to stir casting process and finally testing
the all work piece such as imapact
strength, tensile strength and hardness test
then finally got the result of composite
material
Percentage (%) Grams(gm)
Specim A B Fl E- A B Fl E-
en L i y Was L i y Wast
as te as e
h h
A 9 2 2 5 85 1 1 42
1 0 7 7
B 8 4 4 10 85 3 3 85
2 0 4 4 STIR CASTING:
Stir casting is a technique used to
C 7 6 6 15 85 5 5 127
fabricate the powders of metals, alloys etc.,
3 0 0 0
in necessary quantities which are blended,
pressed into desired shape(Compacted),and
then heated(Sintered) in a controlled
atmosphere to bond the contacting
STIR CASTING PROCESS: surfaces of the particles.
Compact load :4.5tons
Sinteringtemperature:670°C
STIRCASTING MACHINIG
CENTRE
Temperature at composite melted
specimen
TESTING
SAMPLE PREPARATION
IMPACT STRENGTH
The Al7075 has been cut in to
Impact strength, is the capability
pieces as per required weighted and melted
of the material to withstand a suddenly
in stir casting furnace at 1000 [Link]
applied load and is expressed in terms of
reinforcement materials also mixed to
energy. Often measured with the
[Link] the composite melted at
Izodimpact strength test or Charpy impact
650 °C and the melted composite is
test, both of which measure the impact
transferred in to die and the work specimen
energy required to fracture a sample.
is acquired.
TheCharpy impact test, also known as the
Charpy V-notch test, is a standardized high
strain rate test which determines the
amount of energy absorbed by a material Tensile Strength Value For Metal
during fracture. Matrix Composite
Impact strength value for Metal CS
ARE
Matrix Composite SAM A PEAK UTS
PLE (m LOA ELONGATI (N/m
NO m2) D (N) ON% m2)
SAMPLE ID IMPACT VALUE
2806.
2.1/1 0.013
2.1/1 51 1 5.92 55.02
2.1/2 0.006
2.1/3 0.013 3530.
2.2/1 0.013 2.1/2 51 69 4.44 69.23
2.2/2 0.013
2.2/3 0.013 931.7
2.3/1 0.013 2.1/3 51 5 1.52 18.27
2.3/2 0.006
565.3
2.3/3 0.013
2.2/1 51 4 1.6 11.09
1245.
2.2/2 51 76 9.08 24.43
7654.
2.2/3 51 42 13.68 15.08
IMPACT VALUE
0.014 7500. 147.0
0.012 2.3/1 51 4 15.2 7
0.01 4305.
0.008 2.3/2 51 99 9.08 84.44
0.006
0.004 3210.
2.3/3 51 32 8.21 75.46
0.002
0
2.1/ 2.1/ 2.2/ 2.2/ 2.2/ 2.3/ 2.3/ 2.3/
1 2.1/ 3 1 2 3 1 2 3
2
TENSILE STRENGTH:
SAMPLE ELONGATION% UTS
Tensile strength, maximum load NO (N/mm2)
that a material can support without fracture 2.1/1 5.92 55.02
when being stretched, divided by the 2.1/2 4.44 69.23
2.1/3 1.52 18.27
original cross-sectional area of the
2.2/1 1.6 11.09
material. . When stresses less than the 2.2/2 9.08 24.43
tensile strength are removed, a material 2.2/3 13.68 15.08
returns either completely or partially to its 2.3/1 15.2 147.07
original shape and size. As the 2.3/2 9.08 84.44
2.3/3 8.21 75.46
stress reaches the value of the tensile
Analysis for Tensile strength
strength, however, a material, if ductile,
that has already begun to flow plastically
rapidly forms a constricted region called a
neck, where it then fractures.
SAMPLE HV1 HV2 HV3 HV4 HV5
TENSILE TEST 1 NO
10000 1.1 98.1 105.9 106.5 88.1 88.2
8000
1.2 93.7 100.2 98.6 105.2 102
6000
4000 1.3 87.5 81.5 84 78.1 82.1
2000
0
2.1/ 2.1/ 2.2/ 2.2/ 2.2/ 2.3/ 2.3/ 2.3/
1 2.1/ 3 1 2 3 1 2 3
2 Analysis for Hardness strength
CS AREA (mm2) PEAK LOAD (N)
HARDNESS TEST
120
80
TENSILE TEST 2 40
160 Axis Title 0
O 1 2 3 4 5
120
LEN HV HV HV HV HV
P
80 M
SA
40
0
2.1/1 2.1/3 2.2/1 2.2/2 2.2/3 2.3/1 2.3/2 2.3/3 RESULT
2.1/2
Elongation % Units
HARDNESS STRENGTH
CONCLUSION
The hardness strength is an ability
We choose aluminium MMC because
of the materials to withstand the resistance
against the indentation or abrasion. It is of low cost to high weight ratio. Its reading
tested by hardness testing machine, available when compared to other metals
Hardness can be tested by the three types
of hardness tester Brinell, Rockwell, and and (AMC’S) plays a virtual role in our
Vickers hardness testing machine. In this day to day life moist of the composites
research the Brinell hardness testing
mainly considerers aluminium has a main
machine is used to analyse the hardness
strength of the sample. The ball type matrix because of its excellent mechanical
indenter tool is used. The hardness values properties. It can satisfy the needs of high
are calculated using the formula which is
mentioned below. material and so it can easily replace the
existing component with less weight. In
2P Automobiles it is mainly used which will
BHN=
πD (D− √ D 2−d 2) increase the millage due to weight
Hardness Value Of Metal Matrix reduction. The aluminium is the best
Composite Composite and in that we specifically
select Al (7075). At present 8 series is also tion with wear behaviourActa Mater.,
used for research works which will also 44 (1996), pp. 451–460.
enrich the properties of [5] E. Robert-Perron, C. Blais, S. Pelletier,
[Link] of Al-Bi-Fly Y. Thomas, 2007. Drilling of high qual-
ashcomposites by Stir casting technique is ity features in green Stir casting compo-
attempted during this project work. nents, Material Science and Engineer-
Composites are prepared by varying ing A 458, p. 195-201.
volume of reinforcement. Compare with [6] B. Pena, G. Aramendi, A. Rivero, L.N.
manual mixing of Powders, Magnetic Lopez de Lacalle, 2005. Monitoring of
Mixing of powders yields better hardness. drilling for burr detection using spindle
It was found that a uniform distribution of torque, International Journal of Ma-
Bismuth and fly ash in the Aluminium chine Tools & Manufacture 45, p. 1614-
Matrix. 1621.
[7] M. Nouari, G List, F. Girot, D. Géhin,
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