Journal of Mechanical Behavior Of Aluminum, Silicon Carbide And Zirconia Metal Matrix Composite

EXPERIMENTAL INVESTIGATION ON MECHANICAL

BEHAVIOR OF ALUMINUM, SILICON CARBIDE AND
ZIRCONIA METAL MATRIX COMPOSITE
Jagadeesh D*, Mohammed Ajardeen S**
*
Mechanical Department, Vel Tech High Tech Engineering College

I. INTRODUCTION
Better-for-the-environment composites are thermally
and biodegradably superior. Automotive and aerospace
Abstract- As the manufacturing sector increasingly favours
industries favour aluminium composites. Aluminium
the use of lightweight materials, research into aluminum-based
composites have better mechanical, metallurgical, and
Silicon carbide composites is becoming more significant. The
tribological properties. Metal matrix composite production
study's findings include the development and mechanical
prices and technology depend on processing methods and
evaluation of hybrid aluminium matrix composites. The
efficiency (MMC). Hybrid metal matrix composites (HMMC)
aluminium alloy was fortified by the addition of silicon
outperformed particle-reinforced and aluminium cast alloys.
carbide (SiC) and zirconia (Zr) particles. Al matrix composites
Aluminium matrix composites are resistant and strong in
were produced by a casting procedure. Researchers have paid
many applications. Aluminium boron carbide composites are
close attention to metal matrix composites (MMCs) for
used to make neutron absorbers and armour plates. These
possible applications in the aerospace and automotive
composites are strong and wear-resistant. Boron carbide's
industries due to their high strength-to-weight ratios and
hardness makes it perfect for reinforcing applications.
outstanding resilience to temperature. In this research, an
Zirconia is lighter and stronger than other ash. Zirconia
attempt was made to use the Casting Method to produce a
reinforces structures and is environmentally friendly. Zirconia
composite material consisting of Silicon Carbide and Zirconia
in the precipitator has a density of 2.0–2.5 gms/cc, compared
based on Aluminium. The various alloy samples were crafted
to 1.0 in the cenosphere. Sand allows for massive casts. Sand
using a composition of Al (at a 90% concentration), Silicon
casting will make aluminium composites because it's cheap.
Carbide, and Zirconia. Examining mechanical characteristics
The method's low cost influenced this choice. Stirring molten
including hardness, impact strength, and corrosion testing is
material promotes wettability, equiaxed fine grain structure,
the focus of this study. Impact and hardness were used as
and particle distribution throughout the matrix. Composting
measures of success. After that, a morphological investigation
and squeeze casting together generate a casting with less
of the structure would be conducted using a light optical
porosity and better quality. ALFA composites, also known as
microscope.
aluminium Zirconia composites, improve material
characteristics, save money, and help the environment.
Keywords: Metal matrix composite, Aluminum, Silicon
Aluminium Zirconia composites reduced energy, cost, and
Carbide, Zirconia, Mechanical properties, Tensile strength,
pollutants. Pistons and brake rotors use aluminium Zirconia
Hardness, Impact resistance, Microstructural analysis, Stir
composites most. Also important are pistons. ALFA
casting.
composites make manifolds, brackets, housings, home
extruded parts and garden tool covers. These composites
contain little Zirconia. Zirconia reinforcement improves
hardness, yield strength, and compression strength. Zirconia
composites lose ductility as the reinforcing component and
particle size increase. The brittle ceramic phase increases
localised fractures and embrittlement at the matrix-reinforcing
particle contact. Localised fractures increase. Cavities may
nucleate and grow during plastic straining of reinforcing
particles, causing ductility loss. Processes formed these voids.
The microstructure and chemical composition of aluminium
Zirconia composites are determined by the chemical
interaction between the matrix and reinforcing particles.
HMMC from aluminium zirconia produces aluminium oxide,
silicon oxide, ferric oxide, and magnesium oxide as
byproducts. HMMC creation involves this. Aluminium

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Journal of Mechanical Behavior Of Aluminum, Silicon Carbide And Zirconia Metal Matrix Composite

Zirconia composites outperformed cast aluminium alloy in Assess how SiC and ZrO2 particle concentrations affect the
tribological characteristics. Few research have used zirconia mechanical properties of the aluminium matrix composite,
content in aluminium matrix at 17%. Zirconia makes such as tensile strength, hardness, and impact
composites denser and stronger, thus more should be added. resistance.Analyse the composite's microstructure, particularly
Zirconia particles and aluminium oxide improve tensile and reinforcement particle distribution and aluminium matrix
compressive characteristics. Strontium improves wear interaction.Compare the mechanical properties of the
resistance in aluminium boron carbide stir cast composites aluminium matrix composite with pure aluminium. SiC and
with 10% reinforcement. Strontium increased the wear ZrO2 particles improve mechanical qualities. Assess the
resistance of aluminium boron carbide composites. Boron aluminium matrix composite for high-strength, wear-resistant,
carbide improves matrix mechanical properties in Al-Si-Mg and thermally stable applications. Give numerical modelling
alloys. Aluminium matrix contained equally distributed boron and simulation studies optimising metal matrix composite
carbide particles. The impact of boron carbide particles with a performance experimental data and insights. Tensile, hardness,
diameter of 20 micrometres and different weight fractions of and impact tests will evaluate the mechanical properties of the
the alloy AL2024 (5%, 4%, 3%, 3%, and 2%) cast by sand aluminium matrix composite. These attributes will be
casting. Trials showed that A359/B4C/8p composites were examined when SiC and ZrO2 particle concentrations
rigid and strong. Inhomogeneous particle and porosity change.Optical and SEM will study the composite's
distribution make casting ALFA composites difficult. Other microstructure. To determine how SiC and ZrO2 particles
issues exist. The observed non-homogeneous distribution is distribute in the aluminium matrix, their mechanical behaviour
due to the poor wettability of boron carbide particles will be examined.Aluminium matrix composite findings will
compared to the aluminium matrix. Controlling process be compared to pure aluminium and other related materials.
parameters and establishing robust design helped solve these Quantitatively evaluate SiC and ZrO2 particle increases.This
issues. Potassium flurotitanate (K2TiF6) was added to study can illuminate the uses of aluminium matrix composites
improve wettability. At their interaction, titanium carbide and enhanced with SiC and ZrO2 particles. The findings can help
titanium diboride form a reaction layer. Coated boron carbide develop high-performance composite materials for
and Zirconia particles improve wettability. Wear automotive, aerospace, and other industries that require
characteristics depend on Zirconia particle size and mechanical strength, wear resistance, and thermal stability.
composition. Tribological parameters affected
Al-Si/12p/FA/15p composites in previous experiments.
Increased load and sliding velocity accelerate wear. Zirconia
particles increased, degrading the material's tribological
characteristics. Silicon carbide increases Al-SiC-Zirconia II. Literature Survey
composite wear rate and hardness. Silicon carbide increases
wear resistance. AA6351/FA composites and examined the
effects of load, sliding velocity, and reinforcement content Shalaby E A, Churyumov A Y, Solonin A N, et al.
using grey relational analysis and ANOVA. Load affected Preparation and characterization of hybrid
wear rate more than sliding velocity or reinforcing content. A359/(SiC+Si3N4) composites synthesized by stir/squeeze
ALFA composites with a small particle size range had far casting techniques. Materials Science and Engineering: A,
better tribological behaviour than those with a wide range. Pin 2016, 674: 18-24. [1] As a result of their excellent mechanical
or chamber heating can be used for high-temperature pin on and tribological properties, aluminium matrix composites, also
disc wear testing. Each method may work. Pin heating is known as AMC, are utilised in a variety of advanced
preferred because it quickly reaches high temperatures with engineering applications, including those in the automotive
little energy. Researchers examined how load, sliding speed, and aerospace industries, as well as lightweight high strength
and temperature affected stainless steel wear and found that applications, to satisfy the requirements of newly emerging
higher temperatures increase frictional coefficient and surface industries. Casting Al7075 that was reinforced with B4C
finish. Load, sliding speed, and sliding distance all affected composites exhibited an improvement in the material's
Al-Al2O3/9p/Gr/3p composites, but sliding distance had the hardness and tensile qualities.
greatest impact. Temperature, stress, and sliding velocity
affected the tribological properties of AA2024/SiC/10p
composites. Composites with 120 micron reinforcing particles Baradeswaran A, Perumal A E. Influence of B4C on the
were tested at 30, 60, and 90 degrees Celsius. Load and tribological and mechanical properties of Al 7075–B4C
temperature affected wear more than sliding velocity. composites. Composites Part B: Engineering, 2013, 54:
Al6063/TiB2 composites were tested for high-temperature 146-152.[2] Aluminum matrix composites, also known as
tribological behaviour under various loads and temperatures. AMC, are utilised in a variety of advanced engineering
Composite wear rates increased significantly when applications as a result of their excellent mechanical and
temperatures were elevated. Titanium diboride also boosts tribological properties. These applications include those in the
wear resistance. Based on the literature review, wear-resistant automotive and aerospace industries, as well as applications
high-temperature composite materials need additional study. requiring lightweight high strength, to satisfy the requirements
This project examined the high-temperature tribological of newly emerging industries. Casting Al7075 that had been
behaviour of aluminium boron carbide and zirconia. strengthened with B4C composites resulted in an increase in
the material's hardness as well as its tensile strength.

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Journal of Mechanical Behavior Of Aluminum, Silicon Carbide And Zirconia Metal Matrix Composite

reinforced with 10% volume fractions of B4C, SiC, and

Al2O3. According to the author, when compared to other
Surappa M K. Aluminium matrix composites challenges particle reinforced composites, the Al7075 reinforced
and opportunities. Sadhana, 2003, 28(1-2): 319-334. [3] composite with B4C provided superior mechanical
Aluminum matrix composites, or AMCs for short, find use in capabilities.
many cutting-edge engineering applications due to their
superior mechanical and tribological qualities. Some examples
of these uses can be found in the automotive and aerospace Baradeswaran A, Perumal A E. Study on mechanical and
sectors, but they also have wide applicability in other areas wear properties of Al 7075/Al2O3/graphite hybrid
where lightweight high strength is required to meet the needs composites. Composites Part B: Engineering, 2014, 56:
of newer, more technologically advanced sectors. An 464-471.[8] the wear and mechanical properties of hybrid
improvement in hardness and tensile strength was observed composites consisting of graphite, aluminium oxide, and
after casting B4C-reinforced Al7075. aluminium 7075. It was found that increasing the percentage
of reinforced particles in the material's weight led to an
increase in the mechanical properties that the material
Zhang X F, Wang D J, Xie G. Manufacturing of possessed.
aluminum/fly ash composite with liquid reactive sintering
technology. Acta Metallurgica Sinica English Letters,
2009, 15(5): 465-470.[4] Aluminum fly ash composites were Alaneme K K, Sanusi K O. Microstructural characteristics
produced by a technology known as liquid reactive sintering mechanical and wear behaviour of aluminium matrix
powder metallurgy, which utilized fly ash particles as hybrid composites reinforced with alumina, rice husk ash
intensifying stages in the manufacturing procedure. It was and graphite. Engineering Science and Technology, an
discovered that increasing the volume proportion of fly ash International Journal, 2015, 18(3): 416-422.[9] The
particles in aluminium composites led to increases in the mechanical and wear properties of aluminium matrix hybrid
material's hardness, modulus, and resistance to wear. composites that were reinforced with graphite particles, rice
husk ash, and alumina were investigated. The findings
demonstrated that an increase in the weight percentage of rice
Dinaharan I, Kalaiselvan K, Murugan N. Influence of rice husk ash and graphite resulted in a decrease in the hardness of
husk ash particles on microstructure and tensile behavior the composites. The graphite component played a significant
of AA6061 aluminum matrix composites produced using influence in the wear resistance of the material, but at the
friction stir processing. Composites Communications, same time, it diminished the mechanical capabilities of the
2017, 3: 42-46.[5] Using friction stir processing, the aluminium alloy while simultaneously increasing the graphite
manufacture and characterisation of AA6061/18vol.% rice weight percentage.
husk ash in AMC was accomplished. The rice husk ash
particles that had been broken up showed evidence of strong
interfacial adhesion with the aluminium matrix. Rice husk ash Reddy P S, Kesavan R, Ramnath B V. Investigation of
particles were used as a reinforcement in the composite mechanical properties of aluminium 6061-silicon carbide,
material, which resulted in an increase in the tensile strength boron carbide metal matrix composite. Silicon, 2018,
of the material. 10(2): 495-502.[10] when compared to aluminium in its purest
form, the hybrid composite possesses superior mechanical
qualities. For the production of the hybrid composite, the stir
casting method was utilized, and the material employed was
Kumar G V, Rao C S P, Selvaraj N, et al. Studies on Al 6061 with varying proportions of silicon carbide and boron
Al6061-SiC and Al7075-Al2O3 metal matrix composites. carbide. Because of the high concentration of carbides that
Journal of Minerals and Materials Characterization and were present in the hybrid composite, it had superior tensile
Engineering, 2010, 9(1): 43-55.[6] The mechanical and flexural strengths, in addition to a higher level of
characteristics and wear behaviour of metal matrix composites hardness.
made of Al6061-SiC and Al7075-Al2O3 were compared.
Microhardness, tensile strength, and density of the composites 2.2 Research Gap
are all increased thanks to the addition of the hard ceramic Scientific investigation requires identifying research
particles that serve as reinforcement. gaps. Metal matrix composites (90% aluminium, 5% silicon
carbide, and 5% zirconia) have several fascinating features,
but additional research is needed.
Senthilvelan T, Gopalakannan S, Vishnuvarthan S, et al. Particle distribution optimisation, which examines
Fabrication and characterization of SiC, Al2O3 and B4C how particle distribution strategies affect composite
reinforced Al-Zn-Mg-Cu alloy (Al7075) metal matrix mechanical and corrosion properties, may have research gaps.
composites: A study. Advanced Materials Research, 2013, Powder metallurgy and stir casting could improve
622: 1295-1299.[7] The mechanical properties of Al7075 performance by uniformly distributing SiC and ZrO2 particles
metal matrix composites that have been stir cast and are in the aluminium matrix.

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Journal of Mechanical Behavior Of Aluminum, Silicon Carbide And Zirconia Metal Matrix Composite

How to better link the aluminium matrix-SiC/ZrO2 the composite will be affected by the production method
reinforcement interface is another fascinating topic. Surface selected (powder metallurgy, stir casting, etc.).
treatments that improve interface bonding could improve the Mechanical Property Characterization: This research
composite's mechanical properties and corrosion resistance. can analyse the hardness and impact resistance of the
Microstructural Analysis: More research can examine composite. To measure the composite's performance in
the composite's microstructure. This method may involve comparison to pure aluminium, one may conduct hardness
analysing intermetallic phases, secondary phases, and tests (such as the Vickers or Rockwell hardness) and impact
reinforcing particle distribution, size, and shape at nano and testing (such as the Charpy or Izod impact tests).
micro sizes. Such investigations provide microstructure- Salt spray testing, electrochemical measurements
property link and optimisation direction. (such as potentiodynamic polarisation or electrochemical
Another unanswered question is how environmental impedance spectroscopy), and immersion tests can all be used
variables affect composite corrosion. Temperature, humidity, to learn more about the composite's corrosion behaviour. The
corrosive chemicals, and industrial environments can be used goal would be to test the composite's corrosion resistance
to test the composite's corrosion resistance. Research on the against that of pure aluminium in a variety of settings.
composite's behaviour can enlighten its many uses. Microstructural Analysis
Research into the composite's long-term stability and Microscopy methods, such as Light optical
durability is essential. This may include testing the microscopy, can be used to examine the composite's
composite's resistance to cyclic loading, temperature cycling, microscopic structure. Analysing the size, shape, and
and other stressors. Understanding the composite's long-term distribution of the SiC and ZrO2 particles within the
performance helps explain its usefulness and dependability. aluminium matrix is possible using this method. The strength
Comparative Analysis: Comparing the composite to of the matrix's interfacial bond with the reinforcements can
other metal matrix composites or conventional materials like also be revealed.
aluminium alloys reveals its pros and cons. Comparing the Mechanical properties, corrosion resistance, and
composite's mechanical, corrosion resistance, and microstructure of the composite may be optimised by
microstructure behaviour to related materials can progress the experimenting with various processing parameters (such as
field. particle size, composition, reinforcement distribution, and
A thorough literature review is needed to identify research manufacturing techniques). The conditions best suited to
gaps or unsolved problems that your study can address. producing the desired characteristics can be determined
through this optimisation procedure.
The project's conclusion should be grounded in a
III. Aim & Objective thorough examination of the experimental data gathered
1) To identify the strength of composite materials from throughout the project's mechanical, corrosion, and
below composition by using Finite Element Analysis microstructural characterization phases. Conclusions about the
composite's performance and its possible applications can then
(Ansys). be derived from the data. Suggestions for future developments
Aluminium 90%, Silicon Carbide 5%, Zirconia 5% or research topics may also be broached.

2) To Perform casting technique of the composition

3) To identify the mechanical behavior such as impact, IV. Material’s : An Overview
hardness, microstructural of casted aluminium Metal 4.1 ALUMINIUM ALLOY
Matrix Composite Aluminium alloys are alloys in which aluminium
(Al) is the predominant metal. The typical alloying elements
4) To identify the Corrosion behavior of the best are copper,magnesium, manganese, silicon and zinc. There are
composition of Metal Matrix material two principal classifications, namely casting alloys and
wrought alloys, both of which are further subdivided into the
5) To compare with casted aluminium alloy and to categories heat-treatable and non-heat-treatable. About 85% of
enrich the strength characteristics of silicon carbide aluminium is used for wrought products, for example rolled
plate, foils and extrusions. Cast aluminium alloys yield cost-
and zirconia when reinforced with aluminium. effective products due to the low melting point, although they
3.1 Scope of the Project generally have lower tensile strengths than wrought alloys.
The following may be included in a project that The most important cast aluminium alloy system isAl–Si,
investigates the mechanical properties, corrosion resistance, where the high levels of silicon (4.0–13%) contribute to give
and microstructure behaviour of a metal matrix composite good casting characteristics. Aluminium alloys are widely
composed of 90% aluminium, 5% silicon carbide, and 5% used in engineering structures and components where light
zirconia: weight or corrosion resistance is required.
Project work may include preparing the metal matrix Alloys composed mostly of aluminium have been
composite by mixing in the appropriate amounts of very important in aerospace manufacturing since the
aluminium, silicon carbide, and zirconia. The final qualities of introduction of metal skinned aircraft. Aluminium-magnesium

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Journal of Mechanical Behavior Of Aluminum, Silicon Carbide And Zirconia Metal Matrix Composite

alloys are both lighter than other aluminium alloys and much Dissimilar metal corrosion might be exfoliation or
less flammable than alloys that contain a very high percentage intergranular. Heat-treating aluminium alloys can go wrong.
of magnesium. Internal element separation causes internal metal corrosion.
Aluminium alloy surfaces will formulate a white, Aluminium alloy corrosion affects aircraft mechanics daily.
protective layer of corrosion aluminium oxide if left The Aluminium Association registers alloys. The
unprotected by anodizing and/or correct painting procedures. Society of Automotive Engineers' aerospace standards
In a wet environment, galvanic corrosion can occur when an subgroups publish more detailed aluminium alloy
aluminium alloy is placed in electrical contact with other manufacturing standards.
metals with more negative corrosion potentials than
aluminium, and an electrolyte is present that allows ion 4.1.3 Heat sensitivity considerations
exchange. Referred to as dissimilar metal corrosion this Consider the metal's heat sensitivity. Aluminium
process can occur as exfoliation or intergranular corrosion. melts without blazing red, complicating even simple workshop
Aluminium alloys can be improperly heat treated. This causes heating procedures. Blow torch forming can reverse heat
internal element separation and the metal corrodes from the treating, therefore avoid it. Internal damage is not visible. Like
inside out. Aircraft mechanics deal daily with aluminium alloy welding heat-treated, high-strength link chain, torch heat
corrosion. destroys strength. Discard the harmful chain.
Aluminium alloy compositions are registered with When warmed, aluminium creeps under internal
The Aluminum Association. Many organizations publish more tensions, causing delayed distortions. Overheated aluminium
specific standards for the manufacture of aluminium alloy, vehicle cylinder heads can deform or shatter years later, while
including the Society of Automotive Engineers standards incorrectly welded aluminium bicycle frames can twist out of
organization, specifically its aerospace standards subgroups. alignment from welding stress. Thus, the aircraft industry uses
4.1.1 Overview rivets, fasteners, or adhesives to link parts without heat.
Aluminium alloys with a wide range of properties are Overheated aluminium can be annealed by heat-
used in engineering structures. Alloy systems are classified by treating and cooling it in an oven. Heat-treating welded
a number system (ANSI) or by names indicating their main bicycle frames can misalign a considerable portion of these
alloying constituents (DIN andISO). Selecting the right alloy pieces. Cooled pieces can be bent into alignment if the
for a given application entails considerations of its tensile misalignment is not severe. If the frame is rigidly built (see
strength, density,ductility, formability, workability, above), bending will require massive force.
weldability, and corrosion resistance, to name a few. Rocketry uses aluminium, even in combustion
Aluminium alloys are used extensively in aircraft due to their chambers where gases can reach 3500 K. The Agena upper
high strength-to-weight ratio. On the other hand, pure stage engine's nozzle's thermally critical throat region was
aluminium metal is much too soft for such uses, and it does made of regeneratively cooled aluminium, which prevented it
not have the high tensile strength that is needed for airplanes from melting even under massive heat flux.
and helicopters.

4.1.2 Aluminium alloys versus types of steel 4.1.4 Household wiring

Aluminium alloys are Al-rich alloys. Copper, Main article: Aluminium wire
magnesium, manganese, silicon, and zinc alloy. Casting and
wrought alloys can be heat-treated or not. Rolled plate, foils, Because of its high conductivity and relatively low price
and extrusions employ 85% of aluminium. Due to their low compared with copper in the 1960s, aluminium was
melting point, cast aluminium alloys are cheaper than wrought introduced at that time for household electrical wiring in North
alloys, although they have lower tensile strengths. The most America, even though many fixtures had not been designed to
important cast aluminium alloy system is Al–Si, where high accept aluminium wire. But the new use brought some
silicon contents (4.0–13%) improve casting. Lightweight or problems:
corrosion-resistant engineering structures and components use
aluminium alloys.  The greater coefficient of thermal expansion of
Since metal-skinned aircraft, aerospace aluminium causes the wire to expand and contract relative
manufacturing has relied on aluminium alloys. Aluminium- to the dissimilar metal screw connection, eventually
magnesium alloys are lighter and less combustible than high- loosening the connection.
magnesium alloys.  Pure aluminium has a tendency to "creep" under steady
If not anodized or painted, aluminium alloy surfaces sustained pressure (to a greater degree as the temperature
will form a white corrosion-resistant layer of aluminium rises), again loosening the connection.
oxide. When an aluminium alloy is electrically connected to  Galvanic corrosion from the dissimilar metals increases
metals with larger negative corrosion potentials than the electrical resistance of the connection.
aluminium and an electrolyte that enables ion exchange,
galvanic corrosion can occur in a moist environment.

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Journal of Mechanical Behavior Of Aluminum, Silicon Carbide And Zirconia Metal Matrix Composite

All of this resulted in overheated and loose connections, and digits reveal the minimum percentage of aluminium, e.g.
this in turn resulted in some fires. Builders then became wary 150.x correspond to a minimum of 99.50% aluminium. The
of using the wire, and many jurisdictions outlawed its use in digit after the decimal point takes a value of 0 or 1, denoting
very small sizes, in new construction. Yet newer fixtures casting and ingot respectively.[1] The main alloying elements
eventually were introduced with connections designed to in the AA system are as follows:
avoid loosening and overheating. At first they were marked
"Al/Cu", but they now bear a "CO/ALR" coding.
Another way to forestall the heating problem is to crimp the  1xx.x series are minimum 99% aluminium
aluminium wire to a short "pigtail" of copper wire. A properly  2xx.x series copper
done high-pressure crimp by the proper tool is tight enough to  3xx.x series silicon, copper and/or magnesium
reduce any thermal expansion of the aluminium. Today, new
 4xx.x series silicon
alloys, designs, and methods are used for aluminium wiring in
 5xx.x series magnesium
combination with aluminium terminations.
 7xx.x series zinc
4.1.5 Alloy designations  8xx.x series tin
 9xx.x other elements
Wrought and cast aluminium alloys use different
identification systems. Wrought aluminium is identified with a
four digit number which identifies the alloying elements.
Cast aluminium alloys use a four to five digit number 4.1.8 Named alloys
with a decimal point. The digit in the hundreds place indicates
the alloying elements, while the digit after the decimal point  Alclad aluminium sheet formed from high-purity
indicates the form (cast shape or ingot).
aluminium surface layers bonded to high strength
4.1.6 Wrought alloys aluminium alloy core material
The International Alloy Designation System is the most  Birmabright (aluminium, magnesium) a product of The
widely accepted naming scheme for wrought alloys. Each Birmetals Company, basically equivalent to 5251
alloy is given a four-digit number, where the first digit  Duralumin (copper, aluminium)
indicates the major alloying elements.
 Hindalium (aluminium, magnesium, manganese, silicon)
product of Hindustan Aluminium Corporation Ltd, made
 1000 series are essentially pure aluminium with a
in 16ga rolled sheets for cookware
minimum 99% aluminium content by weight and can
be work hardened.  Pandalloy Pratt&Whitney proprietary alloy, supposedly
 2000 series are alloyed with copper, can having high strength and superior high temperature
be precipitation hardened to strengths comparable to performance.
steel. Formerly referred to as duralumin, they were  Magnalium
once the most common aerospace alloys, but were  Magnox (magnesium, aluminium)
susceptible to stress corrosion cracking and are
increasingly replaced by 7000 series in new designs.  Silumin (aluminium, silicon)
 3000 series are alloyed with manganese, and can  Titanal (aluminium, zinc, magnesium, copper, zirconium)
be work hardened. a product of Austria Metall AG. Commonly used in high
 4000 series are alloyed with silicon. They are also performance sports products, particularly snowboards and
known as silumin. skis.
 5000 series are alloyed with magnesium.  Y alloy, Hiduminium, R.R. alloys: pre-war nickel-
 6000 series are alloyed with magnesium and silicon, aluminium alloys, used in aerospace and engine pistons,
are easy to machine, and can be precipitation
for their ability to retain strength at elevated temperature.
hardened, but not to the high strengths that 2000 and
7000 can reach. 4.1.9 Automotive alloys
 7000 series are alloyed with zinc, and can be 6111 aluminium and 2008 aluminium alloy are extensively
precipitation hardened to the highest strengths of any used for external automotive body panels,
aluminium alloy. with5083 and 5754 used for inner body panels. Hoods have
 8000 series is a category mainly used been manufactured from 2036, 6016, and 6111 alloys. Truck
for lithium alloys and trailer body panels have used 5456 aluminum.
Automobile frames often use 5182 aluminium or 5754
4.1.7 Cast alloys
aluminium formed sheets, 6061 or 6063 extrusions.
The Aluminum Association (AA) has adopted a nomenclature
similar to that of wrought alloys. British Standard and DIN Wheels have been cast from A365.0 aluminium or formed
have different designations. In the AA system, the second two 5xxx sheet

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Journal of Mechanical Behavior Of Aluminum, Silicon Carbide And Zirconia Metal Matrix Composite

The Carborundum Company to make bulk SiC for

abrasives.The company resolved with the Electric Smelting
and Aluminium Company in 1900 after a judge accorded its
founders "priority broadly" "for reducing ores and other
substances by the incandescent method". Acheson found hard,
blue-black crystals while trying to dissolve carbon in liquid
corundum (alumina). He felt they were a composite of carbon
and corundum, ergo carborundum. He may have termed it
4.2 SILICON CARBIDE "carborundum" after corundum, another hard material (9 on
Carborundum (SiC) is a silicon-carbon compound the Mohs scale).
having the chemical formula SiC. It's the uncommon mineral SiC was initially an abrasive. E-applications
moissanite. Abrasive silicon carbide powder has been mass- followed. In 1907, Henry Joseph Round applied a voltage to a
produced since 1893. Sintering silicon carbide grains creates SiC crystal and observed yellow, green, and orange
strong ceramics used in bulletproof vests, vehicle brakes, and fluorescence at the cathode, creating the first LED. Silicon
clutches. Silicon carbide was first employed as LEDs and carbide was employed as a detector in early radios . O. V.
detectors in early radios in 1907, and today it is frequently Losev replicated such trials in 1923 in the USSR.
used in high-temperature/high-voltage semiconductor circuits.
Synthetic moissanite can be carved from large Lely-grown
silicon carbide crystals. Plant SiO2 can make high-surface-
area silicon carbide.

4.2.1 Early production

4.2.2 Natural occurrence

Fig: 4.1 A replication of H.J. Round's LED experiments

J. J. Berzelius's reduction of potassium fluorosilicate

by potassium (1810); Charles Mansuète Despretz's (1792– Fig: 4.2 Moissanite single crystal (≈1 mm in size)
1863) passing an electric current through a carbon rod Natural moissanite occurs in extremely low
embedded in sand (1849); Robert Sydney Marsden's (1856– concentrations in several varieties of meteorite, corundum
1919) dissolution of silica in molten silver in a graphite deposits, and kimberlite. Almost all moissanite jewellery,
crucible (1881); Albert Colson's heating silicon under a stream which contains silicon carbide, is man-made. In 1893, a little
of ethylene (1882); and In 1890, Edward Goodrich Acheson piece of the Canyon Diablo meteorite was discovered in
began mass production. Acheson melted clay (aluminium Arizona, and the material was dubbed moissanite in 1905 after
silicate) and powdered coke (carbon) in an iron bowl to make its discoverer, Dr. Ferdinand Henri Moissan. It was first
fake diamonds. He termed the blue crystals Carborundum, thought that Moissan's sample of naturally occurring SiC
thinking they were a novel carbon-aluminum composite like might have been tainted by silicon carbide saw blades already
corundum. Henri Moissan identified the uncommon SiC on the market, hence his discovery was met with scepticism.
mineral in Arizona's Canyon Diablo meteorite rock samples in Silicon carbide may be hard to get by on Earth, but
1893. Moistanite was named for him. Moissan also it's surprisingly common throughout the cosmos. Primitive
synthesised SiC by dissolving carbon in molten silicon, (unaltered) meteorites have been recovered with samples of
melting calcium carbide and silica, and reducing silica with this type of stardust, which is abundant in the vicinity of
carbon in an electric furnace. Moissan claimed Acheson carbon-rich stars. Beta-polymorph silicon carbide makes up
discovered SiC in 1903.Acheson patented silicon carbide nearly all of the silicon carbide in space and meteorites.
powder production on February 28, 1893.Acheson invented Anomalous isotope ratios of carbon and silicon in SiC grains
the electric batch furnace used to make SiC today and founded

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Journal of Mechanical Behavior Of Aluminum, Silicon Carbide And Zirconia Metal Matrix Composite

identified in the carbonaceous chondrite meteorite Murchison

indicate an extrasolar origin; 99% of these SiC grains originate
near carbon-rich asymptotic giant branch stars. The infrared
spectra of these stars reveal that SiC is abundant in their
environments.

4.2.3 Production

Because of the rarity of natural moissanite, most

silicon carbide is synthetic. It is used as an abrasive, and more
recently as a semiconductor and diamond simulant of gem Fig: 4.3 Synthetic SiC crystals ~3 mm in diameter
quality. The simplest manufacturing process is to combine
silica sand and carbon in an Acheson graphite electric
resistance furnace at a high temperature, between 1600 and
2500 °C. Fine SiO2 particles in plant material (e.g. rice husks)
can be converted to SiC by heating in the excess carbon from
the organic material.[14] The silica fume, which is a byproduct
of producing silicon metal and ferrosilicon alloys, also can be
converted to SiC by heating with graphite at 1500 °C.[15]

PROPERTIES OF MAJOR SIC POLYTYPES

Polytype 3C (β) 4H 6H (α)

Crystal structure Zinc blende (cubic) Hexagonal Hexagonal

Space group T2d-F43m C46v-P63mc C46v-P63mc

Pearson symbol cF8 hP8 hP12

Lattice constants (Å) 4.3596 3.0730; 10.053 3.0730; 15.11

Density (g/cm3) 3.21 3.21 3.21

Bandgap (eV) 2.36 3.23 3.05

Bulk modulus (GPa) 250 220 220

Thermal conductivity (W cm−1K−1)

3.6 3.7 4.9
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@ 300K (see [28] for temp. dependence)
Journal of Mechanical Behavior Of Aluminum, Silicon Carbide And Zirconia Metal Matrix Composite

create the beta modification (-SiC). Although the beta form

has had limited commercial application up until recently, it is
increasingly being considered as a support for heterogeneous
catalysts because of its greater surface area compared to the
alpha form.

4.2.4 TABLE FOR PROPERTIES OF MAJOR SIC

POLYTYPES

Pure SiC is colorless. The brown to black color of industrial

productresults from iron impurities. The rainbow-like luster of
the crystals is caused by a passivation layer of silicon dioxide
Fig: 4.4 Synthetic SiC Lely crystals that forms on the surface.

The high sublimation temperature of SiC

(approximately 2700 °C) makes it useful for bearings and
furnace parts. Silicon carbide does not melt at any known
Distance from the graphite resistor heat source affects
pressure. It is also highly inert chemically. There is currently
the quality of the material generated in the Acheson furnace.
much interest in its use as a semiconductor material in
The purest crystals are colourless, pale yellow, and green, and
electronics, where its high thermal conductivity, high electric
they can be found in close proximity to the resistor. Crystals
field breakdown strength and high maximum current density
are less pure and seem bluer and blacker the further they are
make it more promising than silicon for high-powered devices.
from the resistor. Common contaminants reduce the electrical
SiC also has a very low coefficient of thermal expansion (4.0
conductivity of SiC; examples include nitrogen and
× 10−6/K) and experiences no phase transitions that would
aluminium.
cause discontinuities in thermal expansion.
Using the so-called Lely technique, SiC powder is
4.2.5 Electrical conductivity
sublimated in an argon environment at 2500 °C and
redeposited as flake-like single crystals, with dimensions of up
to 22 cm2. Silicon carbide is a semiconductor, which can be
doped n-type by nitrogen or phosphorus and p-type by
aluminium, boron, gallium or beryllium. Metallic conductivity
Due of the high growth temperature, the resulting
has been achieved by heavy doping with boron, aluminium or
single crystals are of a high quality 6H-SiC phase. With a
nitrogen. Superconductivity has been detected in 3C-SiC:Al,
section 81 times larger than the standard Lely method, the
3C-SiC:B and 6H-SiC:B at the same temperature of 1.5 K. A
single crystals produced by a modified Lely process utilising
crucial difference is however observed for the magnetic field
induction heating in graphite crucibles can reach a diameter of
behavior between aluminium and boron doping: SiC:Al is
4 inches (10 cm). Chemical vapour deposition (CVD) is
type-II, same as Si:B. On the contrary, SiC:B is type-I. In
typically used to create cubic SiC, however it is a more
attempt to explain this difference, it was noted that Si sites are
expensive method. Gas and liquid phase methods can be used
more important than carbon sites for superconductivity in SiC.
to generate both homoepitaxial and heteroepitaxial SiC layers.
Whereas boron substitutes carbon in SiC, Al substitutes Si
The polymer poly(methylsilyne) can be thermally decomposed
sites. Therefore, Al and B "see" different environment that
into pure silicon carbide at low temperatures in an inert
might explain different properties of SiC:Al and SiC:B.
atmosphere. The polymer can be shaped in a variety of ways
before being thermally transformed into the ceramic, making
the pyrolysis procedure preferable to the CVD process.

The crystalline forms of silicon carbide number in the

hundreds. SiC's polymorphism is defined by a broad group of
polytypes, or crystalline structures with comparable structures.
They're both forms of the same chemical substance, but in the
third dimension, these compounds are distinct from one
another. As such, they can be conceptualized as a series of
layers.

The most common polymorph is alpha silicon carbide (-SiC),

which crystallises into a hexagonal lattice (like Wurtzite) at
temperatures above 1700 °C. A zinc blende crystal structure
(like diamond) is generated at temperatures below 1700 °C to

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Journal of Mechanical Behavior Of Aluminum, Silicon Carbide And Zirconia Metal Matrix Composite

Silicon carbide, together with alumina and boron

carbide, is used in bulletproof vest ceramic plates and
USES composite armour such as Chobham. Pinnacle Armor's
Dragon Skin has discs made of silicon carbide.
Abrasive and cutting tools
When ceramics, glass fusing, or glass casting are
being fired in a high temperature kiln, silicon carbide is
employed as a support and shelving material. When compared
to its alumina counterparts, SiC kiln shelves are much more
portable and long-lasting.

Automobile parts

Fig: 4.5 Cutting disks made of SiC

In the arts, silicon carbide is a popular abrasive in

modern lapidary due to the durability and low cost of the
material. In manufacturing, it is used for its hardness in
abrasive machining processes such as grinding, honing, water-
jet cutting and sandblasting. Particles of silicon carbide are
laminated to paper to create sandpapers and the grip tape on
skateboards.
Fig: 4.6 The Porsche Carrera GT's carbon-ceramic (silicon
carbide) disc brake
In 1982 an exceptionally strong composite of
aluminium oxide and silicon carbide whiskers was discovered.
Silicon-infiltrated carbon-carbon composite is used
Development of this laboratory-produced composite to a
for high performance "ceramic" brake discs, as it is able to
commercial product took only three years. In 1985, the first
withstand extreme temperatures. The silicon reacts with the
commercial cutting tools made from this alumina and silicon
graphite in the carbon-carbon composite to become carbon-
carbide whisker-reinforced composite were introduced by the
fiber-reinforced silicon carbide (C/SiC). These discs are used
Advanced Composite Materials Corporation (ACMC) and
on some road-going sports cars, including the Porsche Carrera
Greenleaf Corporation
GT, the Bugatti Veyron, the Chevrolet Corvette ZR1,
Bentleys, Ferraris, Lamborghinis, and some specific high
performance Audis.[37] Silicon carbide is also used in a sintered
form for diesel particulate filters.

4.2.7Electric systems
4.2.6 Structural material
SiC was first used in electricity in lightning arresters
Trauma plates in bulletproof vests are made of silicon in electrical grids. These components have to show high
carbide. Silicon carbide was the subject of various European, resistance up until a certain voltage threshold VT is reached,
Japanese, and American high-temperature gas turbine research and then they have to decrease to a lower level and stay there
programmes in the 1980s and 1990s. The turbine blades and until the applied voltage drops below VT again.
nozzle vanes made of nickel superalloy were what these parts
were designed to replace. However, due to its poor impact SiC's voltage-dependent resistance was discovered
resistance and brittleness, it was never used in any early on, leading to the use of SiC pellet columns coupled to
commercially viable applications. high-voltage power lines. The SiC column will conduct when
the line voltage is high enough from a lightning strike,

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Journal of Mechanical Behavior Of Aluminum, Silicon Carbide And Zirconia Metal Matrix Composite

diverting the strike electricity to the earth rather than the impeded by issues with the interface of SiC with silicon
power line. These SiC columns were found to conduct dioxide as well as poor crystal quality. Nitridation has
strongly at typical power-line voltages, necessitating the significantly decreased the flaws that were creating the
addition of a spark gap in series with them. When the voltage interface issues, however the process is still unknown.The first
of the power line conductor is increased by lightning, the 1200 V rated commercial JFETs appeared on the market in
spark gap is ionised and rendered conductive, thereby linking 2008, and the first 1200 V rated commercial MOSFETs
the SiC column between the power conductor and the ground. appeared in 2011. Companies began incorporating the bare
chips into their power modules even before they began
As a result of material failure or contamination by manufacturing SiC switches and SiC Schottky diodes (also
dust or salt, spark gaps used in lightning arresters often fail to Schottky barrrier diodeSDB) in the ubiquitous TO-247
strike an arc when necessary or to turn off thereafter. The package. PFC circuits and IGBT power modules are two
initial intent of using SiC columns in a lightning arrester was common applications for SiC SBD diodes.
to do away with the spark gap. As a form of lightning
protection, gapped silicon carbide (SiC) arresters were 4.2.9 LEDs
marketed under names like GE and Westinghouse. Columns of
zinc oxide pellets, known as no-gap varistors, have largely The history of SiC LEDs is quite remarkable: the first
replaced the gapped SiC arrester. LED action was demonstrated in 1907 using SiC and the first
commercial LEDs were again based on SiC. Yellow LEDs
Electronic circuit elements made from 3C-SiC were manufactured in the Soviet Union in
the 1970s, and blue ones (6H-SiC) worldwide in the 1980s.
The production was soon stopped because gallium nitride
showed 10–100 times brighter emission. This difference in
efficiency is due to the unfavorable indirect bandgap of SiC,
whereas GaN has a direct bandgap which favors light
emission. However, SiC is still one of the important LED
components – it is a popular substrate for growing GaN
devices, and it also serves as a heat spreader in high-power
LEDs.

4.2.10 Astronomy

The low thermal expansion coefficient, high

hardness, rigidity and thermal conductivity make silicon
carbide a desirable mirror material for astronomical
telescopes. The growth technology (chemical vapor
deposition) has been scaled up to produce disks of
polycrystalline silicon carbide up to 3.5 meters in diameter,
and several telescopes (like the Herschel Space Telescope) are
already equipped with SiC optics.

Fig: 4.7 Ultraviolet LED 4.2.11 Thin filament pyrometry

4.2.8 Power electronic devices Image of the test flame and glowing SiC fibers. The
flame is about 7 cm tall. Silicon carbide fibers are used to
Silicon carbide is a semiconductor that has shown measure gas temperatures in an optical technique called thin
promise for rapid, high-temperature, and/or high-voltage filament pyrometry. It involves the placement of a thin
devices in both laboratory and early mass-production settings. filament in a hot gas stream. Radiative emissions from the
Schottky diodes were the first high-power switching devices filament can be correlated with filament temperature.
available, followed by Junction-gate FETs and MOSFETs. We Filaments are SiC fibers with a diameter of 15 micrometers;
are currently working on thyristors and bipolar transistors.The about one fifth that of a human hair. Because the fibers are so
removal of defects such as edge dislocations, screw thin, they do little to disturb the flame and their temperature
dislocations (both hollow and closed core), triangle defects, remains close to that of the local gas. Temperatures of about
and basal plane dislocations has been a key challenge for the 800–2500 K can be measured.[48][49]
commercialization of SiC.As a result, devices built using SiC
crystals had subpar reverse blocking capability at first. Heating elements
However, scientists have been slowly but surely working on
strategies to improve this. Development of SiC-based power References to silicon carbide heating elements exist
MOSFETs and insulated-gate bipolar transistors has been from the early 20th century when they were produced by

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Journal of Mechanical Behavior Of Aluminum, Silicon Carbide And Zirconia Metal Matrix Composite

Acheson's Carborundum Co. in the U.S. and EKL in Berlin. remains undamaged by temperatures up to 1800 °C.
Silicon carbide offered increased operating temperatures Moissanite has become popular as a diamond substitute, and
compared with metallic heaters. Silicon carbide elements are may be misidentified as diamond, since its thermal
used today in the melting of non-ferrous metals and glasses, conductivity is much closer to that of diamond than any other
heat treatment of metals, float glass production, production of diamond substitute. Many thermal diamond-testing devices
ceramics and electronics components, igniters in pilot lights cannot distinguish moissanite from diamond, but the gem is
for gas heaters, etc. distinct in its birefringence and a very slight green or yellow
fluorescence under ultraviolet light. Some moissanite stones
Nuclear fuel particles also have curved string-like inclusions, which diamonds never
have.
Silicon carbide is an important material in TRISO-coated fuel
particles, the type of nuclear fuel found in high temperature Steel production
gas cooled reactors (such as the Pebble Bed Reactor). A layer
of silicon carbide gives coated fuel particles structural support
and is the main diffusion barrier to the release of fission
products.

Nuclear fuel cladding

Silicon carbide composite material has been investigated for

use as a replacement for Zircaloy cladding in light water
reactors. The composite consists of SiC fibers wrapped around
a SiC inner layer and surrounded by an SiC outer layer.
Problems have been reported with the ability to join the pieces
of the SiC composite.

Jewelry

Fig: 4.9 Piece of silicon carbide used in steel making

Silicon carbide, dissolved in a basic oxygen furnace used for

making steel, acts as a fuel. The additional energy liberated
allows the furnace to process more scrap with the same charge
Fig: 4.8 A moissanite ring of hot metal. It can also be used to raise tap temperatures and
adjust the carbon and silicon content. Silicon carbide is
As a gemstone used in jewelry, silicon carbide is called cheaper than of a combination of ferrosilicon and carbon,
"synthetic moissanite" or just "moissanite" after the mineral produces cleaner steel and less emissions due to low level of
name. Moissanite is similar to diamond in several important trace elements, has a low gas content, and does not lower the
respects: it is transparent and hard (9-9.5) on the Mohs scale temperature of steel.[55]
(compared to 10 for diamond), with a refractive index between
2.65 and 2.69 (compared to 2.42 for diamond). Moissanite is Catalyst support
somewhat harder than common cubic zirconia. Unlike
diamond, moissanite can be strongly birefringent. This quality The natural resistance to oxidation exhibited by silicon
is desirable in some optical applications, but not in gemstones. carbide, as well as the discovery of new ways to synthesize the
For this reason, moissanite jewels are cut along the optic axis cubic β-SiC form, with its larger surface area, has led to
of the crystal to minimize birefringent effects. It is lighter significant interest in its use as a heterogeneous catalyst
(density 3.21 g/cm3 vs. 3.53 g/cm3), and much more resistant support. This form has already been employed as a catalyst
to heat than diamond. This results in a stone of higher luster, support for the oxidation of hydrocarbons, such as n-butane, to
sharper facets and good resilience. Loose moissanite stones maleic anhydride.
may be placed directly into wax ring moulds for lost-wax
casting; unlike diamond, which burns at 800 °C, moissanite

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Journal of Mechanical Behavior Of Aluminum, Silicon Carbide And Zirconia Metal Matrix Composite

Carborundum printmaking benefits

Silicon carbide is used in carborundum printmaking – a

collagraph printmaking technique. Carborundum grit is
applied in a paste to the surface of an aluminium plate. When
the paste is dry, ink is applied and trapped in its granular
surface, then wiped from the bare areas of the plate. The ink
plate is then printed onto paper in a rolling-bed press used for
intaglio

printmaking. The result is a print of painted marks embossed

into the paper.

Density, g/cm3 2.95 - 3.00

Thermal Conductivity, W/m•K 170 - 200
-1
Thermal Expansion Coefficient, E-6 K tailor-made from 6.5 to 9.5
Electrical Resistivity, •cm 30 - 50
Applications:
Bending Strength, MPa 350 - 500
Elastic Modulus, GPa 200 – 230 1.Advanced Printed Circuit
Board
Graphene production
2. Microelectronic packaging
Silicon carbide is used to produce epitaxial graphene by
graphitization at high temperatures. This is considered as one 3. Radiofrequency and microwave packaging
of the promising methods to synthesize graphene at large scale
for practical applicationsProperties of major SiC polytypes 4. Optoelectronic packaging
Polytype 3C (β) 4H 6H (α) Crystal structure Zinc blende
(cubic) Hexagonal Hexagonal Space group T 2d-F43m C46v-
Table of Typical Properties:
P63mc C46v-P63mc Pearson symbol cF8 hP8 hP12 Lattice

1. Tailor-made coefficient of thermal expansion (eliminates thermal cycling fatigue due to CTE mismatch).

2. High thermal conductivity (conducts heat almost like aluminum)

3. Light weight and strong (almost as light as aluminum but stronger, it is excellent for aerospace, automotive and
other mobile applications).

4. Precision surface treatment (surface roughness; hole-drilling; plating with nickel, gold, silver, tin, etc.)

5.costeffectiveproduction
constants (Å) 4.3596 3.0730; 10.053 3.0730; 15.11 Density
(g/cm3) 3.21 3.21 3.21 Bandgap (eV) 2.36 3.23 3.05 Bulk
modulus (GPa) 250 220 220 Thermal conductivity (W
cm−1K−1)

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 Journal of Mechanical Behavior Of Aluminum, Silicon Carbide And Zirconia Metal Matrix Composite

4.3.2 Types of Zirconias

There are many different types of zirconias. These have
4.3 ZIRCONIA evolved as researchers and manufacturers sought to exploit the
Zirconia can be found in three crystal structure. different properties of the various phases. Some of the phases
These are monolithic (m), tetragonal (t) and cubic (c) are stable at high temperatures and need to be “frozen” in such
structures. Monolithic structure is stable between room that they can be used at room temperatures, while others
temperature and 1170 0C while it turns to tetragonal structure exploit toughening mechanisms that are only found in these
above 1170 0C. Tetragonal structure is stable up to 2379 0C and few other materials. Some of these materials are listed
and above this temperature, the structure turns to cubic below along with their typical ABBREVIATIONS.
structure.Zirconia (ZrO2) is a ceramic material with adequate Tetragonal Zirconia Polycrystals TZP
mechanical properties for manufacturing of medical devices. Partially Stabilised Zirconia PSZ
Zirconia stabilized with Y2O3 has the best properties for these Fully Stabilised Zirconia FSZ
applications. When a stress occurs on a ZrO2 surface, a Transformation Toughened Ceramics TTC
crystalline modification opposes the propagation of cracks. Zirconia Toughened Alumina ZTA
Compression resistance of ZrO2 is about 2000 MPa. Zirconia Transformation Toughened Zirconia TTZ
is a crystalline dioxide of zirconium. Its mechanical properties Materials (oxides) added to stabilise or toughen the
are very similar to those of metals and its color is similar to zirconia will also be noted as a prefix to the abbreviations
tooth color. listed in table 1. They will sometimes be used in conjunction
4.3.1Background with numbers which indicate the amount of the stabilising
 The fundamental properties of zirconia ceramics agent added. Typical examples include Y, Ce, Mg and A
which correspond to yttria (Y2O3), ceria (CeO2), magnesia
Y- Mg- 3Y2 (MgO) and alumina (Al2O3) respectively. So a
Property Ce-TZP ZTA material denoted as 3Y-TZP would tetragonal zirconia
TZP PSZ 0A
Density (g.cm-3) 6.05 6.15 4.15 5.75 5.51 polycrystal with an addition of 3mol% Y 2O3 as a
stabiliser.
102 147
Hardenss (HV30) 1350 900 1600 4.3.3 Property Comparison
0 0
240 Table lists properties for various grades of
Bend Str. (MPa) 1000 350 500 800
0 zirconia and has been compiled from a variety of
200 sources. However, as with most ceramic materials
Compressive Str. (MPa) 2000 - - -
0
properties are dependent on many factors such as
Young’s Modulus (GPa) 205 215 380 205 260 starting powders and fabrication techniques. Most
Poisson’s Ratio 0.3 - - 0.23 - ceramic fabrication techniques have been applied to
8- zirconias such as dry pressing, isostatic pressing,
Fracture Toughness (MPa.m-1/2) 9.5 15-20 4-5 6
15 injection moulding, extrusion and tape casting.
Thermal Exp. Co-Eff (x10-6 °C-1) 10 8 8 10 9.4 Addition of impurities during processing may also
Thermal Conductivity (W.m-1.K- introduce flaws and degrade properties.
1 2 2 23 1.8 3
)
which are of interest to the engineer or designer are:
Table for Typical properties of various types of zirconia.
 High strength,
 High fracture toughness,
 High hardness, 4.3.4 Yttria (Y2O3)
Melting point of yttria is 2410 0C. It is very stable in
 Wear resistance,
the air and cannot be reduced easily. It can be dissolved in
 Good frictional behavior, acids and absorbs CO2. It is used in Nerst lambs as filament
by alloyed with zirconia and thoria in small quantities. When
 Non-magnetic, added to zirconia, it stabilizes the material in cubic structure.
 Electrical insulation, Primary yttria minerals are gadolinite, xenotime and
fergusonite. Its structure is cubic very refractory.
 Low thermal conductivity,
 Corrosion resistance in acids and alkalis,
 Modulus of elasticity similar to steel,
 Coefficient of thermal expansion similar to iron. V. METAL MATRIX COMPOSITE
A metal matrix composite, often known as an MMC,
is a form of material that is made up of a metal matrix that is

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Journal of Mechanical Behavior Of Aluminum, Silicon Carbide And Zirconia Metal Matrix Composite

then reinforced with one or more other types of materials. The properties are desirable. Other applications include
supplementary components, also known as reinforcements, heat sinks.
might take the form of fibres, particles, or whiskers,
depending on the particular application. In comparison to the
Certainly! Additional information regarding metal matrix
base metal by itself, the combination of the metal matrix and
the reinforcements results in enhanced mechanical, thermal, composites can be found as follows:
and electrical properties.  Types of Reinforcements Metal matrix composites
An MMC typically consists of a lightweight metal have the ability to incorporate a wide variety of
such as aluminium, magnesium, or titanium as its metal matrix reinforcements, including the following:
component. Reinforcements like this can be manufactured  Continuous fibres High-strength fibres, such as
from a wide variety of materials, such as metals, ceramics, or
carbon fibres or ceramic fibres, are encased in a
carbon fibres, among others. The qualities of the composite
that are sought after should guide the selection of reinforcing metal matrix to create a continuous fibre structure.
materials. Continuous fiber-reinforced composites are widely
Metal matrix composites offer various advantages utilised in a variety of applications within the
over ordinary metals. The following are some of the most aerospace industry due to their high level of strength
important advantages: and stiffness.
 High tensile and flexural strengths: The addition of  Short fibres or whiskers are randomly or consistently
reinforcements enhances the composite material's spread throughout the metal matrix. This type of fibre
tensile and flexural strengths, making it stiffer and is referred to as a discontinuous fibre. In comparison
stronger than the base metal by itself. to the basic metal, the strength and wear resistance of
 MMCs typically display greater thermal conductivity these composites are significantly improved.
and heat dissipation capabilities compared to  Particulates are introduced into the metal matrix in
unreinforced metals, which contributes to their the form of ceramic, metallic, or carbon particles.
overall improved thermal characteristics. Because of Particulate-reinforced composites have improved
this, they are suited for use in applications that need hardness, thermal stability, and wear resistance over
for effective management of heat. their unreinforced counterparts.
 Increased resistance to wear The addition of  Hybrid reinforcements: It is also feasible to combine
reinforcements can greatly improve the wear several types of reinforcements in order to develop
resistance and durability of the composite, making it hybrid metal matrix composites with qualities that are
ideal for applications that are subjected to conditions specifically matched to the application.
with high levels of friction or abrasion.  Fabrication Techniques: Manufacturing metal matrix
 qualities that can be tailored: The qualities of an composites can be accomplished by a variety of
MMC can be modified to fit the requirements of a means, including the following:
certain application by selecting a different type of  Powder metallurgy is the process of producing
reinforcement and a different amount of that composite materials by combining metal powders
reinforcement. Because of this versatility, it is and reinforcement particles in a powder, then
possible to customise based on the particular mix of compacting the mixture and sintering it.
qualities that is required.
 During the manufacturing process, reinforcements
 Weight reduction: Despite having better are generated within the metal matrix by the use of
characteristics, MMCs are typically able to maintain chemical processes. This process is known as in-situ
a relatively low weight in comparison to standard synthesis.
metals. This makes MMCs appealing for applications
 Infiltration of molten metal: This technique involves
in where reducing the amount of weight used is
injecting molten metal into a preform that already
essential.
contains the reinforcement material. This enables the
 Applications can be found for metal matrix metal to fill the void spaces and connect with the
composites in a wide variety of fields. They find reinforcement at the same time.
widespread application in a variety of industries,
 Stir casting is a process in which reinforcements are
including aerospace, automotive, defence, and
stirred into molten metal, and then the resulting
electronics, among others. Components of engines,
mixture is allowed to cool and solidify to produce a
braking discs, heat sinks, electrical contacts, and
composite.
structural components are just some of the specific
Solid-state processing: This refers to techniques such as hot
applications in which high strength and lightweight pressing, hot isostatic pressing (HIP), or diffusion bonding, in

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Journal of Mechanical Behavior Of Aluminum, Silicon Carbide And Zirconia Metal Matrix Composite

which the metal matrix and reinforcements are solidified enhanced. Combining SiC particles with an aluminium matrix
under conditions of high temperature and pressure. creates a composite that may be more resistant to wear,
abrasion, and erosion. This is useful in situations when the
Properties and Applications: The properties of metal matrix parts will come into abrasive or sliding contact with one
composites can vary widely depending on the type of another.
reinforcement and matrix material that is used to make the Zirconia has excellent thermal properties, such as a
composite. The following are some noteworthy properties and low thermal expansion coefficient and strong thermal stability.
applications: Zirconia benefits from these qualities, which enhance its
MMCs provide great strength and stiffness while overall performance. By including zirconia particles into the
maintaining a low weight, which contributes to their high composite, the material's thermal stability and resistance to
strength-to-weight ratio. They find use in the automotive and thermal cycling may be enhanced. To boot, adding SiC to the
aerospace industries, as well as in athletic products. mix can boost the composite's thermal conductivity, which in
turn improves its ability to dissipate heat.
Thermal management: Due to their high thermal In order to improve its fracture toughness, zirconia is
conductivity and ability to dissipate heat, MMCs are ideal for known to undergo a phase change called transformation
use as heat sinks, in electronic packaging, and in high- toughening. Zirconia can change from its tetragonal phase to
temperature applications. its monoclinic phase under stress. The energy is absorbed and
Wear resistance: MMCs with reinforced particles or fibres the fracture bends as a result. This technique boosts the
give enhanced wear resistance, which makes them helpful in composite's crack propagation resistance and, in turn,
components prone to friction and abrasion, such as brake pads, increases its fracture toughness.
clutch plates, and bearings. Wear resistance can be improved Customised electrical characteristics The electrical
by using MMCs with reinforced particles or fibres. conductivity of the composite may be altered by the addition
of zirconia or silicon carbide. Despite aluminum's excellent
Electrical conductivity: Because of their modifiable conductivity, the composite's electrical conductivity can be
electrical conductivity, metal matrix composites can be used lowered by using zirconia as an insulator. However, SiC
for a variety of applications, including electromagnetic particles may have a minor effect on the electrical
shielding, electrical contacts, and connections. conductivity, depending on the amount of SiC present and
how it is dispersed throughout the matrix.
Damping capacity: Certain multi-material composites Challenges with processing include: Particles of
(MMCs) have excellent damping properties, which makes zirconia and silicon carbide can cause a variety of issues
them suitable in applications where vibration dampening is during MMC production and assembly. Establishing a uniform
essential, such as precision machinery and aircraft dispersion and maintaining the particle-matrix bonding is
constructions. Research That Is Still Going On One Active crucial for optimising the reinforcements' performance.
Branch Of Research That Is Still Going On Is The Research Specialised processing methods, such as powder metallurgy or
That Is Going On To Develop Metal Matrix Composites. New solid-state processing, may be required to assure the precise
reinforcing materials, cutting-edge production methods, and distribution of the particles and their capacity to connect
the tailoring of material characteristics to a variety of uses are together.
all being investigated by researchers. This encompasses The properties and functionality of an aluminum-
developments in nanocomposites, functionally graded based MMC reinforced with zirconia and silicon carbide will
materials, and methods of additive manufacturing for the differ depending on factors like the reinforcements' size,
creation of MMC. shape, and volume percent, as well as the processing methods
Metal matrix composites are an adaptable and high- employed. High-performance engineering components,
performance alternative to traditional metals. They make it aerospace components, and automotive components are just
possible to produce materials with improved qualities in order some of the many uses that might benefit from optimised
to fulfil the requirements of a variety of sectors. composite materials.
5.2 SAND CASTING PROCESS
5.1 IMPACT OF ZIRCONIA In the metal casting technique known as sand casting
Zirconia (ZrO2) and silicon carbide (SiC), when (or sand moulded casting), sand is used to create the mould. In
added to aluminium in a metal matrix composite (MMC), can addition to describing the method of production, the phrase
alter the material's properties and performance in a number of "sand casting" can also be used to describe the finished
ways. Some potential results are as follows: product. Foundries are the factories that make sand castings.
Zirconia and silicon carbide are two examples of The sand casting method accounts for more than 70% of all
materials with high tensile and compressive strengths. When metal casting production.
integrated into an aluminium matrix, they have the ability to
greatly boost the composite's strength and hardness. The Sand casting is inexpensive and durable enough to be
mechanical properties are greatly enhanced due to the hard used in steel foundries. Mixing or naturally occurring with the
reinforcements' role as obstacles for dislocation motion. sand provides a suitable bonding material, typically clay. To
Improvements in wear resistance The already make the aggregate moldable, wet the mixture with water (or
impressive wear resistance of silicon carbide has been further another suitable liquid) to increase the clay's strength and

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Journal of Mechanical Behavior Of Aluminum, Silicon Carbide And Zirconia Metal Matrix Composite

plasticity. A flask is a frame or mould box structure used to

hold sand during the casting process. Sand is compacted 5.2.4 Molding
around moulds, patterns, or is carved directly into the sand to The process of creating moulds involves a number of
form the mould chambers and gate system. steps and is referred to as moulding. In horizontal casting, the
mould is enclosed in a two-piece frame known as a flask. This
type of casting is done on a flat surface. The cope is the name
given to the upper half of the flask, and the drag is the name
given to the lower portion. At the beginning of the process, a
flask is crammed full of moulding sand around the pattern.
There are six steps in this process: Following the removal of the pattern, the gating and runner
arrangements are placed in the drag half of the mould cavity,
1. Place a pattern in sand to create a mold. and the sprue is positioned in the cope section of the cavity. In
order for the molten metal to flow into the mould cavity,
2. Incorporate the pattern and sand in a gating system.
gating mechanisms are required to be installed. In the event
3. Remove the pattern. that they are required, cores are also inserted into the drag
4. Fill the mold cavity with molten metal. section of the mould. After the cope (top) section of the mould
5. Allow the metal to cool. has been positioned on top of the drag (bottom) piece, the
6. Break away the sand mold and remove the casting. mould is then closed and clamped together to complete the
process. The process of creating moulds in big automated
moulding machines (Disamatics), which may be found at the
5.2.1 A Basic Overview foundries owned and operated by Metal Technologies, merits
Casting is the method of making an object by pouring its own in-depth description.
molten metal into a mould. The object produced in this way is
also known as a casting. Sand is used to fill a mold's cavity for 5.2.5 Melting & Pouring
sand casting. In addition, any cores in the mould are created Melting is the preparation of the metal for casting,
from sand. In the space between the inner surface of the mould and its conversion from a solid to a liquid state in a furnace. It
and the outer surface of the core, the molten metal cools and is then transferred in a ladle to the molding area of the foundry
solidifies. There you have it: the standard procedure for where it is poured into the molds. After the metal has
making a sand casting. solidified, the molds are vibrated to remove the sand from the
casting, a process called shakeout.
5.2.2 Patternmaking
Making a pattern is the first stage in sand casting. 5.2.6 Cleaning
The pattern is a scaled-down version of the casting's exterior When talking about castings, "cleaning" typically
that accounts for finishing and shrinkage. If the casting is to refers to the process of removing any and all materials that
have hollow interior spaces, then extra patterns called cores will not be a part of the final casting. The removal of the
must be used. Wood, plastic, metal, and plaster are the most gating mechanisms from the casting is what is meant by
common materials used to create patterns, but other materials "rough cleaning." After the item has been released from the
or material combinations may be used if the pattern needs to mould, the initial finishing process involves removing any
meet specialised criteria. The type of material used to create core sand or mould residue that may still be present on the
the pattern depends on a number of factors, including the piece. During trimming, any excess metal will be removed.
expected number of castings from the mould and the desired The surface of the casting is cleaned in the last stages of the
characteristics of the final casting. finishing process so that it will have an improved appearance.
In addition, the inspection of the casting for flaws and
5.2.3 Core making conformity to quality standards takes place at this phase in the
The creation of the core is the next stage of the process. This inspection may include non-destructive testing
procedure. The inner contours of the casting are created with to assess whether or not the part will operate satisfactorily for
the help of cores, which are forms that are placed inside the the application for which it was designed.6.1.
mould. Typically, the core is formed by baking a sand mixture
that consists of sand, water, and organic adhesives known as
binders. This combination is then baked in order to make the
core. This makes it possible for the cores to be sturdy while
also being able to collapse, which enables them to be easily
extracted from the finished casting. As a result of the fact that
cores are produced in moulds, they ask for a design and mould
that is referred to as a core box. The core pattern is constructed
in the same manner as the casting pattern, with the exception
that the core box is fabricated from a hardy material such as
metal or wood. Sand is used to make the cores, hence the
mould itself can't be formed of sand like that either.

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Journal of Mechanical Behavior Of Aluminum, Silicon Carbide And Zirconia Metal Matrix Composite

VI. MECHANICAL TESTING

Fig(6.3). Vickers Hardness Test

Fig(6.1). Test sample

Fig(6.4). Vickers Hardness Test

Fig(6.2). Vickers Hardness Test

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Journal of Mechanical Behavior Of Aluminum, Silicon Carbide And Zirconia Metal Matrix Composite

Fig(6.7). Vickers Hardness Test

Fig(6.5). Vickers Hardness Test

Fig(6.8). Vickers Hardness Test

Fig(6.6). Vickers Hardness Test

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Journal of Mechanical Behavior Of Aluminum, Silicon Carbide And Zirconia Metal Matrix Composite

Fig(6.11). Impact Test

Fig(6.9). Impact Test

Fig(6.12) Tested sample

Fig(6.10). Impact Test

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Journal of Mechanical Behavior Of Aluminum, Silicon Carbide And Zirconia Metal Matrix Composite

Fig(6.15). Light optical microscopy

Fig(6.13). Light optical microscopy

6.2 COMPARISON OF RESULTS

Fig(6.14). Light optical microscopy 6.2.1 Vickers hardness test: (ASTM E92)

Test parameters Observed values

HV 5kg 50.7,51.2,51.8

Table: Vickers hardness test

Vickers Hardness (ASTM E92)

100 % 90% aluminium -5%
Aluminium Silicon Carbide - 5%
Zirconia
43 51.2

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Journal of Mechanical Behavior Of Aluminum, Silicon Carbide And Zirconia Metal Matrix Composite

Fig (6.15) Vickers hardness test: (ASTM E92)

6.2.2 Charpy impact test:(ASTM E23)

Table: Charpy impact test
Specimen size (mm) Notch type Test Temperature Absorbed Energy-Joules Average
Parameters/unit
10×10×75 V 240C 20 58 36 38

Charpy impact (ASTM E23)

100 % Aluminium 90% aluminium -5% Silicon
Carbide - 5% Zirconia

34 39

Fig (6.16) Charpy impact (ASTM E23)

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Journal of Mechanical Behavior Of Aluminum, Silicon Carbide And Zirconia Metal Matrix Composite

Micro examination:

Fig(6.17).Mag: 200x
Fig(6.19)Mag: 50x

Fig(6.20)Mag: 20x
Fig(6.18)Mag: 100x

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Journal of Mechanical Behavior Of Aluminum, Silicon Carbide And Zirconia Metal Matrix Composite

effective load transfer and high mechanical

characteristics.
4. When seen using a light microscope, the grain
structure of the aluminium matrix may be seen. The
6.3 MICROSTRUCTURE INFERENCES 5. size, shape, and orientation of the aluminium grains
can provide insight into both the processing history
1. Using light optical microscopy, one can get several of the material and the likely grain development
pieces of information regarding the microstructure of mechanisms that occurred during the manufacturing
a metal matrix composite (MMC) that is composed of process. imperfections and empty spaces: The use of
90% aluminium, 5% silicon carbide (SiC), and 5% light microscopy makes it possible to detect the
zirconia (ZrO2).By utilising light optical microscopy, presence of void spaces, porosity, and other
one is able to ascertain the manner in which the SiC imperfections within the MMC. It is possible that
and ZrO2 particles are dispersed throughout the improper processing or an absence of particle-matrix
aluminium matrix. A hallmark of a manufacturing bonding led to these faults, which can have a
process that has been carried out successfully is the detrimental effect on the mechanical characteristics
presence of a well-distributed network of reinforcing and performance of the composite.
elements. It is possible that improper processing or 6. The many phases of the MMC, as well as the
mixing led to the clumping together of the particles if transitions between those phases, can be seen more
they are seen. clearly using light microscopy. Zirconia is capable of
2. Analysis of particles with light microscopy can undergoing phase changes between the tetragonal and
provide information about the dimensions and monoclinic phases, which can be observed as distinct
contours of the particles' constituent parts. Particles areas or variations to the material's texture. These
of SiC and ZrO2 may be seen scattered throughout transformations can take place.
the microstructure in some places. Whether they are 7. Despite the fact that it has some restrictions when it
round, irregular, or elongated, the shape of the comes to resolution and the ability to make out finer
reinforcements may provide insight into the details at the nanoscale, light optical microscopy is
production procedure as well as the behaviour of the nevertheless a valuable source of information
reinforcements. regarding the microstructure of MMCs. Light
3. Bonding at Interfaces: The SiC/ZrO2 particle- microscopy is one approach that can be used to begin
aluminum matrix interface can be evaluated for how the process of characterization; however, additional
well it bonds the two materials together. At the techniques, including as scanning electron
interface between the particle and the matrix, a well- microscopy (SEM), transmission electron microscopy
bonded interface is indicated when there are no (TEM), and X-ray diffraction (XRD), can be utilised
cavities, fissures, or holes present. A strong to get further information.
connection between the matrix and the
reinforcements is necessary if one want to achieve

Netural salt spray ASTM -B- 117-2019

Test Parameter Specified value Observation
Test Duration (Hours) 24 Hrs 24 Hrs
Test starting date (DD/MM/YY) 27/03/23
Test ending date (DD/MM/YY) 28/03/23
Tower temperature (*C) 47.5-48.5
Air pressure (Psi) 14-18
Chamber temperature (*C) Chamber
Components loading in chamber temperature(*C)
Position (Degree Angle) 15-30 Degree from
Concentration of solution (%) vertical
Ph value
Volume of slat solution 4.80-5.30 % of Nacl
collected(ml/hr) 6.65-6.85
Test observation 1.00-1.50

No white Rust
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up to 24 Hrs.
Journal of Mechanical Behavior Of Aluminum, Silicon Carbide And Zirconia Metal Matrix Composite

uniform distribution of the reinforcements. The grain

VII. CONCLUSION
structure of the cast aluminium alloy and the quality of the
In conclusion, the impact resistance, hardness, particle-matrix bonding both play important roles in
corrosion resistance, and microstructure behaviour of a casted influencing the overall behaviour of the composite.
aluminium alloy matrix composite can be modified by adding
The casting technique, casting parameters, particle
5% silicon carbide (SiC) and 5% zirconia (ZrO2). This is what
size, particle-matrix interface, and overall composite
we learned:
composition will all play a role in determining the final
The impact resistance of the cast aluminium alloy properties and behaviour of a 90% aluminium, 5% SiC, 5%
composite can be improved by adding SiC and ZrO2. SiC's ZrO2 composite using a casted aluminium alloy. To
exceptional strength and toughness allow it to better absorb completely understand the performance and behaviour of this
and distribute impact energy than other materials. ZrO2's particular composite composition in a casted aluminium alloy,
phase change behaviour can help deflect cracks and absorb it is necessary to conduct extensive testing and
energy, which both improve the composite's resistance to characterization procedures, including as impact tests,
impact. hardness measurements, corrosion investigations, and
microstructural research.
The toughness of the cast aluminium alloy composite
can be greatly improved by using SiC and ZrO2. The addition
of hard elements like SiC and ZrO2 improves hardness by
impeding dislocation migration inside the matrix. Particle size,
dispersion, and bonding with the matrix of the casted
aluminium alloy will all play a role in the precise hardness
enhancement.
Resistance to Corrosion: The inclusion of SiC and
ZrO2 can modify the composite's corrosion behaviour. While
aluminium alloys are naturally prone to corrosion, these
reinforcements can help provide a barrier that slows the
process. Corrosion resistance may also be affected by galvanic
effects between the composite's phases and the quality of the
particle-matrix interface.
The distribution, size, and shape of the SiC and ZrO2
particles inside the matrix characterise the microstructure of
the casted aluminium alloy composite. To maximise the
composite's mechanical qualities, it is vital to achieve a

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Journal of Mechanical Behavior Of Aluminum, Silicon Carbide And Zirconia Metal Matrix Composite

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