International Journal of Latest Technology in Engineering, Management & Applied Science (IJLTEMAS)
Volume VI, Issue I, January 2017 | ISSN 2278-2540
“Fatigue and Fracture Toughness Behavior of Al
2219/B4C Particulate Metal Matrix Composites”
M. N.Choudhari1, Jayant. K. Kittur2
1
Assistant Professor, Department of Mechanical Engineering, Alpha College of Engineering, Bangalore.
2
Professor and Dean, Research and Development, K.L.S Gogte Institute of Technology, Belagavi.
Abstract: In the present study, the fatigue and fracture toughness thermal expansion [1-3], but the only drawback of these
behavior of Al 2219/B4C particulate metal matrix composites is composites is that, the inclusion of ceramic reinforcement in
investigated. The composites were fabricated by reinforcing B4C Al matrix composites makes them brittle and exhibit low
particles of 125microns with varying wt% of 2 and 4, using stir fracture toughness values [4-6]. The characters of particles
casting process. The performance of the prepared composites
play an important role in controlling the toughness of the
was compared with the alloy Al 2219 to study the improvement
in fatigue and fracture toughness behavior as a result of composites, and the degradation of toughness is considered to
reinforcement particles. The homogeneous dispersion of the be due to cracking of particles, non uniformity of particles and
reinforcement particles in the matrix was examined using optical changes in matrix flow behavior [7]. It was commonly
microscope. The result reveals that the addition of B4C improves observed that an increase in volume fraction of SiCP would
both fatigue strength and fracture toughness of composites over decrease fracture toughness of the composite [2&7].
the alloy, further by increasing the wt% of B 4C reinforcement in
the matrix, there was a significant improvement in both the Literature evidences that, numerous studies have been done on
properties. As load increases there was decreasing cycles which mechanical behavior of particles reinforced MMCs but very
indicates load has more effect on the fatigue strength. Overall, few studies only have been explored on the mechanical
fatigue strength and Fracture toughness of the composites was properties of B4C particles reinforced MMCs [8]. Thus the
improved to 63.97% and 33.34% respectively with respect to present study deals with the fabrication of Al 2219 alloy
4wt% B4C particles reinforcement compare to base alloy. matrix composite reinforced with B4C particles with varying
Keywords:- metal matrix composites (MMCs), particulate metal wt% of 2 and 4 and analyzing its microstructure, fatigue
matrix composites (MMCp), stir casting, fracture toughness, strength and fracture toughness.
fatigue strength
Toughness can be understood as a measure of energy
I. INTRODUCTION absorbed in the process of fracture. The toughness of MMCs
depends on, the matrix alloy composition, the reinforcement
A composite material is defined as a multiphase structural
material created synthetically or artificially by
combining two or more materials having dissimilar
type, size and orientation and the processing method. Fatigue
is the phenomenon of failure of a material or a component
under cyclic loading. Non uniform distribution and improper
characteristics.The constituents are combined at macroscopic
bonding of reinforcement particles in the matrix phase, is the
level and are not soluble in each other and the material
main reason for fatigue crack initiation and fatigue failure of
fabricated exhibits a desirable combination of the best
the composites under cyclic loading [9].
properties of the constituent phases. Particle reinforced
MMCs have become very important because they are
II. METHODOLOGY AND EXPERIMENTAL
inexpensive vis a vis continuous fiber reinforced composites
PROCEDURE
and they have relatively isotropic properties compared to fiber
reinforced composites. Aluminium MMCs have been widely
The methodology adopted in the present work consists of the
developing in the recent past years due to their novel
following steps:
characteristics like light weight, low cost, good corrosion
1. Selection of materials.
resistance, higher thermal and electrical conductivity. They
2. Preparation of composite by Liquid metallurgy
offer a large variety of mechanical properties depending on
method (stir casting), by varying the amount
the chemical composition of the Al-matrix and the type of the
of reinforcement.
reinforcement.
3. Fabrication of cast products for the Preparation of
Aluminium alloys with discontinuous/particulate test specimens, for evaluating fatigue and fracture
ceramic reinforcements have gained greater industrial behavior, for both unreinforced & reinforced Al
importance, since they can exhibit enhanced mechanical 2219 alloy.
performance, i.e strength, wear resistance and coefficient of
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International Journal of Latest Technology in Engineering, Management & Applied Science (IJLTEMAS)
Volume VI, Issue I, January 2017 | ISSN 2278-2540
4. Preparation of specimens for Fatigue and Fracture The Materials chosen for the fabrication of the composite is,
toughness as per ASTM standards. Al 2219 alloy as base matrix and B4C particle as
5. Microstructure study reinforcement material. Alloy Al 2219 has been chosen
6. Fatigue and fracture testing of specimens, as per because of its applications in tip truck bodies, rail car,
standard test procedures. pressure vessels, ship building, mine skips and cages. The
7. Comparison of the results of composites with the B4C particle is selected for reinforcing with the base matrix
results of base matrix Al 2219. due to its high hardness ranked next to diamond and cubic
boron nitride. The density of the alloy and B 4C are 2.71
2.1 Material selection gm/cm3 and 2.51 gm/cm3 respectively. Chemical composition
of Al 2219 is as shown in Table 1. Al 2219 alloy in the form
of ingots and particulate B4C are as shown in Figure 1 and 2.
Table – 1: Chemical composition of Al 2219 by weight percentage [%]
Cu Fe Mg Mn Si Ti V Zn Zr Al
5.8-6.8 0.3max 0.02 0.2-0.4 0.2 0.02-0.1 0.05-0.15 0.1 0.1-0.25 Bal.
ensure homogenous dispersion of reinforcement particles in
the composite and then the composite melt was degassed
using hexachloroethane. Again the melt was superheated
above 8000C and finally poured in to a preheated permanent
cast iron moulds, prepared for cylindrical shape of size 15mm
diameter and 125mm length and a rectangular shaped mould
of size 75mm*15mm*15mm respectively for fatigue and
fracture specimen preparation.
2.3 Preparation of specimens
Fatigue test specimens were machined as per ASTM (E 206)
Fig -1: Al-Alloy Ingot standard and charpy impact test specimens with V notch at the
centre were also machined and finished as per ASTM
standards, are shown in Figure 3 and 4.
Fig-3: Fatigue test specimen, ASTM ( E206 )
Fig-2: Boron carbide Powder
2.2 Fabrication of composites
Stir casting technique was adopted for the preparation of Al
2119/B4C MMC. The weighed quantity of matrix metal Al
2219 was melted in a graphite crucible in an electric
resistance furnace by heating it above 7300C. At this stage
preheated B4C powder of particle size 125microns with
varying wt% of 2 and 4 was introduced in to the vortex of the
molten metal and slurry was stirred continuously for about 5 Fig – 4: Fatigue test specimen, ASTM
to 10 minutes by rotating the impeller at a speed of 450 rpm to (Note: All dimensions in mm)
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International Journal of Latest Technology in Engineering, Management & Applied Science (IJLTEMAS)
Volume VI, Issue I, January 2017 | ISSN 2278-2540
2.4 Microstructure study
The specimens for microstructure study were machined from
cast specimens, then grinded in bench grinder and belt grinder
for burr removal and rough finish respectively. Later
specimens were polished with emery sheets of fine grade for
smooth finish. The polished specimens were etched before
their micro structural examination under optical microscope
III. RESULTS AND DISCUSSIONS
3.1 Micro structure evaluation
Micrographs were captured by optical microscope. Figure 5
(a) shows a microstructure of Al 2219 alloy with no
reinforcement, figure 5(b) and 5 (c) shows the microstructure
of Al 2219 with 2wt% of B4C and Al 2219 with 4wt% of B4C.
From the microstructure, it is observed that white area is Al Fig – 5 ( c ) Al 2219 + 4 wt% B4C
matrix and remaining dark grey area is B 4C particles
reinforcement. From micrographs 5 (b) and (c) it is obvious 3.2 Fatigue Behavior
that, more uniform distribution of reinforcement particles in
composite was observed with 4 wt % of B4C over 2 wt% of Fatigue behavior of Al2219/B4C composite was evaluated in
B4C. The homogenous distribution of the reinforcement terms of fatigue life. Fatigue tests, on prepared specimens
particles in the composite was observed due to the greater were conducted on single end rotating cantilever testing
wettability of the B4C with the aluminium alloy [10]. machine at a constant speed of 2000rpm. Data of the test is
tabulated as shown in Table-1 and specimens before and after
failure are as shown in figure 6(a) and (b)
Fig - 5 ( a ) Al 2219 + 0 wt% B4C
Figure 6 (a)
Fig- 5 ( b ) Al 2219 + 2 wt%B4C
Figure 6 (b)
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International Journal of Latest Technology in Engineering, Management & Applied Science (IJLTEMAS)
Volume VI, Issue I, January 2017 | ISSN 2278-2540
Sl.N Stress amplitude S ( Speed No of cycles to
Material Load (kg)
o. MPa) (RPM) failure (N)
2 0.70 2000 73465
3 1.05 2000 55691
1 Al 2219
4 1.40 2000 31269
2 0.70 2000 85983
Al2219+2%B 3 1.05 2000 68477
2
4C 4 1.40 2000 43289
2 0.70 2000 98421
Al2219+4%B 3 1.05 2000 76985
3
4C
4 1.40 2000 48876
Table – 1: Fatigue test data
Figure 7 (c)
Figure 7 (a)
Fatigue behavior of all test specimens is depicted from S-N
plots as shown in Figure 7, where all the components
exhibited typical S-N behavior, reaching the fatigue limit
before 105 cycles, which was set as the run- out point for the
fatigue experiments.
Al2219 with 4wt% of B4C, showed a higher
fatigue life over 2 wt% B4C reinforcement and pure
alloy Al2219. At a absolute stress level of 1.05MPa
fatigue life of Al2219, Al2219 with 2wt% of B4C and
Al2219 with 4wt% of B4C were recorded to be 55691,
68477 and 76985 cycles. This is due to uniform
distribution and proper bonding of reinforcement
particles in the matrix phase, which otherwise the main
reason for fatigue crack initiation and fatigue failure of
the composites under cyclic loading [9]. The composite
Figure 7 (b)
with 4wt% B4C particles reinforcement, showed an
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International Journal of Latest Technology in Engineering, Management & Applied Science (IJLTEMAS)
Volume VI, Issue I, January 2017 | ISSN 2278-2540
improvement of 63.97% more fatigue life than Al2219 determines the amount of energy absorbed by a material
alloy. during fracture. Tests were conducted on pendulum type
impact tesing machine and results are tabulated in table 2.
3.3 Fracture toughness
Test specimens before and after fracture are as shown in
Fracture behavior of the composites was evaluated in terms of figure 6 (a) and (b).
fracture toughness and fracture strength through Charpy V-
notch test, is a standardized high strain-rate test which
Fracture
Depth at Fracture Toughness
Width „b‟ C/SArea Frictional strength
Sl.no. Material notch „d‟ „U‟ (Nm)
(mm) „A‟(mm2) Energy N-m K=U/A
(mm)
Nm/mm2
1 Al2219 10 8 80 0.2 3.924 0.04905
2 Al2219+2%B4C 10 8 80 0.2 5.886 0.0745
Al2219+ 4%B4C
3 10 8 80 0.2 11.772 0.1471
Figure – 6 (a)
Figure 7(b)
From the plots shown in figure 7a and 7b it was
clearly interpreted that as weight percentage of B4C
particulates in metal matrix increases from 0, 2, and 4 there
was drastic increase in fracture strength or fracture
Figure – 6(b) toughness. This is mainly due to good bonding between
matrix and reinforcement particulates and good dispersion
of B4C particulates in matrix. The 4wt% B4C particles
reinforced composite showed an increase of 33.34%
fracture toughness more than Al2219 alloy.
IV. CONCLUSIONS
The present work focused on evaluation of fracture and
fatigue behavior of Al 2219/B4C particulate metal matrix
composites. MMCP with varying wt% of 0, 2 and 4 were
successfully fabricated using liquid stir casting process. The
homogenous dispersion of B4C particles in the metal matrix
was attained, since B4C particles exhibit a greater wettaability
with aluminium alloy, was observed during microstructure
evaluation under optical microscope. With the increment of
B4C reinforcement in Al 2219 alloy matrix, both fatigue life
Figure 7(a) and fracture toughness gets improved due to- reinforcement
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International Journal of Latest Technology in Engineering, Management & Applied Science (IJLTEMAS)
Volume VI, Issue I, January 2017 | ISSN 2278-2540
type, size and uniform distribution of particles in the matrix. [6]. A.Mortensen, Proc.Int.Conf.Fabrication of Particulate Reinforced
Metal Matrix Composites, Quebec, Canada, ( 1990 ) 217-23.
Analysis shows that, 4 wt% of B4C reinforcement in Al 2219
[7]. Lihe Qian, Toshiro Kobayashi, Hiroyuki Toda, Takashi Goda and
matrix has improved the fatigue life by 63.97% and fracture Zhong- guang Wang, “ Fracture toughness of a 6061Al matrix
toughness by 33.34% over Al 2219 alloy. composite reinforced with fine SiC particles”, Materials
Transactions, Vol.43, No.11 ( 2002) pp.2838 to 2842. Copyright
2002 The Japan Institute Of Metals.
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