Mechanical properties of Aluminum-Copper composite metallic materials Technology Journal of Applied Researchand

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Availableonlineatwww.sciencedirect.com

Journal of Applied Research and Technology

www.jart.ccadet.unam.mx JournalofAppliedResearchandTechnology14(2016)293–299

Original

Mechanical properties of Aluminum-Copper _(p) composite metallic materials

Siddabathula Madhusudan

^a,∗

, Mohammed Moulana Mohiuddin Sarcar

^b

, Narsipalli Bhargava Rama Mohan Rao

^c

aDepartmentofMechanicalEngineering,K.L.University,Vijayawada522502,India

bJNTU,Anantapur515002,India

cDepartmentofMetallurgicalEngineering,AUCollegeofEngineering,Visakhapatnam530003,India Received28July2015;accepted24May2016

Availableonline4October2016

Abstract

Compositemetallicmaterials(CMMs)arepreparedbydispersingcopperparticulatesinaluminummatrixusingstir-casttechnique.Theirbehavior iscomparedwiththealloyhavingsimilarcomposition.Theeffectofparticulatecompositionisstudiedbyvaryingthecopperconcentrationbetween 5and15wt%.Hardnessincreasedwithincreasingparticulatecontentsinbothcastandhomogenizedconditions.Compositesshowa13%dropin strengthand15%dropinstraincomparedtothealloy.Withincreasingreinforcementcontent,thestrengthincreasedanddropped.Agglomeration duetoincreasedreinforcementcontentsmaybethereasonforthedecreaseinstrengthvalues.Microstructurescorroboratetheaboveresults.

Keywords:Stircasting;Microstructure;Mechanicalproperties;Interfaces;Intermetallics

1. Introduction

Metal matrix composites are designed to achieve high strength properties. Metal matrix composites (MMCs) rein- forcedwithceramicparticlesarewidelyusedbecauseoftheir highspecificmodulus,strength andwearresistance.Manyof the investigations have shown improved mechanical proper- tiesbutarelimitedwithlowandpoorductility.An optimized combinationofsurfaceandbulkmechanicalpropertiesmaybe achievedifAl-MMCsareprocessedwithacontrolledgradient ofreinforcingparticlesandalsobyadoptingabettermethodof manufacturing.Thoughthereis noclearrelationbetweenthe mechanicalpropertiesofthecomposites,typeandvolumefrac- tionofreinforcement,surfacenatureofreinforcementandsize of the reinforcement are provedto be effective inimproving the strength of the composites. Composite ductility is gov- ernedbymatrixprocessorsthatwillbeaffectedbythepresence of the reinforcements. This is evidenced by the decrease in

∗Correspondingauthor.

E-mailaddress:[email protected](S.Madhusudan).

PeerReviewundertheresponsibilityofUniversidadNacionalAutónomade México.

ductility while increasing reinforcement volumefraction. An increasing trendof hardness withincrease inweightpercent- ageof SiChasbeen reportedbySingla,Dwivedi,Singh,and Chawla (2009). Several investigators Taya, Lulay, andLloyd (1991),WangandRack(1991),BhansaliandMehrabian(1982) reviewedtheinfluenceofthemanufacturingrouteontheprop- erties of MMCs andthe factorswhich control the properties of particulate MMCs by Kelly (1973). Kok (2005) studied the mechanical properties of Al2O3 particle reinforced 2024 Al alloycomposites producedthrough vortexmethod.It was reportedthatoptimumconditionsoftheproductionprocessare 700^◦C(pouringtemperature),550^◦C(preheatedmoldtemper- ature),900rev/min (stirringspeed),5g/min (particleaddition rate),1min(stirringtime)and6MPa(appliedpressure).Kumar, Lal,andKumar(2013)reportedthat thehardness andtensile strengthofA359/Al2O3MMChasbeenincreased.Itwasalso observed that electromagnetic stirring action adopted during the fabricationresulted insmallergrainsizeandgoodpartic- ulatematrixinterfacebonding.Asuccessfulattempthasbeen made byVenkatesh andHarish(2015)on Al/SiCcomposites producedthrough thepowder metallurgy routetoachieve the desiredpropertiesandalsotoimprovethemechanicalproper- ties.Foravarietyofreinforcements,improvementinstrength,

http://dx.doi.org/10.1016/j.jart.2016.05.009

1665-6423/©2016UniversidadNacionalAutónomadeMéxico,CentrodeCienciasAplicadasyDesarrolloTecnológico.Thisisanopenaccessarticleunderthe CCBY-NC-NDlicense(http://creativecommons.org/licenses/by-nc-nd/4.0/).

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fatigue,modulus,wear resistanceandcreep hasbeendemon- stratedbyNeihandChellman(1984)andFriend(1987).Studies ontrimodalaluminummetalmatrixcompositesandthefactors affectingtheir strengthare reported by Yao etal.(2010). Of these,tensilestrengthisthemostconvenientandwidelyquoted measurement and is of central importance in many applica- tions.Saravanan,Subramanian,AnandaKrishnan,andSankara Narayanan (2015)observed that there is an increase of 30%

inhardness and anincrease intensile strength that is almost twice that of base aluminum alloy for TiB2 particulate reinforced composites. The effects of matrix microstructure and particledistributiononfractureofAlmetalmatrixcomposites arealsoreportedbyNair,Tien,andBates(1985).Theinfluence ofstirringspeedandstirringtimeonthedistributionofparti- clesinSiCAMChasbeenanalyzedbyPrabu,Karunamoorthy, Kathiresan,andMohan(2006).Theductilityandfracturetough- nessoftheMMCandhenceindirectlythestrengthisgoverned bythereinforcementdistributionapartfromthereinforcement level.Itisessential tohaveauniformdistributionoftherein- forcementforeffectiveutilizationoftheloadcarryingcapacity oftheresultantcomposite.Nieh,Raninen,andChellman(1985) alsoobserved,intheearlystagesofprocessing,anon-uniform distributionofreinforcement,whichpersiststothefinalproduct inthe formsof steaksor clustersof reinforcementwiththeir attendantporosityallofwhichloweredthestrength,ductility, and toughness of the material. For agiven matrix alloy,the elongationtofailureisreducedbyincreasingvolumefraction (Crowe, Gray,&Hasson,1985;Kamat,Hirth, &Mehrabian, 1989;Liu,Ricket,&Lewandoski,1989)andthesizeoftherein- forcement(England&Hall,1986;Girot,Quenisset,&Naslain, 1987;Manoharan&Lewandowski,1989;Mummery&Derby, 1991).Thoughthere aremanyapplications forMMCs, fabrication,secondaryprocessing,compatibilitybetweenthematrix andreinforcementandcharacterizationarestillthemajorhur- dlesintheapplicationofthesecomposites.Themaindamaging mechanismsofMMCshavebeenfoundtobelossofductility, particlematrixinterfacedebonding,particlecracking,particle pull outandagglomerationof particulates.Thoughthasbeen giventohavethe advantagesof bothMMCsandmetal–metal combinationsystemsbychoosingconventionalalloysystemsfor themanufactureofcompositeswithrestrictedsolubility.Tohave goodcompatibilitybetweenthematrixandthereinforcement, anestablishedalloysystemwithprovenapplicationneedstobe chosen,wherethesolventactsasthematrixandthesoluteasthe reinforcement.

Majorfractionofthesecompositesareproducedbyfoundry routes.Theadvantagesincludebulkproduction,easeoffabrica- tionandcosteffectiveness.Thepresenceofdendriticstructures restrictsdirectapplicationtoamajorextent.Andthiseffectis muchmoreaccentuatedbecauseofthe presenceof reinforcements.Ingotsaresecondaryprocessedtonullifytheseeffects.

Several workability tests are available to study the deforma- tionbehaviorunderthecombinedstress andstrainconditions which are usually found with bulk deformation processes.

Rozovsky,Hahn,andAvitzur(1973)reportedthatthecompres- sionofashortcylinderbetweenanvilsisamuchbettertestfor metalworkingapplications.Thedeformationbehaviorofsolid

cylindersofanaluminumalloymetalmatrixcompositeunder dry condition was estimated by Joardar, Sutradhar, and Das (2012).Itwasreportedthat acylindricalpreformcanbesuc- cessfullycompressedtoaheightreductionby28–32%without fracture.Dikshitetal.(2010)carriedoutcoldupsettingexperi- mentsunderunlubricatedcondition oncastandhomogenized AA2014/SiC composites to study the effect of homogenization on deformation behavior. Orbulov and Ginsztler (2012) indicated that engineering factors such as the aspect ratio (height/diameter ratio) of the specimens and the temperature ofthetests,havesignificanteffectonthecompressivestrength and properties. The effect of reinforcing particle shape and interface strength on the deformation and fracture behavior of an Al/Al2O3 composite was investigated by Romanova, Balokhonov,andSchmauder(2009).Itwasalsoreportedthat interface debondingandparticlecracking arethe twomecha- nismsfor aparticlefracture.Minghettietal.(2001)observed highdeformationrateswithcrackfreeAA6061–Al2O3partic- ulateMMCsamplesbythecoldformingprocess.

Cored structures are most common in as-cast metals. For someapplications,acoredstructureisobjectionable.Thereare twomethodsforsolvingtheproblemofcoring.Themethodpre- ferredbytheindustryistoachieveequalizationofcomposition orhomogenizationofthecoredstructurebydiffusioninthesolid state.Atroomtemperature,formostmetals,thediffusionrate isveryslow,butifthealloyisreheatedtoatemperaturebelow solidus line,diffusionwillbemorerapidandhomogenization willoccurinarelativelyshorttime.

Withthisbackground,inthepresentinvestigationanattempt hasbeenmadetoknowthehomogenizationeffect,compression behaviorandmechanicalpropertiesofAl–Cucompositemetal- licmaterials(CMMs).Theresultsarecomparedwiththatofthe alloy.

2. Experimental

2.1. Fabricationofalloyandcomposite

Cutingotsofpurealuminumaremeltedinastationarypot typeelectricheatingfurnaceinclaygraphitecrucibleat700^◦C.

Copperpieceswrappedinaluminumfoilareaddedtothealu- minummeltat850^◦Candthesametemperatureismaintained until coppermeltscompletely.Forthefabricationofthecom- posite, thereinforcements(powders)areproducedinitiallyby filingthe copperrod,rotating onalathe.IE gradealuminum (99.5%),suppliedbyM/sNationalAluminumCompany,India, isusedasthebasematrixmaterialinthepresentinvestigation.

A pre-weighedquantity of aluminumis meltedin agraphite crucibleusinga3-phasebottom-pourelectricresistancefurnace (Bhargava,Samajdar,Ranganathan,&Surappa,1998).Thebath temperatureismaintainedat720^◦C.Pre-weighedquantitiesof copperparticles(averageparticlesize250␮m),thoroughlydried at200^◦Cinamufflefurnace,areaddedquicklyanduniformly tothevortexinthemelt,suchthatparticlesaresuspendedinthe melt. Madhusudan,Sarcar, andBhargava(2009)reportedthat the EDXanalysisforthe Al–Cucompositeshowed agradual

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variationincopperconcentrationfromtheparticletothematrix withhighcountstolowcounts.

2.2. Homogenization

Thealloyandthecompositesarethoroughlyhomogenizedat 100^◦Cfor24hinamufflefurnace.Hardnessvaluesarerecorded usingaVickershardnesstester.Atotalof6samplesaretestedin eachcaseandaveragevaluesarereported.Theobtainedvalues areconvertedtoMegaPascal’susingtheconversionfactor.

2.3. Compressiontest

Compression tests are carried out on standard cylindrical specimensbetweentheflatplatensataconstantcrossheadspeed of0.3mm/minindryconditionusing100T,FIE-UTE-100com- pressiontestingmachine.Standardsamplesof27mm×18mm Φ(heighttodiameterratio,i.e.,aspectratioas1.5)areusedin thepresentinvestigation.Concentricgroovesof0.5mmdepth aremadeonparallelfacesforlubricantretention,tominimize frictionhill,therebymaximizingtheuniformityindeformation.

Samplesaregridmarkedatmid-heightfordeformationstudies.

Upsettestswereperformedatroomtemperaturebetweentwo flat platens oncomputer controlledservo hydraulic universal testingmachineataconstantcrossheadspeed.Specimensare subjectedtoplasticdeformationbyupsettingto50%orthefrac- tureinitiation,whicheverhappensearlier.Atotalof6samples are testedin each case andaverage values are reported.The PCbaseddataloggingsystemwasusedtorecordandstorethe deformationbehaviorcontinuously.

2.4. Tensiletest

Samplesaretestedona10tonDAKtensiletestingmachine ataconstantcrossheadspeedof1mm/min.Standardsamples of tensilespecimens ASTM-E8M are preparedfor testing.A totalof6samplesaretestedineachcaseandaveragevaluesare reported.

3. Resultsanddiscussions 3.1. Homogenizationeffect

Fig.1showsthehardnessofthealloyincastandhomoge- nizedconditions.Thealloyshowslesshardnessincastcondition as compared to the homogenized. Homogenization aids the solutecopperdiffusionfromtheregionsofhighconcentration tolowconcentrationregions,resultinginuniformcomposition ofthealloythroughout.Asaresult,thehardnessisimprovedin homogenizedcondition.Thecompositehasleandiffusionofthe particulatematerialinthematrix,duetolowstirtime.Thepres- enceoffineanduniformdistributionofparticulatesenhanced the hardness of the resultant composite. Hardness increased withincreasing particulatecontentsinbothcast andhomoge- nizedconditions.Bailey(1969)reportedthatanincreasedalloy contentwithincreasedparticulateconcentrationsisthereason

600

500

400

300

200

100

0

As cast Homogenized

Hardness,Mpa

Alloy Composite

Fig.1.Effectofheattreatmentoncaststructures,alloyandcomposite.

fortheimprovementinhardnessincomposites,ingeneral.The presenceofreinforcementenhancesthiseffectfurther.

Fig.2 showstheeffectof copperadditionontheresultant hardnessandtheeffectiveincrementinhardness.Agoodrise inhardnessvaluesby10%,increment50%and78%inthecast conditionhasbeenobservedwithincreasedparticulatecontents.

Thelowincrementatlowerconcentrationisduetoleanalloy formationandlowconcentrationsofreinforcement,only1.5%

by volumeas reportedbyWu (2000). Though thecomposite withhighestconcentrationshowsanincrementinhardness,the effectiveincrementinhardnessisonly28%(78–50),showing alesserratecomparedtothe10%reinforcementaddition.This dropisduetolimited stirtime.Intotal,thisincrementisdue totheincreasedsurfaceareaoftheparticulatewithincreasing reinforcementcontentandthepresenceofthereinforcementas well,BhaskarandSharief(2012).

Fig.3showsthehardnessofcompositesincastandhomog- enized conditions. Increase in reinforcement concentrations enhances the hardness in homogenized condition. The lack ofenhancementduringhomogenizingatlowerconcentrations

900 800 700 600 500 400

Hardness,Mpa % increment

% copper

5 10 15

300 200 100 0

90 80 70 60 50 40 30 20 10 0

% increment As cast

Fig.2.Effectofparticulatecontentonhardness,composites,castcondition.

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900

800

700

600

500

400

Hardness Mpa Hardness Mpa

% of copper

5 10 15

300

900

800

700

600

500

400

300

Homogenized Cast

Fig.3. Effectofcoppercontentoncompositeswithreferencetoheattreatment.

is due to poor particulate diffusion in aluminum because of limitedstirtime.Thereasonfortheincrementinhardnessduring homogenizationisdiscussedintheearlierparagraphs.

3.2. Compressionbehavior

Al–5%Cualloyandcompositeswith5,10,and15wt%parti- clesofcopperaresubjectedtodeformationupto50%.Boththe alloyandthecorrespondingcompositewith5%reinforcement could deform upto 50% (Fig.4).The thorough deformation ofthealloyisself-explanatoryasitconsistsofasolidsolution ofaluminumandintermetallicsCuAl2.Thecompositehaving similarcomposition does consistof alean aluminum–copper alloymatrixandthecopperparticulatesasreinforcementswith aninterface,comprising aseriesof alloysfromthe matrixto thereinforcement,aluminumrichalloystocopperrichalloys, respectively.Compositeswithhigherconcentrations(10%and 15%)ofreinforcementhavefailedat30%and20%,respectively (Fig.4).Thereasonfortheearlyfailureisduetothefastaddition ofthereinforcementsinshorttimes(30s),leadingtoagglomera- tion/clustering(Fig.5).Duringdeformation,agglomeratesresult ininhomogeneousdeformationcausevoidgenerationbetween theparticulates(Figs.6and7).

60

50

40

30

% deformation

20

10

0

Alloy

Alloy/Composites

50% comp 10% comp 15% comp

Fig.4.Effectofcoppercontentondeformation,alloyandcomposites.

Fig.5.Clusteringofparticulates,Al–15%Cucomposite,100×.

Fig.6.Microstructureshowingpresenceofvoidincomposite,100×.

Fig.7.Presenceofvoidsincomposite.

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3.3. Tensileproperties

Table1 showsthe summaryof tensile strength,strain and hardness.Fig.8showsthecomparisonofmechanicalproperties betweenthealloyandthecompositehavingthesamecomposi- tion.Thecompositesshowa13%dropinstrengthand15%drop instraincomparedtothealloy.TheCMMs’behaviorisnottrue withthatoftheMMCs,wherecompositingincreasesstrength at the cost of strain. Wu (2000) reported that reinforcement enhancesstrengtheningbutsimultaneouslyreducestheforma- bilityofmatrix;resultinginadecreasedstrain.Thestrengthof thealloypertainstothepresenceofsolidsolutionandtheinter- metallicsandtheir constitution. Compared to thealloy, alloy formationaroundthecopperparticleincompositeismuchlean, whosecontributionistoamuchlesserextent.Itmeansthatthe strengtheningofthecompositeisacombinedeffectofthepres- enceofthebasemetal(Al),thealloyandthereinforcements.

Strengtheningoccursmainlybecause of reinforcementof the basemetal(Almatrix)asthetimegiventoformthealloy(dis- tributionofcopperinAl)ismuchshorter,whichcontributesto alimited extent.Thedropinstrainwithcompositecompared tothealloycorroboratesthephenomenaofcompositing(Wu, 2000).Fig.9showstheeffectcopper(reinforcements)content ontheresultantcomposites.Withincreasingreinforcementcon- tent,thestrengthincreasesandthenfalls.Agglomerationdueto theincreasedreinforcementcontentsmaybethereasonforthe decreaseinthestrengthvalues.Withincreasingcoppercontent, alloyformationalsoincreases,whichleadstotheformationofa continuouslayerbetweenthemetalmatrixandthecopperpar- ticles.Thedeformationbecomesmuchmoredifficult,resulting inincreasedstrengthvalues.Hence,the resultedstrength isa combinationofthealloyformation,reinforcementandagood interface.On further incrementin the reinforcement content,

Table1

Summaryoftensilestrength,strainandhardness.

Alloy/composite Tensilestrength(MPa) Strain Hardness(MPa)

Al–5Cualloy 150 0.084 510

Al–5Cucomposite 130 0.071 491

180 160

0 20 40 60 80 100 120 140

Alloy/Composite

Alloy 50% comp

Tensile strength,Mpa/Strainx10-3

Tensile strength Strain

Fig.8.Comparisonbetweenalloyandcomposite,mechanicalproperties.

170 160

100 110 120 130 140 150

0.1 0.09

0 0.04 0.03 0.02 0.01 0.05 0.06 0.07 0.08

Reinforcement

15% comp

50% comp 10% comp

Tensile strength, Mpa Strain

Tensile strength Strain

Fig.9.Effectofcoppercontentonmechanicalproperties,composites.

adropinstrengthisobtainedwhichmaybeduetotworeasons.

Theamountof alloycontenthasgonebeyond5%,whichhas becomestrongerthanthereinforcementcausingthevoidforma- tionduetothelackofcompatibilitybetweenthematrix,interface andthereinforcement.Figs.6and7showthemicrostructures of thecomposite,with15%reinforcement.Thevoids present cause the decrease in strength. Secondly, there is always a chance of agglomeration of particleswith an increased rein- forcementcontent.Thisleadstotheformationofvoidsandthis effectaccumulatesfurtherduringdeformation.Theagglomer- ationofparticulatesmultiplytheeffectofthedropinstrength further(Fig.5).Thedropinstrainwithincreasingcoppercon- tentsupportsthecompositebehaviorwhereincreaseinstrength was reported withdecreased strain. Fig. 10 shows the mate- rialbehaviorduringhardnesstesting.Asdiscussedearlier,the alloy represents strengthening due to the solid solution and intermetallics, while the composite representsthe particulate reinforcementsinthe aluminummatrix.The hardness testing overestimates the tensile value as it does not show the drop instrength values at15% composite. Thehardness testing is compressiveinnatureandalsotheareaunderthe indentation isworkhardened;resultinginenhancedvalues.Accordingto Harindar,Nripjit,Sarabjeet,andTayagi(2012),intensiletest- ing,the loadingis tensileinnature, wherethe deformationis uniformandarebounceeffectduetowork-hardeningisnegligi- ble.Andthiseffectismuchmorepronouncedwithdecreasing thematrixstrengthasreportedbyLiaw,Diaz,Chiang,andLoh (1995).

Fig. 11 compares the effect of copper content on tensile strength andhardness. Unliketensile behavior,increasing the

600 500 400 300 200 100 0

Alloy /Composite

Alloy 50% comp

Tensile strength,Mpa/ Hardness,Mpa

Tenslie strength Hardness

Fig.10.Comparisonbetweenalloyandcomposite,mechanicalproperties.

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1000 900 800 700 600 500 400

170 160 150 140 130 120

Tensile strength, Mpa

Hardness, Mpa

% reinforcement

110 100

50% comp 10% comp 15% comp

Tensile strength Hardness

Fig.11.Effectofcoppercontentonmechanicalproperties,composites.

coppercontent composite showed increased hardness values.

Thetrendcanbearesultofthealloyformationandreinforcing effect.Asdiscussedearlier,itisthefundamentaldifferenceinthe loading,inwhichthematerialundergoesuniformplasticdefor- mation,whileplasticdeformationisrestrictedandconcentrates inthelocalizedregion.

4. Conclusions

1. Thealloyandthecompositewithsamecompositionsexhibit uniformdeformationupto50%.

2. Increasingreinforcementconcentrationsdecreasetheupset- tingcharacteristicsoftheresultantcomposites.

3. CMMsrespondsimilarlytoMMCsintensileproperties.

4. Matrix alloy withlean composition is the reason for low strengthoftheresultantcompositecomparedtothealloyof samecomposition;however,itiscompensatedbytherein- forcementeffectoftheparticulates.

5. Withcompositing,thepresenceofreinforcementdecreases thestraintofailure.

6. The agglomeration of reinforcementsat higher concentra- tionscausesadropinstrength.

7. At all concentrations of the reinforcement, composites exhibithigherhardness.

Conﬂictofinterest

Theauthorshavenoconflictsofinteresttodeclare.

Acknowledgements

Itisagreatpleasuretoexpressmydeepsenseofgratitude andindebtednesstomyresearchguidesProf.M.M.M.Sarcar, ViceChancellor,JNTUAnantpur,IndiaandProf.N.Bhargava RamaMohanRao,DepartmentofMetallurgicalEngineering, AndhraUniversity,Indiafortheirinspiration,guidance,encour- agement,moralsupportandaffectionduringthecourseofmy work.Iplaceonrecordmyprofoundfeelingof reverencefor sparingtheir valuable timeinspite of busyschedules.Under theirguidanceIhadanopportunitytoenjoythefreedomand libertyofwork.Ishallforevercherishmyassociationwiththem fortheir perennialapproachabilityandactionsIhaveenjoyed duringthepastseveralyears.

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