Fabrication of metal matrix composites using stir casting method
- 1. Fabrication Of Metal-Matrix Composites Using Stir Casting Method Presented By:- 1. Harisagar Gupta ( 15UME024 ) 2. Amarjeet Kumar ( 15UME004 ) 3. Abhishek Kumar Singh ( 15UME009 ) Guided By: Sir Dr. Anil Kr. Birru HOD & Professor-In-Charge, Mechanical Engineering Department PROJECT WORK-I
- 2. CONTENTS 1. ABSTRACT 2. INTRODUCTION 3. OBJECTIVES 4. COMPOSITE MATERIALS 5. METAL MATRIX COMPOSITES 6. STIR CASTING 7. APPARATUS SETUP 8. EXPERIMENTATION 9. RESULTS 10. APPLICATIONS 11. A BRIEF LOOK OF THE PROCESS (VIDEO)
- 3. ABSTRACT • Composite Materials play a vital role in the Automobile, aircraft industries & manufacturing industries. • Preparation of metal-matrix composites are light weighted, high strength, extremely hard materials. • Growth of these sectors emphasize the production of metal-matrix AlSiC composites using stir casting and at the end the composition of SiC would be varied along with the composition of Al. • Then the hardness and impact testing will be done.
- 4. INTRODUCTION • Metal Matrix Composites are extremely hard, abrasion resistance and mostly light weighted. • Useful for the preparation of the high temperature and speed parts like pistons, axles, high speed wheels and so on. • Main focus is on the preparation of AlSiC composites using stir casting with high temperature into the graphite crucible with coal-fired furnace(or electrical furnace using KANTHAL & NIKROTHAL heating wires) followed by die casting. • These composites have very high strength, fatigue resistance, abrasion resistance, corrosion resistance, stifness etc., • Keywords :- Composite Materials, Metal-Matrix Composite, AlSiC Stir-Casting.
- 5. OBJECTIVES • To Develop the strong light weighted metal-matrix AlSiC composite material which are uselful in the industrial Sectors and aerospace industries. • The most important objective is to fabricate AlSiC metal- matrix by homogeneous stir casting to produce High Strength Low Cost Material (HSLCM). • To test the hardness and the Impact Strength of the metal-matrix composite so obtained for varying compositions of the Al & SiC. Fig: MMC simulation Image
- 6. COMPOSITE MATERIALS • Composites are considered to be mixture of materials(or metals) of different composition. • The materials retain their identities in the matrix, i.e, they do not dissolve completely into each other. • These materials can physically be verified and reveal an interface between one another. • The various types of composites used :- MMCs, PMCs & CMCs but nowadays the use of metal-matrix, ceramic-matrix plays a significant job whereas SiC is the best used matrix for fabrication. • SiC is made by 60% sand and 40% coke with addition of saw dust in an electric furnace at very high temperature about 1500°C with traces amount of salts. • The SiC particles are mixed with a temporary binding agent like glue resins and then compressed and dried at temperature 2000°C which gives homogenous interlocked SiC crystals. Fig: Composite Material
- 7. METAL-MATRIX COMPOSITES •Metal-Matrix composite consists atleast two materials, one being METAL necessarily, the other may be metal or any other material. • And thus they gain high strength, hardness, ductility and thermal conductivity.
- 8. STIR CASTING • Stirring is done to ensure homogeneous mixing of the components. •It is also done to ensure proper melting. • A electrical motor is used to facilitate automatic stirring. •A dimmer is also used to control the RPM of the stirrer.
- 10. EXPERIMENTATION • Aluminium is heated till it is completely melted in the furnace. Fig: FurnaceFig: Al Plates
- 11. EXPERIMENTATION • SiC is Preheated in the Preheat Furnace(Muffle Furnace).
- 12. EXPERIMENTATION • Mg Powder is put in Al melt (to increase the wettability of the Al with SiC to improve the solubility).
- 13. EXPERIMENTATION • The Molten Metal is then stirred for uniform melting.
- 14. EXPERIMENTATION • SiC is added uniformly through the pathway after being preheated.
- 15. • The Mixture is stirred and then is poured into the die for casting. EXPERIMENTATION
- 16. • The experiment is repeated by varying the compositions of composite powder SiC ( 5%, 10%, 15%, 20%, 25% and 30% ), weight of Al + weight of SiC are also varied. EXPERIMENTATION Percentage Al-98.41% SiC-320 Grit 5% 1900gm 100gm 10% 1800gm 200gm 15% 1700gm 300gm 20% 1600gm 400gm 25% 1500gm 500gm 30% 1400gm 600gm
- 17. RESULT •The objective was to prepare aluminium based silicon carbide MMC with an objective to develop a conventional low cost method of producing MMC. •To achieve this stir casting was adopted.
- 18. APPLICATIONS Fig: In Aircraft’s Propulsion Manufacturing Fig: In autmobiles Fig: In Engines and Piston Manufacturing
- 19. A BRIEF LOOK OF THE PROCESS
- 20. THANK YOU