INVESTIGATION ON MECHANICAL AND

TRIBOLOGICAL PROPERTIES OF A I -N I -S I C
COMPOSITE
Mentor: Mr. Ravi Kumar V (Asst. Professor)

Project By:
H S KARTHIK DEEP

BL.EN.U4MEE12502

M NANDHAGOPAL

BL.EN.U4MEE12034

JAI GANESH N

BL.EN.U4MEE12016

K HARSHAVARDHAN REDDY

BL.EN.U4MEE12019
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OBJECTIVE
To fabricate Al-Ni-SiC composite with SiC reinforcement of
2, 4, 6 & 8%, and Ni fixed at 4%
To investigate various mechanical and tribological properties
of the specimens
To propose scope for application of the composites in
industry

COMPOSITE
Composites are made up of two or more distinct materials,
and possess improved properties
Matrix - ductile, light
Reinforcement - stiff, dense
High strength to weight ratio, make materials superior to
the metallic matrix

CLASSIFICATION BASED ON TYPE

OF MATRIX MATERIAL

MATRIX MATERIAL - ALUMINIUM

Low density, high strength, thermal and electrical
conductivity, high corrosion resistance
Easily available, widely used

REINFORCEMENT MATERIALS
S I C AND N I
Choice based on the properties that the final composite is
required to possess
Silicon carbide is a highly wear resistant material with
good mechanical properties
Nickel was chosen as it possesses excellent corrosion
resistance to chemical attacks
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APPLICATIONS OF COMPOSITES
Automobile industry - to manufacture lightweight parts for
weight reduction, achieve better aerodynamics, etc.
Defense industry - to manufacture anti-ballistics, armor,
etc.
Civil engineering - structural elements, as reinforcing bars
for concrete, patches for damaged concrete
Sports protective equipment, accessories for most of the
sports applications, etc.
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FABRICATION
There are two major processes:
Liquid metallurgy
Powder metallurgy

Liquid Metallurgy:

 Powder Metallurgy: method of fabrication using fine

powders of different materials
Produces finished or near net shape components
Processes involved:
Powder preparation
Powder mixing
Compaction
Sintering

POWDER PREPARATION
Powders may be pre prepared by grinding, crushing,
electrolytic deposition, or chemical reactions
Major methods:
Atomization gas and water atomization
Ball Milling
Centrifugal deposition

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ATOMIZATION
Gas atomization - performed by introducing an inert gas
into nozzle at high pressure
Preferred for ferrous metals
Water atomization uses water instead of gas, particles are
quenched, increases hardness, produces finer particles

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POWDER MIXING
Combining powders of different
materials into a homogeneous
mixture
Powders are mixed using various
mixers, commonly used is doublecone mixer
Fig 1 Al-Ni-SiC Powder
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POWDER COMPACTION
Process of compacting metal
powder in a die through the
application of high pressures
The density of the finished
component is dependent mainly
upon the compaction pressure
Compaction will be performed at
high temperature or room
temperature
Fig 2 Die used for compaction

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 Various compaction techniques are:

Hot Isostatic Pressing (HIP) Compresses and sinters the part
simultaneously, reduces the pressure required for compaction
Cold Isostatic Pressing (CIP) - Pressure is applied to the mould
at room temperature.
Hydroforming - Specialized type of die moulding that utilizes
highly pressurized fluid to form specimen
Metal Injection Moulding Finely powdered metal is mixed
with binder, capable of being handled by plastic processing
equipment through a process known as injection mould
forming
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SINTERING
The green compact is placed
into a furnace and heated to
sintering temperature
Generally sintering temp. is
70-90% of the melting
temperature of base metal
At that temperature, the
particles melt and grain
growth takes place, and the
powder is formed into solid
component

Fig 3 Sintering in
muffle furnace

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APPLICATIONS OF PM
PM method is cost effective and offers the ability to create
unique materials. Some applications are:
Bearings
Gears
Friction materials for brake linings
Heat pipes
Sinks
High precision parts

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TESTING
The prepared specimen of different compositions were
subjected to the following tests:
Hardness Test
Corrosion Test
Wear Test
Microstructural Analysis

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HARDNESS TEST
Determined by Brinell Hardness Tester
Hardened steel ball indenter is pressed with known loadindent is formed
Diameter of indent is measured at the rim, and BHN is
calculated
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Fig 4 Brinell Hardness Number

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CORROSION TEST
Performed by measuring variation of cathodic and anodic
current versus electrochemical potential
Curves are extrapolated and corrosion current is obtained
Rate of corrosion is dependent upon corrosion current, can
be determined using formula
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Fig 5 Rate of Corrosion

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WEAR TEST
It is performed by rotating a
counter-face test disc against a
stationary test specimen pin
It travels in one direction for
an specified time
Amount of material worn is
measured

Fig 6 Specimen
undergoing wear test

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 Specimen is allowed to slide for 5000m, and the wear is

measured in micrometers
Wear rate can be obtained from the slope

Fig 7 Comparison of wear rates

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Fig 8 Amount of wear for different specimens

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MICROSTRUCTURE ANALYSIS
Surface of material is first polished with abrasive emery
papers of decreasing grit sizes
Fine abrasive powders are used to polish to a mirror finish
Dipped in etchant solution, the excess portion is rinsed off
and dried, then placed under a microscope for examination
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SUMMARY
The prepared composites have exhibited improved
mechanical characteristics hardness and wear resistance
increased
The addition of Ni has improved the corrosion resistance,
however the increase of SiC percentage decreases the
corrosion resistance
Composite with 4% Ni and 4% SiC was found to be
optimum
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