Studies of Microstructure, Mechanical and Tribological behaviour of Aluminium can composites

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International e-Journal For Technology And Research-2017

Studies of Microstructure, Mechanical and Tribological behaviour of Aluminium can composites Siddareddy 1 , Rohith R2, Shiva Kumar 3, Suneel M.V4, Mahadev Prasad5 , Avinash L6 UG Student, Department of Mechanical Engineering, NMIT Bangalore,Karnataka,India1,2,3,4 Assistant Professor,Department of Mechanical Engineering, NMIT Bangalore, Karnataka,India5,6

Abstract: Aluminum can composite widely used for application in mechanical and tribological component of automobile parts like screws,nuts ,rivets,etc.metal matrix composites(MMCs)constitute an important category of design and weight-efficient materials this article highlights on the work where an attempt is taken to fabricate aluminum can composites reinforced with rice husk ash(RHA) particles and agricultural byproducts with high amount of silica.RHA particles upon analysis are incorporated into aluminum cans melt by stir casting.4, 8 and 12% of wt,of RHA are added in to the aluminum can.The micro-structure analysis reveals the homogeneous particles distribution in the matrix.the result found in the test shows a increasing in RHA increases strength and hardness and wear behavior of composites .

Keywords:Aluminum can,rise husk ash,metal matrix composite,Stir Casting,micro structure,Agro waste.

1.INTRODUCTION Aluminum alloy cans is widely used in the canning industries for food storage in place of traditional glass jars, bottle and steel cans. This trend is informed by the peculiar mechanical properties of aluminum such as light weight, form-ability, corrosion resistant, excellent barrier, reduced thickness, damage tolerance, ease of transportation, attractiveness and ease of printing a high-quality image on the cans [1]. The first aluminum alloy can was invented in 1972 when their weight was ten times less than that of glass jars.

Modern cans in use today are even 40 % lighter than those cans used as far back as in 1972.

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In India, the traditional bottle based packaging companies such as Coca-Cola, Seven –up have completely modernized their production line or in some cases shifted completely to the use of Aluminum can for packaging. The transition from the traditional bottle packaging to aluminum can packaging has come with their environmental issues. Large volumes of aluminum cans drinks are being consumed daily across India and the empty cans are not properly disposed. Environmental pollution is increasing greatly, becoming uncontrollable; streets and drainage s are being littered by empty drink cans, plastics, polythene bags used in our day to day lives. Those wastes were dropped in drainage, preventing water from flowing leading to water logging which aids breeding of mosquitoes and disease outbreaks. At extreme cases, canals, drainage and gutters are blocked. In rainy season, this leads to over flooding of cities which at times claiming many lives [2].

In order to reduce if not completely eliminated menaces associated with poor waste management, there is a need for recycling of waste materials. As the name implies, recycling is the new emerging technology which involves waste conversion into raw materials for production of new materials for various engineering applications and also for wealth creation.

In 1992, the Commonwealth Government released the National Waste Minimization and Recycling Strategy with a target of reducing the amount of solid waste going to landfill per capital by 50 % from 1990 to 2000 [3]. The recycling of wastes reduces waste, saves energy, conserves natural resources, lessens use of municipal landfills and provides recycle's and municipalities with considerable revenue [3].

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International e-Journal For Technology And Research-2017 Aluminum is 100 % recyclable Recycling of Aluminium uses only 5 % of the energy required for its initial extraction and processing, 10 % of the initial capital equipment costs and saves 97 % of the greenhouse gas (GHG) emissions. Aluminium is an ideal materials used for architectural, automobile and aerospace applications because of its light weight, corrosion resistance and ease of formability but its low strength and hardness has greatly limited its use in high strength, hardness and surface wear resistance applications. Currently, the design of high performance Aluminium based composites at significantly reduced cost is receiving much attention from materials researchers. This is discernible from the dominant use of stir casting by most researchers from developing countries; and the sustained interest in the consideration of industrial and agro wastes as reinforcements in AMCs. Agro waste ashes obtained by the controlled burning of agro waste products such as bagasse, bamboo leaf, coconut shell, groundnut shell, and rice husk among others; have the advantages of low densities and processing cost compared with common synthetic reinforcing ceramics such as silicon carbide and alumina. The agro waste ashes have been successfully utilized to produce Al matrix composites with property levels which can be improved with the complement of synthetic reinforcements such as silicon carbide and alumina. The design concept is built on harnessing the high strength and wear capabilities of notable synthetic reinforcements such as silicon carbide and alumina with the light weight and low cost of processing of Agro waste ashes. There are very few literatures which have considered the design of AMCs with the use of reinforcements of Agro waste ashes.

The mechanical properties of some of these low cost Al matrix composites have been reported to be encouraging depending on the weight ratio between the synthetic reinforcement and the agro waste ashes selected. The corrosion and wear properties of these Al matrix hybrid composites are yet to receive any notable attention considering available literature s.

Corrosion and wear are very important scientific phenomena requiring consideration in composite materials design to ensure material reliability in applications where they come in contact with the environment and other surfaces. The corrosion behavior of AMCs is widely acclaimed for its in conclusiveness judging from the often contradicting IDL - International Digital Library

findings reported by authors for the same MMC system. Thus it is very unlikely for the corrosion behavior of newly developed AMCs to be predicted without subjecting them to experimental studies. The wear properties of AMCs have been reported to be dependent on factors such as the nature, size, and volume percent of the reinforcing particles.

Investigations on the wear behavior of Al MMCs produced with the use of agro waste ashes as complementing reinforcement are quite limited in literature. In this present work, metal matrix composites have been produced from discarded Aluminium cans and rice husk ash (RHA). The aim of this work is to study mechanical, corrosion and wear resistance properties of the produced Aluminum can/RHA metal matrix composites. This work is also aimed at providing solution to menaces associated with poor management of Aluminium cans and RHA through recycling of these waste materials. It embraces conversion of waste into wealth which on a large scale production will enhance technological development and economic growth. ď Ź Material Selection and sample preparation The materials used in this work include Rice Husk Ash (RHA), Aluminium cans, 220-400 grade emery papers and polishing cloth. The elemental analysis of the Aluminium can used is shown on Table 1.

Table 1: Chemical composition of aluminium can (weight percentage) Element % Composition

Si 0.53

Fe 0.51

Cu 0.03

Mn 0.77

Mg 0.02

Ti 0.04

Al 98.10

Preparation of RHA The ash, obtained by burning rice husk was thoroughly washed with water to remove the dust and dried at room temperature for 1 day. Washed rice husk was then heated to 200 ° C for 1 h in order to remove the moisture and organic matter. It was then heated to 600 ° C for 12 h to remove the carbonaceous material [4]. The chemical composition of the RHA determined using X-ray fluorescence spectroscopy is presented in Table 2.

Table 2: Chemical composition of Rice Husk Ash (RHA)

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International e-Journal For Technology And Research-2017 Composition %weight

2.OBJECTIVES.

Graphite 4.77

CaO 1.58

MgO 0.53

K2O 0.39

Fe2O3 0.21

Wear Test a.Load

Conclusions from the literature review prompted for the need of a systematic study of various mechanical properties of Rice Husk Ash (RHA) reinforced aluminium can (recycled waste) composites. This study can lead one to explore the possibility of identifying the use of these composites for engineering applications. Therefore the work taken up had the following objectives: Fabrication of aluminium can / RHA composites by Stir Casting route.

2. Microstructure characterization of the composites using optical microscopes 3. Evaluation of mechanical and Wear properties of composites 4. Comparing the results of mechanical, Corrosion and Wear properties of as-cast alloy with composites.

5. Drawing Conclusion based on the obtained result.

The present study is thus aimed at producing MMCs with aluminium can (recycled waste) as the matrix material with Rice Husk Ash (RHA) as reinforcement processed by stir casting route of these composites in order to obtain mechanical properties suitable for a wide range of engineering applications

SiO2 90.23

Drawing conclusion based result

Figure3.1: Flow Chart of Experimental Work

1.

3.Methodology

4.IMPLEMENTATION    

Automotive components such as screws,nuts and rivets.

Aluminium utensil.

Foils and conductor cables.

Aeronautical application

5.OUTCOMES  

Starting Aluminium can with rice husk ash reinforcement



We can expect uniform distribution of reinforcement (RHA) with matrix material (Aluminium can) by stir casting process Uniform distribution may lead to good Microstructure of composites Further there will be a good improvement in mechanical properties of Composites

Specimen Preparation by stir casting process

 Aluminium can

Optical Microscopic Studies

Aluminium can composites

Micro-structural characterization  Optical Microscopy

Evaluation of Mechanical Properties  Tensile Test(UTS,YTS)  Hardness Test

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Fig 5.1(a)Aluminium Can Ac Fig 5.1(b)Aluminium Can+4% RHA

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International e-Journal For Technology And Research-2017 From Figure 5.2 it is found that hardness increase with increasing Rice Husk Ash (RHA) respectively in the material. As compared to as-cast 4% RHA .

Rice Husk Ash addition shows an increase of 9.7 BHN (21.74%). In contrast 8% and 12% Rice Husk Ash addition shows an increase of 14.8 BHN (33.18%) and 15.5 BHN (34.75%) respectively.

Percentage increase in hardness was significant from 0% to 4 %,( i.e. around 21.74%). The improvement in hardness in casted composites may be attributed to uniform distribution of reinforcement in the matrix material.

Fig 5.1(c)Aluminium Can+8% RHA Fig 5.1(d)Aluminium Can+12% RHA

Figure 5.1 shows the microstructure of Aluminium can and its composites.Figure 5.1(a), 5.1(b), 5.1(c), 5.1(d) shows the micro photographs of both the matrix alloy (Aluminium Can-recycled waste) and its composites system. Figure 5.1(b). 5.1(c), 5.1(d) revealed that presence of rice husk ash (RHA) particles in alloy matrix and further confirms that there was a fairly uniform distribution of rice husk ash particles in the base matrix of Aluminium Can alloy .

 

Tensile Test Results:-

Table :5.2UTS values of Al Can and its RHA composites



Hardness Test Result:

Table :5.1 Hardness of Aluminium can and its composites SL

Alloy/Composite

NO

Designation

BHN(Hardness)

% increase in Hardness

1

Aluminium Can Ac

44.6

_________

2

Aluminium Can+4RHA

54.3

21.74%

3

Aluminium Can+8RHA

59.4

33.18%

4

Aluminium Can+8RHA

60.1

34.7%

SL

Alloy composite

NO

Designation

UTS

% Increased in strength

1

Al Can

219.2

-

2

Al Can + 4% RHA

230.9

5.37

3

Al Can + 8% RHA

252.8

15.32

4

Al Can + 12% RHA

271.5

23.85

Fig:5.3UTS Values Of Al Can And Its RHA Composites

Fig :5.2 Hardness values of Aluminium can and it’s RHA Composites

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From the graph absorbed that addition of rice husk particle ultimate tensile strength value of composite compared to Aluminium Can the improvement of UTS of 4%RHA composite compared over Aluminium can is 5.37% and enhancement of 15.32% and 23.85 UTS of 8% RHA and 12% RHA is observed than compare 4|P a g e

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International e-Journal For Technology And Research-2017 Fig 5.5(c) Fractographic image Fig 5.5(d) Fractographic image of

to Aluminium Can desperation of RHA particles in soft ductile matrix result in improvement of UTS so UTS value obtained during experiment a taken for the average of 5 sample which curve closed to each other they have been used in this table and graph

of Aluminium Can+8% RHA

Table :5.3 Percentage elongation values of Al Can and its RHA composites SL

Alloy Composite

NO

Designation

UTS

%

% Decreased

Elongation

in Ductility

1

Al Can

219.2

3.03

-

2

Al Can + 4% RHA

230.9

2.32

23.43

3

Al Can + 8% RHA

252.8

1.80

40.59

ď Ź

4

Al Can + 12% RHA

271.5

1.73

42.90

Table :-5.4Wear Test Results SL NO

1

2

Can+12% RHA

Wear Test Results:Alloy Designation

Load (N)

Wear Rate (WR) in (microns)

Wear Rate (WR) in (mm3/m)* 10-4

Al can

5

83

6.95

10

86

7.20

15

173

14.4

5

61

5.10

10

77

6.45

15

83

6.95

5

47

3.93

10

48

4.02

15

52

4.35

Al + 4%

Fig :5.4Percentage elongation values of Al Can and its RHA composites

From Fig 5.4 Aluminium can has the highest % Elongation and has the value of % and RHA increased the ductility decreased from the table ď Ź Fractographic Studies of Aluminium can and Its RHA Composites

sAluminium

Figure 5.5 shows the Fractographic images of Aluminium can and its composites. Figure 5.5(a), 5.5 (b), 5.5 (c), 5.5 (d) shows the Fractographic images of both the matrix alloy (Aluminium Can-recycled waste) and its composites system.From the figures 5(a)we can observe dimples resulting due to overload failure under tension. We can observe dendritic structure in the fractured surface .Whereas ductile and brittle mode of fracture is observed in Fractographic observation of composite.

3

4

Al + 8%

Al + 12%

5

27

2.26

10

36

3.01

15

37

3.09

Fig 5.5(a) Fractographic image Fig 5.5(b) Fractographic image of Aluminium Can

of Aluminium Can+4% RHA

Fig:5.6Wear rate V/S Load of Al Can and its RHA Compositions

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International e-Journal For Technology And Research-2017 Fig shows the effect of applied load on the wear resistance of Aluminum can and Rice husk ash (RHA) composites respectively from the fig we can see the wear resistance of Rice husk ash composites is higher than Aluminum can at all load the important of wear result could loss due to ability of Rice husk ash particles to carry the greater portion of applied load  Wear Track Analysis for the Aluminium can and Its R composites:

With rice husk ash content. The strength of Aluminium can composite maximum in 12% RHA where as minimum in Aluminium can.

In corporation of rice husk ash particle in Aluminium matrix can leads to the production of low cost Aluminium composite with improved hardness strength this composites can finds where the light weight materials are required with stiffness and strength.

2 1

REFERENCES

Fig 5.7(a) Wear morphology Fig 5.7(b) Wear morphology of Of Aluminium can

Aluminium cam+RHA 4%

2

1

Fig 5.7(c) Wear morphology

Fig 5.7(d) Wear morphology of

Of Aluminium can+RHA 8%

Aluminium cam+RHA 12%

Fig shows the wear surface morphology of applied load on the wear resistance of Aluminum can and Rice husk ash (RHA) composites respectively.From the above figure 1 denotes the sliding direction and 2 denotes the delamination or particle pull out from the wear surface respectively. Fig 5.7(a) shows more wear out of the surface compared to Fig 5.7(b),Fig 5.7(c),and Fig 5.7(d).The surfaces are less wear out compared to aluminium can

CONCLUSION Rice husk ash particles were successfully incorporated in a Aluminium can by using stir casting techniques Microstructure analysis shows the distribution of rice husk ash in Aluminium can the microstructure reveled Good inter facial bond between Aluminium alloy and rice husk particles the ultimate strength is increased IDL - International Digital Library

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[5] Basavaraj Mathpathi and Bharat S kodli., ―mechanical behavior of pure aluminum reinforced with the alloy of Silicon Carbide and coconut shell ash which was fabricated by liquid metallurgical (stir casting) method‖ International Journal of Engineering Research & Technology (IJERT) vol. 1, Issue 3,November 3,2012, pp 1-14.

[6] Ankit Mittal and Ram Narayan Muni., the mechanical behaviour of aluminum alloy used as the matrix, RHA and copper as the reinforcements‖ Archives and Foundry Engin, vol. 8, no. 3, June 7, 2008, pp.59.

[7] D. Siva Prasad and Dr. A. Rama Krishna,‖ Production and Mechanical Properties of A356.2 /RHA Composites‖ International Journal of Advanced Science and Technology Vol. 33, August, 2011 [8] J.O. Agunsoye, S.A. Bello, I.S. Talabi, A.A. Yekinni, I.A. Raheem, A.D. Oderinde, T.E.Idegbekwu,‖ Recycled Aluminium Cans/Eggshell Composites: Evaluation of Mechanical and Wear Resistance Properties‖ Vol. 37, No. 1 (2015) 107-116 [9] Kenneth Kanayo Alaneme, Peter Apata Olubambi, ―Corrosion and wear behaviour of rice husk ash— Alumina reinforced Al–Mg–Si alloy matrix hybrid composites‖ j mater res technol. 2013; 2(2):188–194 6|P a g e

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International e-Journal For Technology And Research-2017 [10] S.I. Talabi, J.O. Agunsoye, S.A. Bello, I.O. Awe ―The Effects of Cocos Nucifera (Coconut Shell) on the Mechanical and Tribological Properties of Recycled Waste Aluminium Can Composites‖ Vol. 36, No. 2 (2014) 155-162 [11] Basavaraj Mathpathi, Bharat S Kodli‖A Study on Mechanical Properties of Aluminum, Rice Husk and Silicon Carbide Matrix Composites ―IJSRD International Journal for Scientific Research & Development| Vol. 2, Issue 08, 2014 | ISSN (online): 2321-0613

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