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A COMPARATIVE STUDY ON THE MICROSTRUCTURE AND MECHANICAL PROPERTY OF ALUMINUM-ZINC ALLOYS Ogie Nosa Andrew*1, Ebhota Larry momodu1, Ibhadode Oise2
1Department
2
of Mechanical Engineering, Petroleum Training Institute, Effurun, Nigeria. Department of Mechanical Engineering, Federal University of Petroleum Resources, P.M.B 1221, Effurun, Delta State, Nigeria.
ABSTRACT
Aluminium-Zinc base alloys are useful materials for manufacture of automotive parts, electronic/electrical systems, household articles, fashion goods, etc. Also, these alloys are characterized by low melting points and high fluidity that make them suitable for foundry applications. Besides, the diecast Aluminium-Zinc alloys possess an attractive combination of mechanical properties, allowing them to be applied in a wide variety of serviceable applications. In this research work, a comparative study on the microstructure and mechanical property of Aluminum-Zinc alloys was carried out. The Aluminum-Zinc alloys of five varied compositional ratios, with sample A as (77.45%Al and 14.68%Zn); for sample B (72.45%Al and 19.68%Zn); for sample C (67.45%Al and 24.68%Zn); for sample D (62.45%Al and 29.68%Zn); and sample E (57.45%Al and 34.68%Zn). The microstructure test which is to determine the metallography of the alloy was carried out through various procedures starting with the sectioning of the five different sample alloys with a hard saw. Mechanical test via Impact test, hardness test, and tensile test were carried out on the five (5) different samples based on their compositional ratios. The microstructure obtained from the alloys indicates the variance in the grain structure with respect to the compositional variation. The mechanical property test of impact test, hardness test and tensile test shows that with increase in the percentage of zinc addition, the more impact strength, hardness strength and tensile strength it becomes. Keywords: Aluminum-Zinc Alloy, Casting, Mechanical Property, Microstructure.
I.
INTRODUCTION
Alloys are metallic materials prepared by mixing two or more molten metals. They are used for many purposes, such as construction and transportation [1]. Zinc-base alloys offer a series of properties that makes them particularly attractive for die-casting manufacturing and, in general, for foundry technologies [2-4]. Aluminum is a chemical element in the boron group with symbol Al and atomic number 13. It is a silvery white, soft, ductile metal. Aluminum is the third most abundant element (after oxygen and silicon), and the most abundant metal in the Earth's crust. Aluminum is remarkable for the metal's low density and for its ability to resist corrosion due to the phenomenon of passivation. Structural components made from aluminum and its alloys are vital to the aerospace industry and are important in other areas of transportation and structural materials. It is a light metal (sp. Gravity 2.7) which melts at 658 ยบC and boils at 1800 ยบC. Aluminum is malleable and ductile especially between 100 ยบC and 150 ยบC near about its melting point. It becomes brittle and can be grounded to powder. It is also an excellent conductor of heat and electricity [5-8]. Zinc, in commerce is also spelter, which is a chemical element with symbol Zn and atomic number 30. It is the first element of group 12 of the periodic table. In some respects zinc is chemically similar to magnesium, its ion is of similar size and its common oxidation state is +2. Zinc alloys generally have high impact strength compared to other die casting alloys, zinc alloys greatly improve on this property over the pure metal, allowing more complex fabrication methods to be used. They are applied in the construction field for the production of roofing, downspouts, gutters, flashlight reflectors, parts for lamps, etc. Lately, a new zinc alloy for extrusion and forging has been also developed [9-11]. Aluminum-Zinc alloy are alloys whose main constituents are Aluminum and Zinc. This alloy is designed to compete with bronze, and cast iron, due to that these alloys uses sand and permanent mould casting methods. Distinguishing features of Al-Zn alloys include high as cast strength, excellent bearing properties, as well as low energy requirements (for melting). One of the main differences between aluminum and zinc alloys is that zinc has a lower melting temperature and requires lower pressures for casting. The addition of zinc to aluminum (in conjunction with some other elements, primarily magnesium and/or copper) which produces heat-treatable aluminum alloys of the highest strength. The zinc substantially increases strength and permits precipitation hardening [12-15].
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Fig.1 Zinc-Al Phase diagram [16-17] The solubility of Zn in Al is the largest among all elements, showing a maximum of 67 (1) at% (mole fraction of Zn×100) at 654 (2) K.2, and this is due to the fact that Zn and Al do not form intermetallic phases. In other words, the interaction between Al and Zn atoms is fairly weak. The atomic radius of Al is 0.143 nm, while the one of Zn is 0.134 nm, this difference of approximately 7 % having a great influence on the microstructure of the Al-Zn and Zn-Al alloys. Al-Zn alloys can gradually (asymptotically) approach the equilibrium state due to rapid quenching and a prolonged ageing at, say, RT. That process can be accelerated at an elevated temperature, say, several tens K's above RT. In such a state, the alloy contains two phases: α-phase (fcc, the matrix, M) containing ≈ 99 at% Al and ≈ 1 at% Zn, and β-phase (hexagonal, the precipitates), often denoted in literature as β (Zn), having ≈ 99.5 at% Zn and ≈ 0.5 at% Al.2,3 It is said that the phase α (M/β) is in equilibrium with the phase β, (croatica chemica acta ccacaa, issn-0011-1643, issn-1334-417x croat. chem. acta 82 (2) (2009) 405–420 CCA-3330 Physics Department, Faculty of Science, University of Zagreb, P. O. Box 331, 10002 Zagreb, Croatia) [18].
2.1 Materials
II.
MATERIALS AND METHOD
The following materials were used in this research work. Aluminum Metal Aluminum metal of 97.45 % purity with weight rating of 6.2 kg was used for this analysis. The aluminum metal was cut into smaller chunks before it was divided into five different samples based on the compositional ratio. Zinc Metal Zinc metal of 94.68 % purity with the weight rating of 2.8 kg was used for the analysis. The zinc metal was also separated into five samples based on the compositional ratio. 2.2 Methods The following methods were adopted. 2.2.1 Mould Making Procedure The following materials was used in making the mould pattern; Mould box, spade, vent wire, pattern, rammer, flat board, stickle, green sand, facing sand, shovel, trowels, lifter, hand riddle, strike off bar, swab, sprue cutter and water.
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Fig. 2 Moulding Box This mould box is made up of two parts, the cope (which is the top) and the drag (which is the bottom). A flat horizontal board whose length and breadth is larger than the mould box is placed on the floor, the surface is sprinkled with water. The drag is placed on top of the flat board. The green sand was filtered to remove impurities and large grain sizes of the sand to enhance proper compaction during ramming. Water is poured on the green sand while shovel is used for proper of water and the green sand to a correct proportion until the green sand mixed to a correct proportion and becomes well stickled together. The green sand is poured into the mould while ramming continues until the drag is filled up. The three similar patterns of the same dimensions were placed inside the mould, when the mould sand was filled up to a certain level and rammed. The cope is placed on top of the drag and is been filled with sand while ramming thoroughly to enhance proper compatibility between the grain sizes of mould sand with the creation of Runner (Runner is a connected channel that convey the molten metal to different part of the mould) and Riser (Riser is the vertical channels that provides a continuous flow of molten metal to eliminate shrinkage as solidification occurs during casting) for the flow-ability of the molten metal to the mould cavity. Two cylindrical rods used to create the riser and the runner. Mark is been indicated on both side of the mould to enable ease of coupling before the removal of the cope from the drag. The patterns in the drag are tap with a ram to enhance easy removal in order to create a mould cavity. Gate is been created, which the molten metal will flow from the runner into the mould cavity. Venting is done in the green sand of the cope to enhance permeability. 2.2.2 The Alloy Casting Procedure The following materials were used for the casting of the Al-Zn Alloy include; Crucible furnace; Skimmer; Fork lift; Black oil and Melting pot with lid. Haven collected the weight of the materials, the material was grouped into five different samples (A-E) and these samples were grouped based on the compositional ratios which were obtained with the weight of the materials. Then each of the samples was then compacted in other to reduce the size, and then was charged differently into five different pots of oil fired crucible furnace, according to their sample specification. The charging started with Aluminum which was allowed inside the furnace for some while and observations were made to when it starts scaling due to higher melting temperature. At about 20minutes the Zinc was then inserted into the furnace with a fork lift. When the both metals were under melting, to form a molten alloy under 5minutes of adding the zinc, an impurities or dross floating as slag on the molten charge was raked off with a heated skimmer. After the complete melting of the metals to form a molten alloy, then the pot was removed from the furnace using a lift fork. Fig 3 shows the melting procedure, while Fig 4 shows the Alloy in its molten state.
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Fig. 3 Melting Process of the Metals inside the Furnace
Fig. 4 Alloy in its Molten State before Pouring and Solidification 2.2.3 The Microstructure Procedure The microstructure test which is to determine the metallography of the alloy was carried out through various procedures starting with the sectioning of the five different sample alloys with a hard saw. The alloys are then grinded with emery paper of different grit was used starting with the coarse to the finest grit. The alloys are then polished with diamond pest before they are then etched with sodium hydroxide (NaOH) and distilled water. After the etching process, the alloys are then taken to a microstructure machine for the photograph of the grain structure. 2.2.4 The Mechanical Property Test Procedures The following mechanical property test was carried out for the experiment: impact test, hardness test and tensile test. A. The Impact Test Procedure Impact test was carried out on the five (5) different samples based on their compositional ratios. The charpy block and the striker in their respective positions were located. Then the work piece is placed on the supports and the center of the work piece notch is aligned with the center of support. The pendulum and latch was raised into it position. The release levers were operated successively before the release of the pendulum. The pendulum is allowed to swing freely to break the work piece. After the rapture, the pendulum brake was operated by means of the brake lever and the energy absorbed in breaking the work piece from the charpy gauge was recorded. Fig. 5 shows the impact test specimen after it has been machined and Fig. 6 is after it has been tested.
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Fig. 5. Impact Test Samples after it has been Machined
Fig. 6 Impact Test Specimen after it has been tested B. The Hardness Test Procedure The hardness test which helps to determine the resistance to indentation by measuring the permanent depth of the indentation. More simply put, when using a fixed force (load) and a given indenter, the smaller the indentation, the harder the material. Indentation hardness value is obtained by measuring the depth or the area of the indentation using the Rockwell hardness test method as follows: i. After the work piece have been machined to a flat mirror surface of about 29 mm length. The indenter is pressed with the test pre-force to a penetration depth of reference level for subsequent measurement of the residual indentation depth. ii. The additional test force is applied for a dwell period defined in accordance with the standard, whereby the indenter penetrates into the specimen to a maximum indentation depth. The test pre-force plus the additional test force gives the total test force. iii. After the dwell period, the additional test force is removed, the indenter moves up by the elastic proportion of the penetration depth in the total test force and remains at the level of the residual indentation depth. This is also referred to as the depth differential (difference in indentation depth before and after application of the total test force). Now the Rockwell hardness (HR) can be calculated using the indentation depth with the standard formula: Brinell, HB =
(1)
where, D = Ball diameter
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d = Diameter of the indent. Fig. 7 shows the hardness specimen after machining and figure 8 shows the hardness test specimen after it has been tested.
Fig. 7 Hardness Test Specimen after Machining
Fig. 8 Hardness Test Specimen after it has been tested C. The Tensile Testing Procedure The tensile testing of the composite was done, on Ultimate tensile testing machine. The sample rate was 9.103 pts/sec and cross-head speed 5.0 mm/min. Standard specimens with 30 mm gauge length were used to evaluate ultimate tensile strength. The following procedure was taken in carrying out the test: i. After the work piece have been machined to a tensile test work piece of about 29mm length and 10mm diameter. With no load applied, the zero knob was adjusted at the rear which should be locked in position to avoid disturbance during tests. ii. The specimen was firmly clamped in the jaws of the machine. iii. Apply a nominal load within the elastic limit to check that the specimen is firmly clamped and then release the load. iv. The setting bar was placed inside the extensometer and checked that it aligns centrally. v. The extensometer was placed around the specimen and the two sleeves were pressed together. vi. With the two sleeves pressed together, the locking screws were tightened onto the specimen, so that the specimen is central inside the extensometer. Align keys and a spanner is supplied with the apparatus. vii. The protective guide was fitted and the specimen was loaded slowly and uniformly.
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The locking disc is tightened to prevent the specimen slipping. The extension at the load increment was recorded until the fracture point. Fig. 9 shows the tensile test specimen after it has been machined, while Fig. 10, shows the tensile test specimen after it has been tested.
Fig. 9 Tensile Test Sample after it has been Machined
Fig. 10 Tensile Test Samplesafter it has been tested
III.
RESULTS AND DISCUSSION
Table 1 shows the result of the chemical composition of the alloy
Table-1: Chemical Composition of the Alloy Elements Aluminum (Al) Zinc (Zn) Magnesium (Mg)
% Compositions 97.45 94.68 0.43
Manganese (Mn)
1.52
Titanium (Ti) Iron (Fe) Tin (Sn) Lead (Pb)
0.13 2.23 2.20 1.36
The cast rods are machined to the length of 55 mm using lathe machine. The thickness and height is machined to 10mm and the work pieces are then notched at the depth of 2 mm. From the Charpy Testing Machine, the impact energy for the five various samples are: Sample A= 0.7 Joule; Sample B= 1.2 Joule; Sample C = 1.7 Joule; Sample D= 2.5 Joule; Sample E= 3.5 Joule. With each of the sample work piece having 55 mm as the Length and thickness (width) = 8 mm (10-2) = 8 mm. The depth of notch cut is 2mm. Toughness = Energy Absorbed Area
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For Sample A: Area = 55 8 = 440 =
= 0.44m2. Toughness =
1.59Joule/m2
For Sample B: Area = 55 8 = 440 =
= 0.44m2. Toughness =
2.73Joule/m2
For Sample C: Area = 55 8 = 440 =
= 0.44m2. Toughness =
3.86Joule/m2
For Sample D: Area = 55 8 = 440 =
= 0.44m2. Toughness =
5.68Joule/m2
For Sample E: Area = 55 8 = 440 =
= 0.44m2. Toughness =
7.96Joule/m2
Table 2 shows the result of Al-Zn alloy Hardness Test Table 2: Result of Al-Zn Alloy Hardness Test samples A B C D E
Diameter of Indenter (mm) 10 10 10 10 10
Diameter of Indentation (mm) 4 4.2 4.5 4.9 5.5
Load (KN) 15 15 15 15 15
Brinell Hardness (KN/mm2) 0.01047 0.01052 0.0107 0.01095 0.0114
The cast rods with length 200mm and 30mm diameter of 5 different compositional samples were machined to a flat surface shape of 10mm diameter using a milling machine. And these specimens where tested for its hardness strength using universal testing machine and the following results were obtained: The Brinell hardness strength formula = For the hardness test of Sample A F=load or force =15KN; D=diameter of indenter =10mm; d=diameter of indentation=5.5mm Brinell hardness (BH) = = 0.0114 1000 = 11.4N/mm2 = For the hardness test of Sample B F=load or force =15KN; D=diameter of indenter =10mm; d=diameter of indentation=4.9mm Brinell hardness (BH) = = = =
0.01095
1000 = 10.95N/mm2 For the hardness test of Sample C F=load or force =15KN; D=diameter of indenter =10mm; d=diameter of indentation=4.5mm Brinell hardness (BH) = = = = 0.0107
1000 =
10.7N/mm2 For the hardness test of Sample D F=load or force =15KN; D=diameter of indenter =10mm; d=diameter of indentation=4.2mm Brinell hardness (BH) = = 0.01052 1000 = 10.52N/mm2 For the hardness test of Sample E F=load or force =15KN; D=diameter of indenter =10mm; d=diameter of indentation=4mm Brinell hardness (BH) = = 0.01047 1000 = 10.47N/mm2 The cast rods with length 200 mm and 30 mm diameter of 5 different compositional samples were machined to a tensile testing specimen shape using a lathe machine. And these specimens where tested for its tensile strength using universal testing machine.
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AO =
(2)
AF =
(3)
%Elongation =
(4)
%Reduction =
(5)
Ultimate Tensile Stress (UTS) =
(6)
Yield Stress =
(7)
Yield Load = Yield Stress where, Initial Length = LO Final Length = LF Initial Diameter = DO Final Diameter = DF): Initial Area = AO Final Area = AF
AO
(8)
Table 3. Result of Al-Zn Alloy Tensile Test
Samples
A
Dim. (mm) Do 9.0
Df 8.8
X-Sectional Area (mm) Ao 63.6
Af 60.8
62.2
56.8
Gauge Length (mm)
Yield Load (KN)
Yield Stress N/mm2
Max load (KN)
Ultimate Tensile Stress N/mm2
% Elong.
% Red.
Lo 139
Lf 142
1.76
27.6
2.3
36.2
2.2
4.4
136
140
3.66
58.9
4.8
77.2
2.9
8.7
C
8.1
8.5
D
9.0
8.3
63.6
54.1
139
146
5.35
84.1
7.0
110.1
5.0
14.9
E
9.0
8.0
63.6
50.3
139
149
7.48
117.6
9.8
154.1
7.2
20.9
The microstructure test results are shown in Fig. 11
Fig 11. The sample A Microstructure of Al-Zn Alloy
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Fig 12. The sample B microstructure of Al-Zn alloy
Fig 13. The sample C Microstructure of Al-Zn alloy of
Fig 14. The sample D microstructure of Al-Zn alloy
Î’+Îą
Grain boundary
Fig 15. The sample E microstructure of Al-Zn alloy
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From the conducted experiments on the five different samples using the length of 55 mm and thickness of 10 mm with the depth of 2mm, the energy absorbed by these alloys samples are: sample A (0.7Joule), Sample B (1.2Joule), Sample C (1.7Joule), Sample D (2.5Joule), Sample E (3.5Joule). The Al-Zn alloys fractures at the release of the striker with their different energy absorbed. These alloys fractures due to their weights and ductility of their physical and chemical properties in which at such they can only withstand the impact load less than the different absorbed energy to the different samples tested, within their elastic limits without fractures, these results in the toughness of the samples as follows: Sample A (1.5 J/m2), Sample B (2.73 J/m2), Sample C (3.86 J/m2), Sample D (5.68J/m2), Sample E (7.96J/m2). Also, with the diameter of 10 mm and a desired length of 200 mm, and a flat surface shape, the energy absorbed by these Al-Zn alloys was 15 KN each. These Al-Zn alloys were indented to show the level of hardness of each sample. The load induced into the specimens to create indention is 15 KN with an indenter of 10 mm diameter. The various samples has different diameters as an indentation created on them as follows; For sample A (5.5mm), Sample B (4.9mm), Sample C (4.5mm), Sample D (4.2mm); Sample E(4.0mm). From the obtained diameters of these samples indentations, their brinell hardness was calculated and the results of the samplesare as follow; Sample A (11.4N/mm2), Sample B (10.95N/mm2), Sample C (10.7N/mm2), Sample D (10.52N/mm2), and Sample E (10.47N/mm2). Also, from the conducted experiment on five samples of Al-Zn alloy using a universal testing machine to carryout tensile test on the different samples. These samples has their initial lengths measured, their initial center diameter equally measured before carrying out the fracture test on them. For the tensile strength of the different samples to be determined, a maximum load is been induced into the specimen and the load which fractures the specimen becomes the maximum load to fracture the specimen and the different maximum load obtained for the different samples includes; Sample A (1.3KN), Sample C (4.8KN), Sample D (7KN), and Sample E (9.8KN). Then the tensile strength is been determined by calculating for the following parameters; the %elongation, %reduction, ultimate tensile strength, yield load, and yield stress. Similarly, based on the necessary calculations needed to determine the ultimate tensile stress which can be withstand based on the elastic limit of the alloys, the following results were obtained; sample A (20.43N/mm2), sample C (90.13N/mm2), sample D(105.28N/mm2), and sample E (150.66 N/mm2). The yield stress which is the maximum stress which a metal can withstand before fracturing was equally determined and the results obtained includes; sample A (992.56N/mm2), sample C (3556.26N/mm2), sample D(5343.80N/mm2, and sample E (7481.1N/mm2). As shown in Fig. 11 to Fig.15, the microstructure of Aluminum-Zinc Alloy that was conducted with the percentage of varying composition of five different samples revealed that sample A is 77.45% Al, 14.68%Zn, sample B (72.45%Al, 19.68%Zn), sample C (67.45%Al, 24.68%Zn), sample D (62.45%Al, 29.68%Zn), and sample E(57.45% Al, 34.68% Zn) with 0.43% Mg, 1.52% Mn, 0.13% Ti, 2.23% Fe, 2.20% Sn and 1.36 % Pb respectively as impurities which alters the temperature of transformation and the composition of phase but not the general characteristics of the phase relation that exist in the alloys. All these microstructures reveal the grain boundary between the aluminum β + ι matrixes. Dispersed within the aluminum grains and along the grain boundary are intermetallic. Two distinct Al-Zn alloys with intermetallic along the grain boundaries could have a negative effect on the mechanical properties of the alloy. The Grain boundaries are regions of high stress and the presence of intermetallic or impurities in the grain boundaries which will hinder the movement of dislocation.
IV.
CONCLUSION
From the results obtained from this research work entitled, comparative study on the microstructure and mechanical property of Al-Zn Alloys, it was observed that the different specimen varies in their result, showing that as the percentage of Zinc mixture increases, it creates a positive effect on the alloys in terms of its mechanical properties. But the grain size and the grain boundary of the alloys tends to increase as zinc percentage mixture increases. Recommendation Since a deep research work has been carried out on the Al-Zn Alloy and conclusions has been made on the mixture of zinc to Aluminum, it is recommended that any person embarking on a similar project should test the use of either Tin; Silicon; Manganese or Magnesium as an alloying element to Aluminum, such
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that its microstructure test and mechanical property test like, Bending test; Hardness test; or Fatique test should also be carried out.
[1] [2] [3] [4] [5] [6] [7] [8] [9] [10] [11] [12] [13] [14] [15] [16] [17] [18]
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