AN INVESTIGATION OF MECHANICAL AND TRIBOLOGICAL PROPERTIES OF AL6061 ALLOY REINFORCED WITH MWCNTS BY

International Journal of Mechanical and Production Engineering Research and Development (IJMPERD) ISSN (P): 2249–6890; ISSN (E): 2249–8001 Vol. 11, Issue 1, Feb2021, 35-44 © TJPRC Pvt. Ltd.

AN INVESTIGATION OF MECHANICAL AND TRIBOLOGICAL PROPERTIES OF AL6061 ALLOY REINFORCED WITH MWCNTS BY POWDER METALLURGY TECHNIQUE A. EL-SAYED M. HASSAN1, ABDELAZIZ H. ABDELAZIZ2, RAGAB K. ABDEL-MAGIED3 & HAMMAD T. ELMETWALLY 4 1,2Department

of Production Technology, Faculty of Technology and Education, Beni-Suef University, Beni-Suef, Egypt

3Department

of Mechanical Engineering, Faculty of Engineering, Beni-Suef University, Beni-Suef, Egypt

ABSTRACT Powder metallurgy technique is considered one of the most important routes for fabricating of carbon nanotubes (CNTs) reinforced metal matrix composites (MMCs). In the present study, Al6061 matrix alloy reinforced with multiwall carbon nanotubes (MWCNTs) as a reinforcement material with different weight fractions of 0, 0.5, 1, and 1.5 wt.% were fabricated. Al 6061 matrix alloy and its composites were compacted at 500, 600, and 700 MPa. A hot compaction powder metallurgy technique was adopted to consolidate the nanocomposites at compaction temperature of 460 ºC.

of friction (COF) was investigated. Moreover, pin-on-disc sliding wear and COF behavior of the present nanocomposites was investigated under a constant applied normal load, sliding speed, and sliding distance of 30 N, 75 m/min, and 376.8 m, respectively. After wear test, microstructure of the worn surfaces was investigated using scanning electron microscope (SEM). Finally, the experimental results showed that MWCNTs play an effective role in improvement of the mechanical and tribological performance of the produced nanocomposite.

Original Article

Nanocomposites characterization i.e. relative density, microstructure, microhardness number, wear rate, and coefficient

KEYWORDS: Mechanical and Tribological Properties, Al6061 Matrix Alloy & Powder Metallurgy Technique.

Received: Dec 19 2020; Accepted: Jan 09, 2021; Published: Jan 16, 2021; Paper Id.: IJMPERDFEB20214

INTRODUCTION Composites of aluminum metal matrix (Al MMCs) have been widely applied in automotive, aerospace, and other industries because of their high physical and mechanical properties. Al alloy composites have been applied in several fields including transportation, marine, defense, automotive and medicine, this may refer to their good mechanical properties as well as their resistance to adhesive and abrasion wear, in addition to their corrosive environment [1- 3]. Al alloy composites reinforced with fibers, particles, and whiskers in the composite’s matrix gain composite good properties compared to pure Al alloy [4, 5]. These composites are mostly manufactured using liquid metallurgy and solid-state techniques. Regarding liquid metallurgy technique, particles distribution in the matrix alloy affects properties of the composites. Whereas, solid state processing prefers a powder metallurgy route to produce Al MMCs, in which the ball planetary mill is used to blend the matrix and reinforcement material. The powders are compacted after blending in a heated die to produce Al MMCs [6].

In the preparing of Al MMCs, common fillers such as boron carbide (B 4C), silicon carbide (SiC), Aluminum oxide (Al2O3), carbon fibers (CFs), and CNTs are used as nanofillers [7- 14]. Al based MMCs with Al matrix and nanoparticles of ceramic reinforcement material showed good mechanical properties than pure Al alloys,

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A. El-Sayed M. Hassan, Abdelaziz H. Abdelaziz, Ragab K. Abdel-Magied & Hammad T. Elmetwally

they are widely applied for tribological applications because of their good strength and high wear resistance. [15- 17].

Iijima in 1991[18] discovered CNTs, which have exceptional mechanical, electrical, and thermal properties, so they could form potential reinforcements in metals, ceramics, and polymer matrices with wide variety of applications. The researchers’ studies in the field of CNTs and their applications in several industries were not only for their properties but also for their fine particle diameter. Good tribological and mechanical properties of CNTs allowed them to be reinforcements in metals, ceramics, and polymer matrix composites with wide variety of applications [19- 22].

Sivananthan et al. [23] studied preparation and characterization of Al nanocomposites based on MWCNTs using powder metallurgy technique. They found that the composite hardness was enhanced by increasing MWCNTs contents up to 3 wt.%, while electrical and thermal conductivity were decreased with increasing MWCNTs contents up to 3 wt.%.

Incorporation of MWCNTs in Al7075 alloy composite materials that are prepared by powder metallurgy technique and hot extrusion was investigated, and an enhancement in wear resistance and mechanical properties with increasing in MWCNTs content were investigated [24]. A significant enhancement of Vickers microhardness number, wear resistance, and relati ve density of Al-MWCNTs composites with filler up to 2 wt.% of MWCNTs has been presented by Kumar et al. [25]. Their results concluded that properties deterioration beyond 2 wt.% of MWCNTs may be because of agglomeration of MWCNTs in Al matrix alloy, while the tensile strength was continuously decreased with addition of MWCNTs. Al6061 has more attention in many scientific studies for its workability and good corrosion resistance. It is used in various industries such as aircrafts fittings, brake components, valves, and automotive [12, 26- 28].

As reported in previous works, it has been reported that the influence of CNTs prepared with different techniques on the Al-alloy composites mechanical properties. However, preparation of Al-CNTs composites by powder metallurgy route as well as their effects for tribological applications seem to be overlocked. Obviously, this technique uses lower temperatures than melting temperature of matrix material. Furthermore, an attention towards study of particulate reinforced Al alloy composites for tribological applications is given.

In the present work, MWCNTs were selected as reinforcement material. Effect of different nanofiller loadings of MWCNTs on the tribological and mechanical properties of Al6061 nanocomposites by a hot compaction powder metallurgy technique for industrial applications was presented. Also, characteristics of the nanocomposites i.e. microstructure, microhardness, wear rate, coefficient of friction, and densification of produced composite were investigated.

2. EXPERIMENTAL WORK 2.1 Materials The matrix material is a powdered Al6061 alloy and was supplied from Alumisr Corporation, Egypt. Al6061 alloy chemical composition as received is presented in Table 1. Al6061 alloy bars was converted into nano size by atomization technique to powder with grain size 400 nm. The zeta sizer nano-series was used to identify the average particle size at the nanotechnology characterization lab. Also, the reinforcement material is composed of MWCNTs with characteristics presented in Table 2.

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Table 1: Typical Composition of Al6061 Alloy as received Ti Elements Mg Cu Fe Si Zn Mn Cr Composition% 0.85 0.35 0.60 0.75 0.15 0.20 0.025 0.065

Table 2: Characteristics of MWCNTs Density Properties Diameter Length Purity 10-12nm 1-20µm 99.9% 1~2 g/cm3 Values

2.2 Nanocomposites Preparation Experimental procedure flow chart was shown in Fig.1. Different weight fractions (wt.%) of MWCNTs (0, 0.5, 1, and 1.5 wt.%) were added to Al6061 alloy. The Al6061 powder with desired wt.% of MWCNTs were mixed using a high-energy ball milling machine for at least two hours under an argon environment. The mixture was compacted at 460°C under 500, 600, and 700 MPa using hot working steel compaction die. The inner die wall was lubricated with graphite, by which the powder prevents the specimen from sticking on die walls. After that, the compaction process was conducted using universal testing machine (GALDABINI, QUASAR 100). Finally, after compaction process, both of diameter and height was 10 mm.

Figure 1: Experimental Procedure Flow Chart.

2.3 Characterization Methods Specimens characterization such as relative density, microstructure, microhardness, wear rate, and COF were conducted out to investigate their tribological and mechanical characteristics.

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Relative density of Al6061 matrix alloy and its nanocomposites was calculated by dividing the experimental by the theoretical value. Archimedes method was used to estimate experimental density, while the rule of mixture was used to calculate the nanocomposite theoretical density. After that, nanocomposites were imaged using SEM to investigate the microstructure of fabricated nanocomposites.

The microhardness test was conducted using Vickers microhardness testing machine (model 412D, made in Netherlands). Specimens were polished using diamond suspension 14-micron finish. Microhardness test was conducted under applied load of 2Kg for 30 seconds. To eliminate the possibility of segregation effect, at least five readings for the specimen were taken at different locations of each specimen.

Wear test was carried out under a constant applied normal load, sliding speed, and sliding distance of 30 N, 75 m/min, and 376.8 m, respectively. The specimens were weighted before and after each experiment on a sensitive balance (with sensitivity of 1x10-5 g digital balance) to determine wear rate of the manufactured composites by weight loss calculation. The friction force was measured continuously using a load cell of 40 kg during wear test. A data logger was connected by the load cell to record the friction force. The average value was determined, and COF was calculated. The specimens’ microstructure as well as their wear surfaces were examined using SEM instrument.

3. RESULTS AND DISCUSSIONS 3.1 Relative Density and Microstructure Figure 2 describes the correlation between the compaction pressure and relative density of Al6061 matrix alloy and its nanocomposites. As indicated in this figure, the relative density increased gradually with an increase in MWCNTs up to 1.5 wt.%. It was also increased by increasing compaction pressure up to 700 MPa, this may be due to the enhancement in the nano-sized MWCNTs content and its uniform distribution, as indicated in Figs 3a and b, will increase the relative density and reduce the porosity because the nanoparticles possess high penetration ability within the pores and voids of the matrix alloy. This drives to improvements in the contact between the components of the composite, thereby enhancing the correlation between them.

Figure 2: Relative density of Al6061 and its nanocomposites.

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Figure 3: Distribution of 1 wt.% MWCNTs in Al6061 matrix alloy: a) 600 MPa and b) and 700 MPa.

3.2 Vickers Microhardness Number Figure 4 shows VHN of Al6061 matrix alloy and its nanocomposites. The microhardness number of nanocomposites is higher than that of pure Al6061 matrix alloy. Also, microhardness was increased with increasing compaction pressure up to 700 MPa. It was increased by adding MWCNTs by 6.69, 13.23, and 26.87% at 0.5, 1, 1.5 wt.% loading, respectively at a compaction pressure of 700 MPa. The strong interfacial adhesion between MWCNTs and Al6061, and the homogeneous distribution of MWCNTs in Al6061 matrix alloy might be why MWCNTs enhanced nanocomposites microhardness number. Also, strengthening properties of MWCNTs led to improve the load carrying capability of Al6061 matrix alloy.

Figure 4: Microhardness number of Al6061 matrix alloy and its nanocomposites.

3.3 Friction and Wear Rate Both COF and wear tests of unfilled Al6061 matrix alloy and Al6061/MWCNTs nanocomposites were performed at a constant applied normal load, sliding speed, and sliding distance of 30 N, 75 m/min, and 376.8 m, respectively, where the experiments result are introduced in Figs. 5 and 6, respectively.

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Figure 5: COF of Al6061 matrix alloy and its nanocomposites.

Figure 6: Wear rate of Al6061 matrix alloy and its nanocomposites.

Figure 5 indicates the COF results versus a compaction pressure at various MWCNTs wt.% loadings under dry sliding conditions. It shows that the MWCNTs reduce COF of unfilled Al6061 by 3.7, 4.41, and 16.2 % at 0.5, 1, and 1.5 wt.% MWCNTs loadings, respectively. Due to low friction coefficient characteristics of MWCNTs, COF of the obtained Al6061/MWCNTs nanocomposites has been enhanced. Also, the transfer film that was formed between the specimen and counterpart during friction led to facilitate the sliding process and reduce the direct contact between them.

Figure 6 represents the wear rate results as a function of the compaction pressure at various MWCNTs wt.% loadings. It indicates that the wear rate of pure Al6061 matrix alloy has higher value compared to Al6061/ MWCNTs composites. Wear rate of Al6061 was enhanced by 18.3, 40.74, and 50.68 % at MWCNTs wt.% loadings of 0.5, 1, and 1.5

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wt.%, respectively under the compaction pressure of 700 MPa. The lowest value of wear rate was investigated at 1.5 wt.% of MWCNTs. Because of high thermal conductivity and high strength of MWCNTs, the wear resistance has been improved due to transmission of frictional heat of nanocomposites and enhancement of the load carrying capacity.

Generally, the wear resistance of Al6061/MWCNTs composites have been improved due to the strengthening properties and high thermal conductivity of MWCNTs that transmit from nanocomposites frictional heat.

Figure 7: SEM micrographs at compaction pressure of 700 MPa: a) wear surface of pure Al6061 after wear, and b) wear surface of Al6061/1.5 wt.% MWCNTs. The worn surfaces of pure Al6061 matrix alloy and Al6061/1.5 wt.% MWCNTs under compaction pressure of 700 MPa was imaged using SEM as presented in Fig. 7. As shown in Fig. 7a, the wear surface of pure Al6061 matrix alloy contains more grooves than that of its reinforced MWCNTs, as shown in Fig. 7b.

During the sliding process, Al6061/1.5 wt.% MWCNTs composites have high surface mechanical strength that resist the formation of deep wear grooves. MWCNTs were easily dragged out from Al6061/ MWCNTs nanocomposites between the sliding surfaces at the contacted area. So that, the formed transfer film between the composite and steel disk sliding surface could enhance the friction and wear behavior of the sliding composites [29]. For these reasons, less and shallower wear grooves of Al6061/1.5 wt.% MWCNTs wear surface under compaction pressure of 700 MPa were investigated, as shown in Fig. 7b. Hence, the Al6061/1.5 wt.% MWCNTs nanocomposites have low COF and high wear resistance compared with pure Al6061 matrix alloy.

4. CONCLUSIONS In the present study, Al6061 alloy reinforced with MWCNTs at different loadings of 0, 0.5, 1, and 1.5 wt.% were fabricated by a hot compaction powder metallurgy route. Microstructure, microhardness, wear rate, coefficient of friction, and densification of produced nanocomposite were investigated. This work could be concluded as following: 

Microstructure of Al6061 alloy reinforced with MWCNTs showed uniform distribution of MWCNTs, and good interfacial adhesion bonding between MWCNTs and Al6061 matrix alloy.



Vickers microhardness number of matrix alloy was improved by increasing MWCNTs wt.%.

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A. El-Sayed M. Hassan, Abdelaziz H. Abdelaziz, Ragab K. Abdel-Magied & Hammad T. Elmetwally



MWCNTs at 1.5 wt.% content play a significant role in improving the wear rate of Al6061 alloy.



COF of pure A16061 matrix alloy was enhanced with increasing MWCNTs due to self-lubricating ability of MWCNTs.



Well enhancement in relative density, microhardness, and wear rate of Al6061/MWCNTs nanocomposites was observed at 1.5 wt.% MWCNTs under compaction pressure of 700 MPa.

ACKNOWLEDGEMENT The present work was accomplished by production technology department at faculty of technology and education, BeniSuef University, and ITEC at Fayoum, Egypt.

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