Performance Analysis & Experimental Evaluation of

Aluminum Copper Composite Material with Different

Composition to Increase Toughness
1
A!T"ACT
Automobiles are using heavy materials which reduce the
mechanical efficiency, thermal efficiency and fuel Consumption is increasing
vice versa. In our point of view all these drawbacks can be over come by
replacing composite materials instead of heavy metals in manufacturing. High
specific stiffness and near-ero coefficient of thermal e!pansion is being
e!perienced in "etal "atri! Composites #""C$%&.'hese are a new class of
materials that combine two or more separate components into a form suitable
for structural applications. (hile each component retains its identity, the new
composite material displays macroscopic properties superior to its parent
constituents, particularly in terms of mechanical properties and economic
value.
Alumina #Al)*+& possesses favorable physical and chemical properties
such as high strength, hardness, elastic modulus and e!cellent resistance to
thermal and chemical environments. However, its applications are somewhat
limited because of poor toughness and inferior thermal resistance ,1-. *n the
other hand, most structural ceramics present poor electrical conductivity. It has
been reported that the incorporation of some amounts of small-sie metal
particles into an Al)*+ matri!, as in the case of Al)*+, Cu #./0-1/0& ,)-,
Al)*+, Cu #1/0-)/0& ,+- and Al)*+, Cu #2/0-+/0& composites, can
significantly improve both the toughness and electrical properties.
3sing an intense mi!ture of Al)*+ with different copper contents #1/,
)/ or +/ mass 0& several Al)*+-Cu composite materials were fabricated. 'he
microstructure of the composites was observed by optical microscope. 'his
result is analysis by destructive testing process.
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Intro<uction
Composite materials are materials made from two or more constituent
materials with significantly different physical or chemical properties which
remain separate and distinct on a macroscopic level within the finished
structure.
In an advanced society like ours we all depend on composite materials in
some aspect of our lives. 7iber glass, developed in the late 1.8/s, was the first
modern composite and is still the most common. It makes up about 9: per cent
of all the composites produced today and is used for boat hulls, surfboards,
sporting goods, swimming pool linings, building panels and car bodies. ;ou
may well be using something made of fiberglass without knowing it.
Composite materials are formed by combining two or more materials that have
<uite different properties. 'he different materials work together to give the
composite uni<ue properties, but within the composite you can easily tell the
different materials apart = they do not dissolve or blend into each other. 4ut
more technically, it has both good compressive strength and good tensile
strength. Composites e!ist in nature.
8
/ses of composites
> 'he greatest advantage of composite materials is strength and stiffness
combined with lightness. ?y choosing an appropriate combination of
reinforcement and matri! material, manufacturers can produce properties that
e!actly fit the re<uirements for a particular structure for a particular purpose
"odern aviation, both military and civil, is a prime e!ample. It would be
much less efficient without composites. In fact, the demands made by that
industry for materials that are both light and strong has been the main force
driving the development of composites. It is common now to find wing and
tail sections, propellers and rotor blades made from advanced composites,
along with much of the internal structure and fittings. 'he airframes of some
smaller aircraft are made entirely from composites, as are the wing, tail and
body panels of large commercial aircraft.
> In thinking about planes, it is worth remembering that composites are less
likely than metals #such as aluminum& to break up completely under stress. A
small crack in a piece of metal can spread very rapidly with very serious
conse<uences #especially in the case of aircraft&. 'he fibers in a composite act
to block the widening of any small crack and to share the stress around.
> 'he right composites also stand up well to heat and corrosion. 'his makes
them ideal for use in products that are e!posed to e!treme environments such
as boats, chemical-handling e<uipment and spacecraft. In general, composite
materials are very durable.
> Another advantage of composite materials is that they provide design
fle!ibility. Composites can be molded into comple! shapes = a great asset
when producing something like a surfboard or a boat hull.
:
> 'he downside of composites is usually the cost. Although manufacturing
processes are often more efficient when composites are used, the raw materials
are e!pensive. Composites will never totally replace traditional materials like
steel, but in many cases they are @ust what we need. And no doubt new uses
will be found as the technology evolves. (e haven$t yet seen all that
composites can do.
Constituent materials
Composites are made up of individual materials referred to as
constituent materials. 'here are two categories of constituent materialsA matri!
and reinforcement. At least one portion of each type is re<uired. 'he matri!
material surrounds and supports the reinforcement materials by maintaining
their relative positions. 'he reinforcements impart their special mechanical and
physical properties to enhance the matri! properties. A synergism produces
material properties unavailable from the individual constituent materials, while
the wide variety of matri! and strengthening materials allows the designer of
the product or structure to choose an optimum combination. 5ngineered
composite materials must be formed to shape. 'he matri! material can be
introduced to the reinforcement before or after the reinforcement material is
placed into the mold cavity or onto the mold surface. 'he matri! material
e!periences a melding event, after which the part shape is essentially set.
Bepending upon the nature of the matri! material, this melding event can occur
in various ways such as chemical polymeriation or solidification from the
melted state.
A variety of molding methods can be used according to the end-item
design re<uirements. 'he principal factors impacting the methodology are the
natures of the chosen matri! and reinforcement materials. Another important
9
factor is the gross <uantity of material to be produced. Carge <uantities can be
used to @ustify high capital e!penditures for rapid and automated
manufacturing technology. %mall production <uantities are accommodated with
lower capital e!penditures but higher labor and tooling costs at a
correspondingly slower rate. 'his process is generally done at ambient
temperature and atmospheric pressure. 'wo variations of open molding are
Hand Cayup and %pray-up.
%trong enough to take harsh loading conditions such as aerospace
components #tails, wings, fuselages, propellers&, boat and scull hulls, bicycle
frames and racing car bodies. *ther uses include fishing rods and storage
tanks. 'he new ?oeing 212 Bream liner structure including the wings and
fuselage is composed of over :/ percent composites.
Carbon composite is a key material in today$s launch vehicles and
spacecraft. It is widely used in solar panel substrates, antenna reflectors and
yokes of spacecraft. It is also used in payload adapters, inter-stage structures
and heat shields of launch vehicles. In )//2 an all-composite military High
"obility "ulti-purpose (heeled Dehicle #H""(D or Hummvee& was
introduced by '4I Composites Inc and Armor Holdings Inc, the first all-
composite military vehicle. ?y using composites the vehicle is lighter,
allowing higher payloads. In )//1 carbon fiber and Bu4ont Eevlar #five times
stronger than steel& were combined with enhanced thermo set resins to make
military transit cases by 5C% Composites creating +/-percent lighter cases
with high strength.
Also in )//1, an all-composite recreational vehicle 6D was introduced
by 4ilgrim International Inc. 'he shell composed of CosmoCite, a
thermoplastic fiber-reinforced composite and the e!terior surface %pectraCite
which incorporates Bu4ont %urlyn, an impact-resistant coating found on golf
2
balls. In )//9, "icrocosm Inc. successfully completed <ualification tests on an
all-composite cryogenic C*F tank. In testing done for the %corpius %pace
Caunch Company #%%CC&, "icrocosm successfully tested a 8)-inch diameter
all-composite li<uid o!ygen #C*F& tank to nearly 8 times its operating
pressure of ::/ psi. 'esting was done at cryogenic temperatures using li<uid
nitrogen. 'he work was done as part of the technology development program
for the %corpius family of low-cost, responsive launch vehicles.
Mechanics
'he physical properties of composite materials are generally not
isotropic #independent of direction of applied force& in nature, but rather are
typically orthotropic #different depending on the direction of the applied force
or load&. 7or instance, the stiffness of a composite panel will often depend
upon the orientation of the applied forces andGor moments. 4anel stiffness is
also dependent on the design of the panel. 7or instance, the fiber reinforcement
and matri! used the method of panel build, thermo set versus thermoplastic,
type of weave, and orientation of fiber a!is to the primary force.
In contrast, isotropic materials #for e!ample, aluminium or steel&, in
standard wrought forms, typically have the same stiffness regardless of the
directional orientation of the applied forces andGor moments.
'he relationship between forcesGmoments and strainsGcurvatures for an
isotropic material can be described with the following material propertiesA
;oung$s "odulus, the %hear "odulus and the 4oisson$s ratio, in relatively
simple mathematical relationships. 7or the anisotropic material, it re<uires the
mathematics of a second order tensor and up to )1 material property constants.
7or the special case of orthogonal isotropy, there are three different material
property constants for each of ;oung$s "odulus, %hear "odulus and 4oisson$s
1
ratioHa total of . constants to describe the relationship between
forcesGmoments and strainsGcurvatures.
Pro<ucts
Cight, strong and corrosion-resistant, composite materials are
being used in an increasing number of products as more manufacturers
discover the benefits of these versatile materials. Composite materials have
gained popularity #despite their generally high cost& in high-performance
products that need to be l strong enough to take harsh loading conditions such
as aerospace components #tails, wings, fuselages, propellers&, boat and scull
hulls, bicycle frames and racing car bodies. *ther uses include fishing rods and
storage tanks. 'he new ?oeing 212 Bream liner structure including the wings
and fuselage is composed of over :/ percent composites.
Carbon composite is a key material in today$s launch vehicles and
spacecraft. It is widely used in solar panel substrates, antenna reflectors and
yokes of spacecraft. It is also used in payload adapters, inter-stage structures
and heat shields of launch vehicles. In )//2 an all-composite military High
"obility "ulti-purpose (heeled Dehicle #H""(D or Hummvee& was
introduced by '4I Composites Inc and Armor Holdings Inc, the first all-
composite military vehicle. ?y using composites the vehicle is lighter,
allowing higher payloads. In )//1 carbon fiber and Bu4ont Eevlar #five times
stronger than steel& were combined with enhanced thermo set resins to make
military transit cases by 5C% Composites creating +/-percent lighter cases
with high strength.
Also in )//1, an all-composite recreational vehicle 6D was introduced
by 4ilgrim International Inc. 'he shell composed of CosmoCite, a
thermoplastic fiber-reinforced composite and the e!terior surface %pectraCite
which incorporates Bu4ont %urlyn, an impact-resistant coating found on golf
.
balls. In )//9, "icrocosm Inc. successfully completed <ualification tests on an
all-composite cryogenic C*F tank. In testing done for the %corpius %pace
Caunch Company #%%CC&, "icrocosm successfully tested a 8)-inch diameter
all-composite li<uid o!ygen #C*F& tank to nearly 8 times its operating
pressure of ::/ psi. 'esting was done at cryogenic temperatures using li<uid
nitrogen. 'he work was done as part of the technology development program
for the %corpius family of low-cost, responsive launch vehicles.
1/
CHA4'56 = )
META# MAT"I) C$MP$!ITE
Intro<uction
"etal matri! composite #""C& is composite material with at least two
constituent parts, one being a metal. 'he other material may be a different
metal or another material, such as a ceramic or organic compound. ""Cs are
nearly always more e!pensive than the more conventional materials they are
replacing. As a result, they are found where improved properties and
performance can @ustify the added cost. 'oday these applications are found
most often in aircraft components, space systems and high-end or Ibouti<ueJ
sports e<uipment. 'he scope of applications will certainly increase as
manufacturing costs are reduced.
In comparison with conventional polymer matri! composites, ""Cs are
resistant to fire, can operate in wider range of temperatures, do not absorb
moisture, have better electrical and thermal conductivity, are resistant to
radiation, and do not display out gassing. *n the other hand, ""Cs tend to be
more e!pensive, the fiber-reinforced materials may be difficult to fabricate,
and the available e!perience in use is limited.
"etal composite materials have found application in many areas of daily life
for <uite some time. *ften it is not realied that the application makes use of
composite materials. 'hese materials are produced in situ from the
conventional production and processing of metals. Here, the Balmatian sword
with its meander structure, which results from welding two types of steel by
repeated forging, can be mentioned. "aterials like cast iron with graphite or
steel with a high carbide content, as well as tungsten carbides, consisting of
carbides and metallic binders, also belong to this group of composite materials.
11
7or many researchers the term metal matri! composites is often e<uated with
the term light metal matri! composites #""Cs&.
%ubstantial progress in the development of light metal matri! composites has
been achieved in recent decades, so that they could be introduced into the most
important applications. In traffic engineering, especially in the automotive
industry, ""Cs have been used commercially in fiber reinforced pistons and
aluminum crank cases with strengthened cylinder surfaces as well as particle-
strengthened brake disks. 'hese innovative materials open up unlimited
possibilities for modern material science and developmentK the characteristics
of ""Cs can be designed into the material, custom-made, dependent on the
application. 7rom this potential, metal matri! composites fulfil all the desired
conceptions of the designer. 'his material group becomes interesting for use as
constructional and functional materials, if the property profile of conventional
materials either does not reach the increased standards of specific demands, or
is the solution of the problem. However, the
technology of ""Cs is in competition with other modern material
technologies, for e!ample powder metallurgy. 'he advantages of the composite
materials are only realied when there is a reasonable cost = performance
relationship in the component production. 'he use of a composite material is
obligatory if a special property profile can only be achieved by application of
these materials. 'he possibility of combining various material systems #metal =
ceramic = non-metal&
gives the opportunity for unlimited variation. 'he properties of these new
materials are basically determined by the properties of their single components.
7igure shows the allocation of the composite materials into groups of various
types of materials. 'he reinforcement of metals can have many different
ob@ectives. 'he reinforcement of light metals opens up the possibility of
application of these materials in areas where weight reduction has first priority.
1)
'he precondition here is the improvement of the component properties. 'he
development ob@ectives for light metal composite materials areA
L Increase in yield strength and tensile strength at room temperature and above
while maintaining the minimum ductility or rather toughness,
L Increase in creep resistance at higher temperatures compared to that of
conventional alloys,
L Increase in fatigue strength, especially at higher temperatures,
L Improvement of thermal shock resistance,
L Improvement of corrosion resistance,
L Increase in ;oung$s modulus,
L 6eduction of thermal elongation.
'o summarie, an improvement in the weight specific properties can result,
offering the possibilities of e!tending the application area, substitution of
common materials and optimisation of component properties. (ith functional
materials there is another ob@ective, the precondition of maintaining the
appropriate function of the material.
*b@ectives are for e!ampleA
L Increase in strength of conducting materials while maintaining the high
conductivity,
L Improvement in low temperature creep resistance #reaction less materials&,
L Improvement of burnout behaviour #switching contact&,
L Improvement of wear behaviour #sliding contact&,
L Increase in operating time of spot welding electrodes by reduction of burn
outs,
L 4roduction of layer composite materials for electronic components,
L 4roduction of ductile composite superconductors,
L 4roduction of magnetic materials with special properties.
1+
7or other applications different development ob@ectives are given, which differ
from those mentioned before. 7or e!ample, in medical technology, mechanical
properties, like e!treme corrosion resistance and low degradation as well as
biocompatibility are e!pected.
Although increasing development activities have led to system solutions using
metal composite materials, the use of especially innovative systems,
particularly in the area of light metals, has not been realised. 'he reason for
this is insufficient process stability and reliability, combined with production
and processing problems and inade<uate economic efficiency. Application
areas, like traffic engineering, are very cost orientated and conservative and the
industry is not willing to pay additional costs for the use of such materials. 7or
all these reasons metal matri! composites are only at the beginning of the
evolution curve of modern materials.
"einforcements
6einforcements for metal matri! composites have a manifold demand profile,
which is determined by production and processing and by the matri! system of
the composite material. 'he following demands are generally applicable
L Cow density,
L "echanical compatibility #a thermal e!pansion coefficient which is low but
adapted to the matri!&,
L Chemical compatibility,
L 'hermal stability,
L High ;oung$s modulus,
L High compression and tensile strength,
L Mood processability,
L 5conomic efficiency.
18
Matrix Alloy !ystems
'he selection of suitable matri! alloys is mainly determined by the intended
application of the composite material. (ith the development of light metal
composite materials that are mostly easy to process, conventional light metal
alloys are applied as matri! materials. In the area of powder metallurgy special
alloys can be applied due to the advantage of fast solidification during the
powder production. 'hose systems are free from segregation problems that
arise in conventional solidification. Also the application of systems with
oversaturated or metastable structures is possible
Pro<uction an< Processing of Metal Matrix Composites
"etal matri! composite materials can be produced by many different
techni<ues. 'he focus of the selection of suitable process engineering is the
desired kind, <uantity and distribution of the reinforcement components
#particles and fibers&, the matri! alloy and the application. ?y altering the
manufacturing method, the processing and the finishing, as well as by the form
of the reinforcement components it is possible to obtain different characteristic
profiles, although the same composition and amounts of the components are
involved. 'he production of a suitable precursor material, the processing to a
construction unit or a semi-finished material #profile& and the finishing
treatment must be separated. 7or cost effective reasons prototypes, with
dimensions close to the final product, and reforming procedures are used,
which can minimie the mechanical finishing of the construction units.
In general the following product engineering types are possibleA
L "elting metallurgical processes
= infiltration of short fiber-, particle- or hybrid preforms by s<ueee casting,
vacuum infiltration or pressure infiltration
= reaction infiltration of fiber- or particle preforms
1:
= processing of precursor material by stirring the particles in metallic melts,
followed by sand casting, permanent mold casting or high pressure die casting
L 4owder metallurgical processes
= pressing and sintering andGor forging of powder mi!tures and composite
4owders = e!trusion or forging of metal-powder particle mi!tures= e!trusion
or forging of spraying compatible precursor materials
L Hot isostatic pressing of powder mi!tures and fiber clutches
L 7urther processing of precursor material from the melting metallurgy by
thi!ocasting or -forming, e!trusion, forging, cold massive forming or super
plastic forming
L Noining and welding of semi-manufactured products
L 7inishing by machining techni<ues
L Combined deformation of metal wires #group superconductors&.
"elting metallurgy for the production of ""Cs is at present of greater
technical importance than powder metallurgy. It is more economical and has
the advantage of being able to use well proven casting processes for the
production of ""Cs.
7or melting metallurgical processing of composite materials three procedures
are mainly used
L Compo-casting or melt stirring
L Mas pressure infiltration
L %<ueee casting or pressure casting.
?oth the terms compo-casting and melt stirring are used for stirring particles
into a light alloy melt. 7igure shows the schematic operational se<uence of this
procedure. 'he particles are often tend to form agglomerates, which can be
only dissolved by intense stirring. However, here gas access into the melt must
be absolutely avoided, since this could lead to unwanted porosities or
reactions. Careful attention must be paid to the dispersion of the reinforcement
19
components, so that the reactivity of the components used is coordinated with
the temperature of the melt and the duration of stirring, since reactions with the
melt can lead to the dissolution of the reinforcement components. ?ecause of
the lower surface to volume ratio of spherical particles, reactivity is usually
less critical with stirred particle reinforcement
than with fibers. 'he melt can be cast directly or processed with alternative
procedures such as s<ueee casting or thi!ocasting. "elt stirring is used by
the Buralcan Company for the production of particle-strengthened aluminum
alloys. At the Can!ide Company a similar process is used, with additional
reactions between the reinforcement components and the molten matri! being
purposefully promoted to obtain a <ualitatively high-grade composite
material . In the reaction procedures of the Can!ide Company it may be
desirable that the reinforcement component reacts completely with the melt to
form the component in situ, which then transfers the actual reinforcement
effect to the second phase in the ""C.
Composition
""Cs are made by dispersing a reinforcing material into a metal
matri!. 'he reinforcement surface can be coated to prevent a chemical reaction
with the matri!. 7or e!ample, carbon fibers are commonly used in aluminium
matri! to synthesie composites showing low density and high strength.
However, carbon reacts with aluminium to generate a brittle surface of the
fiber. 'o prevent this reaction, the carbon fibers are coated with nickel or
titanium boride. *ver recent decades many new composites have been
developed, some with very valuable properties. ?y carefully choosing the
reinforcement, the matri!, and the manufacturing process that brings them
together, engineers can tailor the properties to meet specific re<uirements.
'hey can, for e!ample, make the composite sheet very strong in one direction
12
by aligning the fibres that way, but weaker in another direction where strength
is not so important. 'hey can also select properties such as resistance to heat,
chemicals, and weathering by choosing an appropriate matri! material.
Matrix
'he matri! is the monolithic material into which the reinforcement is
embedded, and is completely continuous. 'his means that there is a path
through the matri! to any point in the material, unlike two materials
sandwiched together. In structural applications, the matri! is usually a lighter
metal such as aluminium, magnesium, or titanium, and provides a compliant
support for the reinforcement. In high temperature applications, cobalt and
cobalt-nickel alloy matrices are common.
"einforcement
'he reinforcement material is embedded into the matri!. 'he
reinforcement does not always serve a purely structural task #reinforcing the
compound&, but is also used to change physical properties such as wear
resistance, friction coefficient, or thermal conductivity. 'he reinforcement can
be either continuous, or discontinuous. Biscontinuous ""Cs can be isotropic,
and can be worked with standard metalworking techni<ues, such as e!trusion,
forging or rolling. In addition, they may be machined using conventional
techni<ues, but commonly would need the use of polycrystalline diamond
tooling #4CB&.
!ome automotive <isc =ra>es use MMCs
7ord offers a "etal "atri! Composite #""C& driveshaft upgrade. 'he ""C
driveshaft is made of an aluminum boron carbide matri!, allowing the critical
speed of the driveshaft to be raised by reducing inertia.
11
Honda has used aluminium metal matri! composite cylinder liners in some of
their engines, including the ?)1A1, H))A and H)+A, 7)/C and 7))C, and the
C+)? used in the O%F.
'oyota has since used metal matri! composites in the ;amaha designed )PP-
M5 engine which is used in the later Cotus 5lise %) versions as well as 'oyota
car models.
1.
C+APTE" ? @
IDE&TI%ICATI$&* "E!EA"C+ A"EA A&D ,$"-
Humans have been using composite materials for thousands of
years. 4lywood is a common composite material that many people encounter in
their everyday lives. 'he most primitive composite materials were straw and
mud combined to form bricks for building constructionK the ?iblical book of
5!odus speaks of the Israelites being oppressed by 4haraoh, by being forced to
make bricks without straw being provided. 'he ancient brick-making process
can still be seen on 5gyptian tomb paintings in the "etropolitan "useum of
Art. 'he most advanced e!amples perform routinely on spacecraft in
demanding environments. 'he most visible applications pave our roadways in
the form of both steel and aggregate reinforced 4ortland cement or asphalt
concrete those composites closest to our personal hygiene form our shower
stalls and bath tubs made of fiberglass. %olid surface, imitation granite and
cultured marble sinks and counter tops are widely used to enhance our living
e!periences. In an advanced society like ours we all depend on composite
materials in all aspects of our lives. 7iberglass, developed in the late 1.8/s,
was the first modern composite and is still the most common. It makes up
about 9: per cent of all the composites produced today and is used for boat
hulls, surfboards, sporting goods, swimming pool linings, building panels and
car bodies. ;ou may well be using something made of fiberglass without
knowing it.
)/
C+APTE" ? .
#ITE"AT/"E "E0IE,

5ffect of composition on friction coefficient of Cu-Aluminium composites,
Naroslav Eovacik, %tefan 5mmer, Noef ?ielek, ubomir
In this paper reveals that that with increasing concentration of
aluminium with Cu, the coefficient of friction and wear rate decreased.
However, in the case of low voltage and high current density, it is re<uired to
employ materials with a very high specific electrical conductivity, good
thermal conductivity and low friction coefficient. such conditions are fulfilled
only by Cu-Aluminium composite materials
"icrostructure of CuQAl
)
o
+
surface composite on a copper substrate, (enming
%onga,b, Mui-rong ;ang a,b, , Nin-@un Cuc,
In this paper reveals that the microstructure and hardness of the
surface infiltrated composite #CuG Al
)
o
+
& layers produced on copper substrates.
High electrical and heat conductive copper is widely used in optics, electrical
contact and heat conducting materials . 'heir low strength and poor wear
resistance are re<uired to improve with the developing industry.
Interfacial design of Cu-based composites prepared by powder metallurgy for
heat sink applications 'h. %chubert , , ?. 'rindade , '. (eiRgSarber , ?.
Eieback
'he use of %iC or diamonds particles as reinforcements in copper based
composites is considered very attractive to meet the increasing demands for
high performance heat sink materials and packages.
)1
(ear and mechanical properties of sintered copper=tin composites
contain graphite or molybdenum disulfide Hirotaka Eato a, , "asahiro
'akamaa, ;oshiro Iwai b, Eauo (ashida c, ;oshinori %asaki c
'he lubricant graphite and "o%) powders were coated with Cu to
reinforce their bonding to the Cu particles in the composites during sintering.
'he friction and wear properties of the materials were improved
(ear resistance of (C particle reinforced copper matri! composites, 4.E.
Beshpande, 6.;. Cin
'ungsten, being a refractory metal, provides some degree of wear and
arcing resistance when used with copper as an electrical contact material. Its
wear resistance is better than that of wear-resisting tool steels. 'ungsten
carbide undergoes no phase changes during heating and cooling and retains its
stability indefinitely.
%tudy of wear mechanisms in copper-based %iCp #)/0 by volume&
reinforced composite, Bhokey a, , 6.E. 4aretkar b
Copper-based composites appear to be a promising material for
engineering applications due to their e!cellent thermo physical properties
coupled with better high temperature mechanical properties as compared to
pure copper.
))
C+APTE" ? 1
&EED $% T+E P"$2ECT
'o study the fundamental characteristics of Aluminium and Copper. 7rom the
e!isting studies, improve the toughness of the aluminium and Copper
Composite material , through with various composition as discussed.
'o analye the Aluminum and copper with various compositions and adopt for
some specific applications.
$2ECTI0E $% P"$2ECT
Copper-aluminum alloy or brass is known for their corrosion resistance.
?rasses are stronger and more ductile than red and semi red brasses. 'hey have
high wear resistance and low friction coefficient against steel. 'he room
temperature phase transformations are slow and usually do not occur, therefore
these alloys are single phase alloys. 'he brones are used in bearings, gears,
piston rings, valves and fittings. Aluminum is added to copper in order to
improve mach inability and toughness. Aluminium increases the tensile
strength and ductility of the copper, but the composition can be ad@usted to
balance machinability and strength re<uirements. 'hese alloys have a slow fail
mechanism that temporarily prevents galling and seiing.
In this pro@ect we have been added aluminum 1/0,
)/0, and +/0 and which one is the best mechanical properties for automobile,
aircraft component. Inorder that some e!perimental investigation conducting
by us and finally we were concluded which one is the best mechanical
properties in this composition.
)+
. C+APTE" ? 3
MET+$D$#$4IE! T$ E AD$PTED
7or completion of this pro@ect the following methodologies are to be adopted.
1. Citerature %tudies
). Oumerical studies with Ansys 75A analysis
+. "etal mi!ing with various composition
8. Heat treatment process
:. %pecimen preparation
9. 'esting
2. 6eport analysis
)8
C+APTE" 5
P"$PE"TIE! A&D APP#ICATI$&! $% MAT"I) 6Cu7
Intro<uction
Copper is a chemical element with the symbol Cu and atomic number
).. It is a ductile metal with very high thermal and electrical conductivity. 4ure
copper is rather soft and malleable and a freshly-e!posed surface has a pinkish
or peachy color, which #besides gold and cesium& is unusual for metals, which
are usually silvery or grayish. It is used as a thermal conductor, an electrical
conductor, a building material, and a constituent of various metal alloys.
Properties of Copper
Cike gold and silver, copper is malleable. 'hat is, it can be bent and
shaped without cracking, when either hot or cold. Copper also is ductile,
that is, it can be drawn out into thin wire. ?esides electricity, copper also
is an e!cellent conductor of heat, making it an important metal in
cookware, refrigerators, and radiators.
Copper is easily worked, being both ductile and malleable. 'he ease
with which it can be drawn into wire makes it useful for electrical work
in addition to its e!cellent electrical properties. Copper can be machined,
although it is usually necessary to use an alloy for intricate parts, such as
threaded components, to get really good machinability characteristics.
Mood thermal conduction makes it useful for heat sinks and in heat
e!changers. Copper has good corrosion resistance, but not as well as
gold. It has e!cellent braing and soldering properties and can also be
welded, although best results are obtained with gas metal arc welding
):
Copper is a metal that does not react with water #H)*&, but the o!ygen
of the air will react slowly at room temperature to form a layer of
brown-black copper o!ide on copper metal.
/ses of Copper
Copper is an essential trace nutrient to all higher plant and animal life. In
animals, including humans, it is found widely in tissues, with concentration
in liver, muscle, and bone. It functions as a co-factor in various enymes
and in copper-based pigments. %ome molluscs have blue-green blood
resulting from a copper compound which they use to transport o!ygen.
Copper and copper alloy powders have been used in industrial applications
for many years. 4robably the best known is the self-lubricating bearing
which was the first ma@or application and still accounts for about 2/0 of
the granular copper powder used. 'his application takes advantage of the
ability to produce a component with controlled interconnected and surface-
connected porosity. 'he production of metallic filters also takes advantage
of this ability.
4ure copper powder is used in the electrical and the electronics industries
because of its e!cellent electrical and thermal conductivities. Alloyed with
'ungsten, inc, nickel and other elements, copper in powder form is used in
structural parts and friction materials. ?rasses, brones and other copper
alloys produced by powder metallurgy methods have the physical and
mechanical properties of their cast or wrought counterparts. Copper is used
also as an alloying element in iron powder components to enhance the
mechanical properties and control dimensional changes during sintering, the
addition being made either by mi!ing or by infiltration.
)9
In addition to the above applications of granular copper powder, a large
<uantity of copper and copper alloy powder is used in flake form, i.e., as a
powder whose thickness is small in relation to its other dimensions. %uch
powders are used, for e!ample, in antifouling paints, decorative and
protective coatings and printing inks.
Copper and copper alloy powders are also used in such nonstructural
applications as braing, cold soldering, and mechanical plating, as well as
for medals and medallions, metal-plastic decorative products and a variety
of chemical and medical purposes.
Copper has a significant presence in decorative art. It can also be used as an
anti-germ surface that can add to the anti-bacterial and antimicrobial
features of buildings such as hospitals.
Applications
Piping
1. Including water supply.
). 3sed e!tensively in refrigeration and air conditioning e<uipment because of
its ease of fabrication and soldering.
Electrical applications of
1. Copper wire.
). *!ygen-free copper.
+. 5lectromagnets.
8 4rinted circuit boards.
:. Cead free solder, alloyed with 'ungsten.
)2
9. 5lectrical machines, especially electromagnetic motors, generators and
transformers.
2. 5lectrical relays, electrical bus bars and electrical switches.
1 Dacuum tubes, cathode ray tubes, and the magnetron in microwave ovens.
.. (ave guides for microwave radiation.
Integrated circuits, increasingly replacing aluminium because it$s superior
)1
C+APTE" 8
P"$PE"TIE! A&D APP#ICATI$& $% A#/MI&I/M 6Al($@7
Intro<uction
It has the symbol Al and its atomic number is 1+. It is not
soluble in water under normal circumstances. Aluminum is the most abundant
metal in the 5arthTs crust, and the third most abundant element, after o!ygen
and silicon. It makes up about 10 by weight of the 5arthTs solid surface.
Aluminum is too reactive chemically to occur in nature as a free metal. Instead,
it is found combined in over )2/ different minerals.
,:-
'he chief source of
aluminum is bau!ite ore.
Aluminum is remarkable for the metalTs low density and for its ability to resist
corrosion due to the phenomenon of passivation. %tructural components made
from aluminum and its alloys are vital to the aerospace industry and are very
important in other areas of transportation and building. Its reactive nature
makes it useful as a catalyst or additive in chemical mi!tures, including
ammonium nitrate e!plosives, to enhance blast power.
Bespite its prevalence in the environment, aluminum salts are not known to be
used by any form of life. Also in keeping with the elementTs abundance, it is
well tolerated
,citation needed-
by plants in soils #in which it is a ma@or component&,
and to a lesser e!tent, by animals as a component of plant materials in the diet
#which often contain traces of dust and soil&. %oluble aluminium salts have
some demonstrated to!icity to animals if delivered in <uantity by unnatural
routes, such as in@ection. Controversy still e!ists about aluminiumTs possible
long-term to!icity to humans from larger ingested amounts.
).
Characteristics
5tched surface from a high purity #......10& aluminum bar, sie ::U+2 mm
Aluminum is a soft, durable, lightweight, ductile and malleable metal with
appearance ranging from silvery to dull gray, depending on the surface
roughness. Aluminum is nonmagnetic and non sparking. It is also insoluble in
alcohol, though it can be soluble in water in certain forms. 'he yield strength
of pure aluminum is 2=11 "4a, while aluminum alloys have yield strengths
ranging from )// "4a to 9// "4a.
,9-
Aluminum has about one-third the
density and stiffness of steel. It is easily machined, cast, drawn and e!truded.
Corrosion resistance can be e!cellent due to a thin surface layer of aluminum
o!ide that forms when the metal is e!posed to air, effectively preventing
further o!idation. 'he strongest aluminum alloys are less corrosion resistant
due to galvanic reactions with alloyed copper.
,9-
'his corrosion resistance is
also often greatly reduced when many a<ueous salts are present, particularly in
the presence of dissimilar metals.
Aluminium atoms are arranged in a face-centered cubic #7CC& structure.
Aluminum has a stacking-fault energy of appro!imately )// mNGm
)
.
,2-
Aluminum is one of the few metals that retain full silvery reflectance in finely
powdered form, making it an important component of silver paints. Aluminum
mirror finish has the highest reflectance of any metal in the )//=8// nm #3D&
and the +,///=1/,/// nm #far I6& regionsK in the 8//=2// nm visible range it
+/
is slightly outperformed by tin and silver and in the 2//=+/// #near I6& by
silver, gold, and copper.
Aluminum is a good thermal and electrical conductor, having 9)0 the
conductivity of copper. Aluminum is capable of being a superconductor, with a
superconducting critical temperature of 1.) kelvins and a critical magnetic field
of about 1// gauss #1/ milliteslas&.
%ome of the many uses for aluminum metal are inA
'ransportation #automobiles, aircraft, trucks, railway cars, marine
vessels, bicycles etc.& as sheet, tube, castings etc.
4ackaging #cans, foil, etc.&
Construction #windows, doors, siding, building wire, etc.&
A wide range of household items, from cooking utensils to baseball bats,
watches.
,+1-
%treet lighting poles, sailing ship masts, walking poles etc.
*uter shells of consumer electronics, also cases for e<uipment e.g.
photographic e<uipment.
5lectrical transmission lines for power distribution
"E" steel and Alnico magnets
%uper purity aluminium #%4A, ....1/0 to ......0 Al&, used in
electronics and CBs.
Heat sinks for electronic appliances such as transistors and C43s.
%ubstrate material of metal-core copper clad laminates used in high
brightness C5B lighting.
+1
4owdered aluminium is used in paint, and in pyrotechnics such as solid
rocket fuels and thermite.
Aluminium can be reacted with hydrochloric acid to form hydrogen gas.
In this pro@ect we have used sand mold casting for produce the re<uirement
sie. !an< casting, also known as san< mol<e< casting, is a metal casting
process characteried by using sand as the mold material.
It is relatively cheap and sufficiently refractory even for steel foundry use. A
suitable bonding agent #usually clay& is mi!ed or occurs with the sand. 'he
mi!ture is moistened with water to develop strength and plasticity of the clay
and to make the aggregate suitable for molding. 'he term Vsand castingV can
also refer to a casting produced via the sand casting process. %and castings are
produced in specialied factories called foundries.
*ver 2/0 of all metal castings are produced via a sand casting process.

+)
C+APTE" 9
DETAI#ED P"$2ECT P#A&
1. 4ro@ect identification
). Citerature survey
+. 4ro@ect area confirmation
8. "aterial identification and selection
:. Oumerical studies and learning
9. 75A with Ansys related works
2. Bocumentation and results discussion
1. Conclusion and future works
++
CHA4'56-1/
A&!;! E0A#/ATI$&
AO%;% is a complete 75A simulation software package developed by
AO%;% Inc = 3%A. It is used by engineers worldwide in virtually all fields
of engineering.
%tructural
'hermal
7luid #C7B, Acoustics, and other fluid analyses&
Cow-and High-7re<uency 5lectromagnetic.
P"$CED/"EA
5very analysis involves three main stepsA
4re-processor
%olver
post processor
+8
AO%;% 5DAC3A'I*O
!T"/CT/"A# A&A#;!I!
%tructural analysis is probably the most common application of the
finite element method. 'he term structural #or structure& implies not only
civil engineering structures such as bridges and buildings, but also naval,
aeronautical, and mechanical structures such as ship hulls, aircraft bodies,
and machine housings, as well as mechanical components such as pistons,
machine parts, and tools.
T;PE! $% !T"/CT/"A# A&A#;!I!
'he seven types of structural analyses available in the AO%;% family
of products are e!plained below. 'he primary unknowns #nodal degrees of
freedom& calculated in a structural analysis are displacements. *ther
+:
<uantities, such as strains, stresses, and reaction forces, are then
derived from the nodal displacements.
%tructural analyses are available in the AO%;% "ultiphysics, AO%;%
"echanical, AO%;% %tructural, and AO%;% 4rofessional programs only.
%'A'IC AOAC;%I%--3sed to determine displacements, stresses, etc. under
static loading conditions. ?oth linear and nonlinear static analyses.
Oonlinearities can include plasticity, stress stiffening, large deflection, large
strain, hyper elasticity, contact surfaces, and creep.
"*BAC AOAC;%I%??3sed to calculate the natural fre<uencies and mode
shapes of a structure. Bifferent mode e!traction methods are available.
HA6"*OIC AOAC;%I%--3sed to determine the response of a structure to
harmonically time-varying loads.
'6AO%I5O' B;OA"IC AOAC;%I%--3sed to determine the response of a
structure to arbitrarily time-varying loads. All nonlinearities mentioned under
%tatic Analysis above are allowed.
%45C'63" AOAC;%I%??An e!tension of the modal analysis, used to
calculate stresses and strains due to a response spectrum or a 4%B input
#random vibrations&.
?3CECIOM AOAC;%I%--3sed to calculate the buckling loads and
determine the buckling mode shape. ?oth linear #eigenvalue& buckling and
nonlinear buckling analyses are possible.
5F4CICI' B;OA"IC AOAC;%I%??'his type of structural analysis is only
available in the AO%;% C%-B;OA program. AO%;% C%-B;OA provides an
interface to the C%-B;OA e!plicit finite element program. 5!plicit dynamic
analysis is used to calculate fast solutions for large deformation dynamics and
comple! contact problems.
+9
In addition to the above analysis types, several special-purpose features are
availableA
7racture mechanics
Composites
7atigue
p-"ethod
?eam Analyses
E#EME&T! /!ED I& !T"/CT/"A# A&A#;!E!
"ost AO%;% element types are structural elements, ranging from
simple spars and beams to more comple! layered shells and large strain
solids. "ost types of structural analyses can use any of these elements.
'able :.1 5lements used in %tructural Analysis
MATE"IA# M$DE# I&TE"%ACE
+2
If we are using the M3I, we must specify the material we will be
simulating using an intuitive material model interface. 'his interface uses a
hierarchical tree structure of material categories, which is intended to assist in
us choosing the appropriate model for our analysis.
T;PE! $% !$#/TI$& MET+$D!
'wo solution methods are available for solving structural problems in
the AO%;% family of productsA the h-method and the p-method. 'he h-
method can be used for any type of analysis, but the p-method can be used
only for linear structural static analyses. Bepending on the problem to be
solved, the h-method usually re<uires a finer mesh than the p-method. 'he
p-method provides an e!cellent way to solve a problem to a desired level of
accuracy while using a coarse mesh. In general, the discussions in this
manual focus on the procedures re<uired for the h-method of solution.
!T"/CT/"A# !TATIC A&A#;!I!
A static analysis calculates the effects of steady loading conditions on
a structure, while ignoring inertia and damping effects, such as those caused by
time-varying loads. A static analysis can, however, include steady inertia loads
#such as gravity and rotational velocity&, and time-varying loads that can be
appro!imated as static e<uivalent loads #such as the static e<uivalent wind and
seismic loads commonly defined in many building codes&.
%tatic analysis is used to determine the displacements, stresses, strains,
and forces in structures or components caused by loads that do not induce
significant inertia and damping effects. %teady loading and response conditions
are assumedK that is, the loads and the structureTs response are assumed to vary
slowly with respect to time. 'he kinds of loading that can be applied in a static
analysis includeA
+1
5!ternally applied forces and pressures
%teady-state inertial forces #such as gravity or rotational velocity&
Imposed #nonero& displacements
'emperatures #for thermal strain&
7luences #for nuclear swelling&
PE"%$"MI&4 A !TATIC A&A#;!I!
'he procedure for a static analysis consists of these tasksA
?uild the "odel
%et %olution Controls
%et Additional %olution *ptions
Apply the Coads
%olve the Analysis
6eview the 6esults
#$AD T;PE!
All of the following load types are applicable in a static analysis.
DI!P#ACEME&T! 6/)* /;* /B* "$T)* "$T;* "$TB7
'hese are B*7 constraints usually specified at model boundaries to
define rigid support points. 'hey can also indicate symmetry boundary
conditions and points of known motion. 'he directions implied by the labels
are in the nodal coordinate system.
%$"CE! 6%)* %;* %B7 A&D M$ME&T! 6M)* M;* MB7
'hese are concentrated loads usually specified on the model e!terior.
'he directions implied by the labels are in the nodal coordinate system.
+.
P"E!!/"E! 6P"E!7
'hese are surface loads, also usually applied on the model e!terior.
4ositive values of pressure act towards the element face #resulting in a
compressive effect&.
TEMPE"AT/"E! 6TEMP7
'hese are applied to study the effects of thermal e!pansion or
contraction #that is, thermal stresses&. 'he coefficient of thermal e!pansion
must be defined if thermal strains are to be calculated. (e can read in
temperatures from a thermal analysis ,CB65AB-, or we can specify
temperatures directly, using the ?7 family of commands.
%#/E&CE! 6%#/E7
'hese are applied to study the effects of swelling #material enlargement
due to neutron bombardment or other causes& or creep.
4"A0IT;* !PI&&I&4* ETCC
'hese are inertia loads that affect the entire structure. Bensity #or mass
in some form& must be defined if inertia effects are to be included.
APP#; #$AD! T$ T+E M$DE#
5!cept for inertia loads, which are independent of the model, we can
define loads either on the solid model #key points, lines, and areas& or on the
finite element model #nodes and elements&. (e can also apply boundary
conditions via 'A?C5 type array parameters. Applying Coads 3sing 'A?C5
'ype Array 4arameters& or as function boundary conditions
8/
APP#;I&4 #$AD! /!I&4 %/&CTI$& $/&DA"; C$&DITI$&!
ICoads Applicable in a %tatic AnalysisJ summaries the loads
applicable to a static analysis. In an analysis, loads can be applied, removed,
operated on, or listed.
C$MP$!ITE! I& A&!;!
Composite materials have been used in structures for a long time. In
recent times composite parts have been used e!tensively in aircraft structures,
automobiles, sporting goods, and many consumer products.
Composite materials are those containing more than one bonded
material, each with different structural properties.
'he main advantage of composite materials is the potential for a high
ratio of stiffness to weight. Composites used for typical engineering
applications are advanced fiber or laminated composites, such as fiberglass,
glass epo!y, graphite epo!y, and boron epo!y.
AO%;% allows us to model composite materials with specialied elements
called layered elements. *nce we build our model using these elements, we
can do any structural analysis #including nonlinearities such as large
deflection and stress stiffening&.
#oa< Type Category
%or <etails on comman<s an< menu
paths for <efining these loa<s
Bisplacement
#3F,3;,3P,6*'F,6*';,6*'P&
Constraints B*7 Constraints in the AO%;% ?asic
Analysis Muide
7orce,"oment
#7F,7;,7P,"F,";,"P&
7orces 7orces#concentrated loads& in the
AO%;% ?asic Analysis Muide
4ressures#465%& %urface loads %urface loads in the AO%;% basic
Analysis Muide
'emperature#'5"4&,7luence
#7C35&
?ody loads ?ody Coads in the AO%;% ?asic
Analysis Muide
Mravity,%pinning,and so on Inertia loads Inertia Coads in the AO%;% ?asic
Analysis Muide
81
M$DE#I&4 C$MP$!ITE!
Composites are somewhat more difficult to model than an isotropic
material such as iron or steel. (e need to take special care in defining the
properties and orientations of the various layers since each layer may have
different orthotropic material properties. In this section, we will concentrate
on the following aspects of building a composite modelA
Choosing the proper element type
Befining the layered configuration
%pecifying failure criteria
7ollowing modeling and post-processing guidelines
C+$$!I&4 T+E P"$PE" E#EME&T T;PE
'he following element types are available to model layered composite
materialsA %H5CC.., %H5CC.1, %H5CC111, %*CIB89, and %*CIB1.1.
(hich element we choose depends on the application, the type of results that
need to be calculated, and so on. Check the individual element descriptions to
determine if a specific element can be used in our AO%;% product. All
layered elements allow failure criterion calculations.
!+E##99 - #inear #ayere< !tructural !hell Element
%H5CC.. is an 1-node, +-B shell element with si! degrees of freedom at
each node. It is designed to model thin to moderately thick plate and shell
structures with a side-to-thickness ratio of roughly 1/ or greater. 7or
structures with smaller ratios, we may consider using %*CIB89. 'he
%H5CC.. element allows a total of ):/ uniform-thickness layers.
Alternately, the element allows 1): layers with thicknesses that may vary
bilinearly over the area of the layer. If more than ):/ layers are re<uired, we
8)
can input our own material matri!. It also has an option to offset the nodes to
the top or bottom surface.
!+E##9' - &onlinear #ayere< !tructural !hell Element
%H5CC.1 is similar to %H5CC.. e!cept that it allows only up to 1//
layers and does not allow us to input a material property matri!. However,
%H5CC.1 supports plasticity, large-strain behavior and a special sandwich
option, whereas %H5CC.. does not. %H5CC.1 is also more robust for large
deflection behavior.
!+E##'8' ? %inite !train !hell
%H5CC111 is a 8-node +-B shell element with 9 degrees of freedom at
each node. 'he element has full nonlinear capabilities including large strain
and allows ):: layers. 'he layer information is input using the section
commands rather than real constants. 7ailure criteria are available using the
7C commands.
!$#ID.3 ? @?D #ayere< !tructural !oli< Element
%*CIB89 is a layered version of the 1-node, +-B solid element,
%*CIB8:, with three degrees of freedom per node #3F, 3;, 3P&. It is
designed to model thick layered shells or layered solids and allows up to ):/
uniform-thickness layers per element. Alternately, the element allows 1):
layers with thicknesses that may vary bilinearly over the area of the layer. An
advantage with this element type is that you can stack several elements to
model more than ):/ layers to allow through-the-thickness deformation slope
discontinuities. 'he user-input constitutive matri! option is also available.
%*CIB89 ad@usts the material properties in the transverse direction
permitting constant stresses in the transverse direction. In comparison to the
1-node shells, %*CIB89 is a lower order element and finer meshes may be
8+
re<uired for shell applications to provide the same accuracy as %H5CC.1 or
%H5CC...
!$#ID'9' ? #ayere< !tructural !oli< Element
%*CIB1.1 is a layered version of the )/-node +-B solid element
%*CIB.:, with three degrees of freedom per node #3F, 3;, 3P&. It is
designed to model thick layered shells or layered solids and allows up to 1//
layers per element. As with %*CIB89, %*CIB1.1 can be stacked to model
through-the-thickness discontinuities. %*CIB1.1 has an option to ad@ust the
material properties in the transverse direction permitting constant stresses in
the transverse direction. In spite of its name, the element does not support
nonlinear materials or large deflections.
In addition to the layered elements mentioned above, other composite
element capabilities e!ist in AO%;%, but will not be considered further in the
chapterA
!$#ID91* the )/-node structural solid element, with E5;*4'#1& W 1
functions similarly to a single layered
!$#ID'9' including the use of an orientation angle and failure
criterion. It allows nonlinear materials and large deflections.
!+E##3@* the 8-node shell element, can be used for rough,
appro!imate studies of sandwich shell models.
A typical application would be a polymer between two metal plates,
where the bending stiffness of the polymer would be small relative to the
bending stiffness of the metal plates. 'he bending stiffness can be ad@usted by
the real constant 6"I to represent the bending stiffness due to the metal
plates, and distances from the middle surface to e!treme fibers #real constants
88
C'*4, C?*'& can be used to obtain output stress estimates on the outer
surfaces of the sandwich shell. It is not used as fre<uently as
%H5CC.1,%H5CC.., or %H5CC111, and will not be considered for anything
other than sandwich structures in this section.
!$#ID31* the +=B 6einforced Concrete %olid 5lement, models an
isotropic medium with optional reinforcing in + different user-defined
orientations.
EAM'88 and EAM'89* the +=B finite strain beam elements, can
have their sections built up with multiple materials.
E#EME&T T;PE /!ED I& T+E P"$2ECT
!$#ID.1 Element Description
%*CIB8: is used for the +-B modeling of solid structures. 'he element
is defined by eight nodes having three degrees of freedom at each nodeA
translations in the nodal !, y, and directions.
'he element has plasticity, creep, swelling, stress stiffening, large deflection,
and large strain capabilities.
8:
%*CIB8: Meometry
TA"4E'5: Element Description
'A6M512/ is used to represent various +-B VtargetV surfaces for the
associated contact elements #C*O'A12+, C*O'A128, C*O'A12:,
C*O'A129 Q C*O'A122&. 'he contact elements themselves overlay the
solid, shell, or line elements describing the boundary of a deformable body and
are potentially in contact with the target surface, defined by 'A6M512/. 'his
target surface is discretied by a set of target segment elements #'A6M512/&
and is paired with its associated contact surface via a shared real constant set.
(e can impose any translational or rotational displacement, temperature,
voltage, and magnetic potential on the target segment element. we can also
impose forces and moments on target elements.
7or rigid target surfaces, these elements can easily model comple! target
shapes. 7or fle!ible targets, these elements will overlay the solid, shell, or line
elements describing the boundary of the deformable target body.
89
'A6M512/ Meometry
3OI M6A4HIC% 4A6' "*B5C DI5(
82
AC = C3 C*"4*%I'5 '5%'IOM %45CI"5O
"A'56IAC %5C5C'I*O
;*3OM$% "*B3C3%
81
AC = C3 %45CI"5O "5%H5B "*B5C
%*C3'I*O C*"4C5'I*O
A# @:D ? C/ 5:D
8.
BI%4CAC5"5O'
:/
F = C*"4*O5O'
:1
P = C*"4*O5O'
F; %H5A6
:)
FP %H5A6
:+
;P %H5A6
A# (:D ? C/ 8:D
:8
BI%4CAC5"5O'
::
) C$MP$&E&T
B C$MP$&E&T
:9
); !+EA"
:2
)B !+EA"
:1
;B !+EA"
A# ':D ? C/ 9:D
:.
BI%4CAC5"5O'
F = C*"4*O5O'
P - C*"4*O5O'
9/
91
F; %H5A6
;P = %H5A6
9)
FP = %H5A6
9+
Comparison Ta=le
Composition E MinC MaxC
Cu?5:D Al@:D
F %tress
P stress
Fyshear
;shear
P!shear
Beformation
Cu?8:D Al(:D
Fstress
Pstress
Fyshear
;shear
P!shear
Beformation
Cu?9:D Al:D
Fstress
Pstress
Fyshearr
;shear
P!shear
Beformation
98
CHA4'56-11
5F456I"5O'AC (*6E
I&!E" A## P+$T$!
9:
I&!E"T A## "E!/#T! ,IT+ 4"AP+!
HARDNESS TEST (ROCKWELL)
CU9% & AL 10%
CU80% & AL
20%
CU70% & AL
30%
93.06 100 382
CHARPY IMPACT TEST (J)
CU9% & AL 10% CU80% & AL 20% CU70% & AL 30%
84.66 119.33 2.66
99
92
C+APTE"
C$&C#/!I$&
Composite materials especially Cu-Al
)
*
+
composites having good
mechanical properties compared with the conventional materials. It is used in
various industrial application these materials having light weight along with
high hardness .It with stand high load compare with the e!isting materials are
most applicable in the engineering products instead of e!isting materials.
7inally considering the ma!imum value the composition ) i.e. Cu1/0
Al )/0 plays a minimum stress, so it has very good mechanical property
comparing to other compositions.
CHA4'56-1)
91
"E%E"E&CE!
,1- H.5. ?oyer, '.". Mall, "etals Handbook, Besk 5d., American %ociety
for "etals, "etals 4ark, *H, 1..1, pp. )/.19=)/.)1.
,)- M. Musmano, A. ?ianco, 6. 4olini, N. "ater. %ci. +9 #)//1& ./1=./2.
,+- N.C. Nohnson, 6.". Merman, Int. N. 4owder "etall. +/ #1& #1..8& .1=
1/).
,8- (.7. (ang, 4owder "etall. 8/ #8& #1..2& ).:=+//.
,:- 6. Nedamik, A. Oeubrand, N. 6odel, N. "ater. %ci. +: #)///& 822=
819.
,9- '.H. Ihn, %.(. Cee, %.E. Noo, 4owder "etallurgy, vol. +2, Oo. 8, 1..8,
pp. )1+=)11.
,2- D.O. 5remenko, 6.D. "inakova, ".". Churakov, %ov. 4owder "etall.
"et. Ceram. 1: #1.29& )1+.
,1- E. ?yoong, "echano-chemical process for production of high density
and ultrafine (GCu composite material, 3% 4atent no. :18)1/1 #1..1&.
,.- ".E. ;oo, 'ungsten skeleton structure fabrication method employed in
application of copper infiltration and (=Cu composite material fabrication
method thereof, 3% 4atent no. :.9+22+ #1...&.
,1/- %.5. Allen, 5. %treicher, 4roceedings of the 88th I555 Holm Conference
on 5lectrical Contacts, 1..1, pp. )29=)1:.
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