International Journal of Advance Foundation and Research in Science & Engineering (IJAFRSE)

Volume 1, Issue 2, July 2014

A Review on Al-Si Alloy as a Matrix material for MMCs.

Ajit Senapati*,Avinash Senapati,Omkarnath Mishra.
Department of Mechanical Engineering,GIET,GUNUPUR
senapati.ajit@gmail.com
ABSTRACT
Over the last few decades the interest of researchers has shifted from conventional materials to
Metal Matrix composite (MMC). The MMCs are now extensively used in the field of aerospace,
automotive, marine applications etc., instead of conventional materials because of their improved
mechanical and tribological properties like strength, stiffness, abrasion and impact resistance.
MMCs have replaced initially used Bronze alloys and cast iron components but because of their
poor seizure and wear resistance. Experiments have been conducted on the physical behavior of
these composites and are reported by a number of research scholars over the past couple of
decades. In this paper, the change in mechanical properties of Al-Si alloy are taken into
consideration with different reinforcements such as SiCp, Al5TilB, B4C, Quartz, Fly ash and AlN
based on literature review.
Index Terms: MMC, Al-Si alloy, Reinforcement, Wear, Tensile strength and hardness.

I.

INTRODUCTION

Recently, metal matrix composites (MMC) have gained importance in the field of engineering and
research. MMCs are materials which are made up of combination of metals and non-metals in specific
proportions. MMCs exhibit better physical and mechanical properties than conventional materials in
terms of density, strength, surface characteristics, microstructure etc. Metal matrix composites (MMC)
are composed of an elemental or alloy matrix in which a second phase is embedded and distributed to
achieve some property improvement [1]. Based on the size, shape and amount of the second phase, the
composite property varies [1]. Aluminium is abundantly available on earths crust. It is the 3rd most
abundant chemical element and the most abundant metal. Aluminum alloys are broadly used as a main
matrix element in Composite materials. Aluminium alloys for their light weight, have been in the net of
researchers for enhancing the technology [2]. In this paper Eutectic AlSi alloy (LM6) is taken as a matrix
material, with the reinforcement of fly ash, SiCp, Al5TilB, B4C, Quartz, AlN. LM6 has wide applications in
Marine, Automobile, Aerospace industries. But it exhibits. Poor tribological properties [2]. Hence the
desire in the engineering community to develop a new material with greater wear resistance and better
tribological properties, without much compromising on the strength to weight ratio led to the
development of metal matrix composites [2].
Above reinforcements were chosen due to the exhibition of specific properties. Fly ash is available as
waste material and can be utilized as the reinforcement. SiC is an excellent abrasive and maintain their
strength to very high temperatures [2]. Al5TilB acts as grain refiner and improves mechanical properties
of LM6 [3]. B4C increases the hardness and decreases density of base matrix [4].Quartz imparts hardness,
corrosion resistance & high chemical stability, in the materials it is reinforced in to [1]. AlN has high
thermal conductivity, high strength (greater than alumina), lower thermal expansion and good electrical
properties [5]. So, the degree of improvement in the properties with the reinforcement of above
materials with LM6 matrix is studied and described in this paper.
II. LITERATURE REVIEW
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Volume 1, Issue 2, July 2014

A. WEAR
S. Kumar et al. [6] produced composites of Al-Si alloy reinforced with 0, 5 & 10wt. % TiB2. The Vickerss
hardness of the composite at 5 kg load was determined and for the wear a track diameter of 45mm with
specimen pin of 8mm diameter and 15 mm height was taken that slide against AISI 52100 steel disc. It is
noted that the friction coefficient decreases with the addition of TiB2 particle irrespective of applied load.
The average coefficient of friction of alloy lies in the range of 0.37-0.40 and that of composite is less than
that of alloy and ranges between 0.25-0.35. The values of mentioned above are measured in the given
sliding range under steady state condition and are all mean values. The flow of metal is restricted by the
Presence of the second phase such as Si and TiB2. It is also found that the wear rate decreased
significantly not only with the increase in TiB2 in the composite but also due to the refined grain size. Fig
1. and Fig 2. Shows the variation of wear rate with respect to normal load and wt. % of TiB2. Prasad Rao
et al [7] showed that the size of the silicon particles, grain size or dendritic arm spacing affect the wear
rate of Al-Si. The improvement in wear resistance of the composite was not because of the presence of
TiB2, but also due to modification and refinement of eutectic Si and refinement of grain size [7].

Figure.1

Figure.2

Fly ash mostly consists of solid particles in the form of sphere known as precipitator fly ash. With
precipitator fly ash some partially solid or hollow spherical particles are also present [8]. The cost and
density of aluminium and its alloys get reduced with the incorporation of fly ash particles in them [9].
Rohatgi reported that the abrasive wear resistance of aluminium alloy is increased significantly with the
addition of the fly ash particles because of the hard alumina silicate constituent present in the fly ash
[10]. The twelve volume percent of fly ash shows lower wear rate compared to the alloy under same load
condition. Sudarshan et al experimented on the dry sliding wear of the Al-Si alloy and 6 and 12 vol. % fly
ash reinforced composite and found that at same load conditions the wear rate exhibited by the 6 volume
percent reinforcement shows twice the wear exhibited by 12 volume percent reinforced composite [11].

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Volume 1, Issue 2, July 2014

Figure .3

Figure.4

Figure 3, Shows the deviation of wear curve of composite from Al-Si alloy, under the effect of load calculated
by weight loss method. Fig 4. Deals with the variation of particle size range i.e., narrow size range and wide
size range and its effect on wear rates. S. K. Dey et al worked on finding out upper limit of the ultra-mild
wear in hyper eutectic Al-Si alloy considering a higher load of magnitude 5.0 N and concluded that ultramild wear in aluminium alloy with 18.5 %Si occurred due to the abrasive action of exposed Si on top and
fracture of larger particles. The mild wear damage was stabilized probably because of the formation of the
oil-residue layer after a prolonged sliding [12]. A.K. Prasad Rao et al reported that using various grain
refiners such as Al3B, Al1Ti3B, Al5Ti1B and Al3Ti for grain refinement of aluminium alloy significantly
improves the wear resistance characteristics of aluminium and aluminium alloys [13]. R.M. Mohanty used
boron carbide [B4C] as an alternative reinforcement to SiC and Al2O3 due to its higher hardness. And he
found that the composite shows increase in wear characteristics due to presence of hard B4C in the
compound [14].
B. TENSILE STRENGTH
Nikhilesh Chawla et al observed that, elastic modulus, microscopic yield and tensile strength of the alloy
increases with the increase in volume fraction of the SiC reinforcement coupled with lower ductility [15]. YU
Xiao-dong et all experimented on aluminium metal matrix composites reinforced with SiC with higher
volume fraction of about 50% and various particle size 10, 28, 40 and 63m and concluded that bending
strength increases with increasing volume fraction and decreasing particle size but fracture toughness
increases with increasing particle size [16]. J.R. Gomes et all investigated that SiC reinforced aluminium
alloys are widely used because of their effective combination of density, hardness and strength. The SiC
reinforced aluminium MMCs exhibits significant increase in elastic modulus, hardness, tensile strength and
wear characteristic [17]. M. Mahendra Boopathi et all noted that tensile property and yield strength
increases with increase in area fraction of SiC reinforcement in matrix coupled with significant decrease in
percentage rate of elongation [18].Ismail Ozdemir et al reported that in reinforced aluminium composite the
increase in tensile strength is not profound but after two step forging there is about 40% increase in tensile
strength. Up to 17% volume fraction of particulate silicon carbide (SiCp) the yield tensile strength of the
composite increases and then decreases with further addition of SiCp strength [8]. Tamer Ozben et al
investigated the effect of SiCp reinforced in Al-Si MMC with reinforcement ratio of 5, 10 & 15 wt. %. The
result shows an increment in tensile strength, hardness & density of aluminium MMC material with increase
in reinforcement ratio but decrement in impact toughness was also noticed [19]. Hayrettin Ahlatci et al ,
concluded that strength of composite increased without significant loss in toughness as amount of Si
increased up to 1% after which the strengths declined with further increase is Si content , when
experimented on mechanical properties of Al-Si with 60 vol. % SiC composite[20]. H. C. Anilkumar et al
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International Journal of Advance Foundation and Research in Science & Engineering (IJAFRSE)
Volume 1, Issue 2, July 2014

investigated on mechanical properties of fly ash reinforced Al-Si alloy. Different sizes of fly ash particles (425, 45-50, 75-100 micro meter) were used in preparing samples. Each set of samples had three types of
composites reinforced with weight fractions of 10, 15 & 20%. It was observed that tensile strength of the
composite decreases with increase in particle size and increases with increase in weight fraction of
reinforced fly ash particles [21]. Basavarajappa et al noted that, with the increase in weight percentage of fly
ash the tensile strength increases. When the dislocation takes place with the application of load, the
dislocation front is obstructed by hard fly ash particles that act as barriers [9]. N. Suresh et al investigated
on composites reinforced with disperse cenospheres of fly ash (from 1-10 %) in the Al-Si alloy matrix. The
increase in ultimate tensile strength for the aluminium composite is of 8.5% for 1% addition (158.8 MPa)
and 44.3% for 10% (211 MPa) addition of the cenospheres of fly ash to the aluminium alloy [22]. M. Sayuti
et al prepared tensile test sample according to ASTM standards with 5%, 10%, 15%, 20%, 25% and 30% wt.
fraction of SiO2 of 65 microns. There is decrease in tensile stress value along with elastic modulus with
increase in addition of SiO2 particulate. On the other hand the tensile strength would be increased by
decreasing SiO2 particulate less than 30% by weight fraction along with particle size as 230 mesh-65
microns [5]. A. M. S. Hamouda et al experimented on the processing and characterization of SiO2p reinforced
Al-Si alloy matrix. From the experiment it was observed that with the increased addition of SiO2p there is a
decrease in tensile strength and modulus of elasticity in Al-Si alloy. The Fig 5. Shows the variation of tensile
strength with respect to Vol. fraction of SiO2.

Figure 5. Tensile Strength vs. Vol. Fraction of SiO2

Figure 6. Youngs Modulus vs. Vol. Fraction of SiO2

Fig 6. Explains the variation of average Youngs Modulus with respect to increase in Vol. fraction of SiO2
[23]. S. Sulaiman et al studied the mechanical properties of Al-Si alloy by varying the Vol. fraction of SiO2
reinforcement from 5% to 30%. It was observed that split tensile strength and Youngs modulus decreased
with increase in Vol. fraction of SiO2 in the composite. The reason behind the decrease in mechanical
behavior is the compressive strength of the quartz particulate reinforced in the alloy matrix. It was noticed
that the compressive strength of the composite increased significantly with increase in SiO2. It is clear that,
due to the influence of quartz (SiO2) particles, the compressive strength effectively dominates its influence
over tensile strength [31]. M. Kok prepared Al-Si metal matrix composite with three different sizes of Al2O3
particles and also with three different wt. fractions ranging up to 30% wt. fraction. The effect of Al2O3
particles on the mechanical properties such as hardness and tensile strength of the composite were
investigated. He noticed that, the tensile strength of the Al2O3 reinforced aluminium alloy increases with
decreasing size and increasing weight percentage of the particles, but the elongation of the MMCs decreases
[24]. Lim Ying Pio et al investigated on the effect grain refiners such as Al5Ti1B on the casting quality and
also on the mechanical properties. For experiment, samples were prepared varying Al5Ti1B from 0 wt. % to
1 wt. %, incremented by 0.25 wt. %. It was found that the inoculation of aluminium alloy with Al5Ti1B
significantly improves the tensile strength (by 39%) and this improvement is achieved with optimal
addition level of grain refiner of 0.5% [3].

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C. HARDNESS
The resistance to indentation is known as hardness. Instruments like Brinnells, Rockwells and Vickers are
used for measuring hardness of materials. M. Singh et al studied the effect of addition of ceramic particles in
the composites and concluded that the addition of ceramic particles increases the hardness of composites
[25]. Y. Sahin et al investigated that there is more or less a linear relationship between the increase in
hardness of Al-Si composite and the volume fraction of particulates in the alloy matrix due to increase in
ceramic phase in the matrix [26]. Rabindra Behera et all studied the effect of different weight fractions of
SiCp reinforced in Al-Si alloy and their influences on machining parameters were noted. It was seen that
there is an increase in the cutting forces at the same cutting conditions with the increase in weight fraction
of SiCp in the MMC and the hardness varies linearly with weight fraction [27]. Rabindra Behera et al carried
out machining tests on Al-Si MMCs with different cutting speeds (30, 68 and 103 m/min) and depth of cut
(0.5, 1 and 1.5 mm) at constant feed of 0.05 mm/rev, and found that there is a decrease in cutting force
components Ft , Ff and Fr with increase in cutting speed of the composite reinforced with 7.5 wt%,10
wt%,12.5wt% of SiCp under same cutting conditions .It also reveals that there is linear increase in weight
percentage of SiCp in composite [28]. Ramachandra et al studied the mechanical properties of hypoeutectic
Al-Si fly ash reinforced composite and concluded that there is an increase in hardness, tensile strength and
decrease in density as the fly ash content increased [29].Wong W.L.E. et al have reported that the reason
behind the increase in hardness is the presence of very hard ceramic reinforcements which acts as barrier to
the dislocation movement within the matrix and thus exhibit greater resistance to indentation [30]. N.
Suresh et al produced Al-Si composites reinforced with cenospheres of fly ash and studied its mechanical
properties. It was observed that the hardness increases by 8.6% for 1% fly ash and by 34.7% for 10% fly ash
based composite, compared with the base alloy [22]. M.N. Wahab et al studied the Characteristic of
aluminium metal matrix composite reinforced with aluminium nitrate and found that hardness of the matrix
increased to 89Hv from 44Hv as the Al composite reinforced with 5 wt% AlN powder. The increase in
hardness value was an indication of the contribution of AlN particles towards the improvement of hardness
of the matrix [2]. S. Sulaiman et al studied Quartz particulate reinforced Al-Si MMC by varying particulate
addition by volume faction and conducted tensile test, hardness test and scanning electron microscopic
studies. Based on the experiments conducted upon the variation in hardness of the Al composites
corresponding to the variation in the volume fraction of Quartz particulate, it is found that value of hardness
of composite increases with the increase in Quartz particulate by volume fraction % [31]. M. Sayuti et all
reported that for 30% weight fraction addition of SiO2 the maximum hardness value based on Rockwell
superficial 15N-S scale was 67.85 [5]. A. M. S. Hamouda et al determined hardness value for different
composite reinforced with different volume fraction of quartz in Al-Si alloy. It was observed that the
hardness value of the Quartz reinforced composites increased with increase in Quartz particulate by volume
fraction [23]. The variation of the hardness value vs. volume fraction of Quartz particulate is shown in Fig.7.

Figure 7 Hardness Rockwell Superficial 15T VS Quartz

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Ling Ying Poi et al 2005 investigated the effect of Al5Ti1B grain refiner on the mechanical property of AlSi alloy and found out that the highest hardness is achieved at 0.5 wt% of grain refiner and no significant
improvement was observed above the level of addition. The hardness was increased to 60 Rockwell HRD
because of the effect of the grain refinement on Al-Si alloy [3]. M. N. Wahab et al carried out an
experiment to study preparation and characterization of Al-Si metal matrix composite reinforced with
aluminium nitride. The hardness of the Al-Si was found to be 44 Hv which increased to 89 Hv for
composite reinforced with 5% wt. % AlN powder. With the addition of AlN powder a significant increase
in hardness of the alloy was observed. The higher value of hardness indicates that the hardness of the
composite is improved with the existence of particulates in the matrix. As aluminium is soft,
reinforcements especially ceramics material being hard, possibly contribute towards hardness positively.
The constraint to the plastic deformation of the matrix during the hardness test increases due to the
presence of stiffer and harder AlN reinforcement [2].
III. CONCLUSION
In this study, the properties of Al-Si alloy based MMCs with different reinforcements like SiCp, Al5TilB,
B4C, Quartz, Fly ash and AlN are accounted. These reinforcements showed changes in various properties
like wear, tensile strength, hardness as noted below:
(a)Wear
It is found that the wear rate decreased significantly with the increase in TiB2 in the composite and also
due to the refined grain size. The abrasive wear resistance of aluminium alloy increases significantly with
the addition of fly ash particles because of the hard alumina silicate constituent present in the fly ash. Dry
slide wear decreases with increasing volume fraction of fly ash in the composite. Ultra-mild wear in
aluminium alloy with 18.5 %Si occurred due to the abrasive action of exposed Si on top and fracture of
larger particles. The mild wear damage was stabilized probably because of the formation of the oilresidue layer after a prolonged sliding. Reinforcement of various grain refiners such as Al3B, Al1Ti3B,
Al5Ti1B and Al3Ti etc. significantly improves the wear resistance characteristics of aluminium alloys. The
composite shows increase in wear characteristics due to the presence of hard B4C in the compound.
(b)Tensile Strength
It is concluded that tensile strength of the alloy increases with the increase in volume fraction and area
fraction of SiC reinforcement coupled with lower ductility and significant decrease in percentage rate of
elongation respectively. The yield tensile strength of the composite increases up to 17% volume fraction
of particulate silicon carbide (SiCp) and then decreases with further addition of SiCp. Tensile strength of
the composite decreases with increase in particle size and increases with increase in weight fraction of
reinforced fly ash particles. There is a decrease in tensile stress value along with elastic modulus with
increase in addition of SiO2 particulate. The reason for the decrease in tensile strength is the dominance
of compressive strength of the SiO2 reinforced alloy matrix over the tensile strength. On the other hand
the tensile strength would be increased by decreasing SiO2 particulate less than 30% by weight fraction
along with particle size as 230 mesh-65 microns. Tensile strength of the Al2O3 reinforced aluminium
alloy increases with decreasing size and increasing weight percentage of the particles with the decrement
in elongation of the MMCs. Inoculation of aluminium alloy with grain refiners like Al5Ti1B improves the
tensile strength significantly with optimal addition level of this grain refiner.
(c) Hardness

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There is an increase in the cutting forces at the same cutting conditions with the increase in weight
fraction of SiCp in the MMC. Also hardness varies linearly with weight fraction. There is an increase in
hardness as the fly ash content increases in the composite. Addition of ceramic particles increases the
hardness of composites. The reason behind the increase in hardness is the presence of very hard ceramic
reinforcements which acts as barrier to dislocation movements within the matrix and thus exhibit
greater resistance to indentation. Reinforcement of Quartz particulates and AlN particles increases
hardness of the matrix
Thus different desirable properties can be achieved with different types of reinforcements in the base
alloys. With properties like better wear resistance, hardness, less density, better tensile strength etc.,
aluminium MMCs prove to be vital in the development of future technology. Hence study of these MMCs
is important for development of new products in industrial sectors like automobile, aerospace, marine
and many more.
IV.

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