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Materials Today: Proceedings 2 (2015) 2984 2990

4th International Conference on Materials Processing and Characterization

Characterization of Aluminium Matrix Composites (AA6061/B 4C)

Fabricated by Stir Casting Technique
B. Ravia*, B. Balu Naikb, J. Udaya Prakashc
a
Department of Mechanical Engineering, Swarna Bharathi Institute of Science & Technology,Khammam -507 002, Telangana,India
b
Department of Mechanical Engineering, JNTUH, Hyderabad -500 085, Telangana,India
c
Department of Manufacturing Engineering, Anna University,Chennai -600 025, Tamilnadu, India

Abstract

Aluminium Matrix Composites (AMCs) are the competent material in the industrial world. They are widely used in aerospace,
automobile, marine industries, etc. due to their excellent mechanical properties. The Aluminium matrix is strengthened when it
is reinforced with hard ceramic particles like SiC, Al2O3, B4C, etc. resulting in enhanced wear resistance and improved strength
to weight ratio. Based on the type of reinforcement, size and morphology, the AMCs are fabricated by different methods. Among
the manufacturing processes, the conventional stir casting is an attractive processing method for producing AMCs as it is
relatively inexpensive and offers a wide range of materials and processing conditions. An attempt has been made to fabricate
Aluminium Matrix Composites (AA6061) reinforced with Boron Carbide (B 4C) of average particle size 25 m with different
weight percentages using indigenously developed stir casting method. The homogeneous dispersion of B4C particles in the
AMCs was revealed from the optical micrographs. Mechanical characterization was done and the tensile strength and hardness
has increased with the increase in weight percentage of B4C particles.

2015
2014Elsevier
The Authors.
Ltd. AllElsevier Ltd. All rights reserved.
rights reserved.
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peer-review under
under responsibility
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the conference committee
committee membersmembers
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Keywords: Aluminum Matrix Composites, Stir Casting, Tensile Test, Hardness.

1. Introduction

Aluminium Matrix Composites (AMCs) are the competent material in the industrial world. Due to their
excellent mechanical properties, they are widely used in aero space, auto mobiles, marines, etc. [Hemanth Joel

* Corresponding author: B. Ravi, Cell: +91-9704232325; fax: +0-874-223-7777 .

E-mail address: bravi1234@gmail.com

2214-7853 2015 Elsevier Ltd. All rights reserved.

Selection and peer-review under responsibility of the conference committee members of the 4th International conference on Materials Processing
and Characterization.
doi:10.1016/j.matpr.2015.07.282
 B. Ravi et al. / Materials Today: Proceedings 2 (2015) 2984 2990 2985

et al., Feng YC et al., Ramesh CS et al.]. The aluminium matrix gets strengthened when it is reinforced with the
hard ceramic particles like SiC, Al2O3, B4C, etc. resulting in enhanced wear resistance and strength to weight
ratio than the conventional alloys [Ramesh CS et al., Lashgari HR et al.]. Boron Carbide reinforced aluminium
matrix composites (AMCs) are more focused in nuclear industries because of their good neutron absorption
capability without forming long lived radionuclides [Abenojar J et al., Shorowordi KM et al.]. In addition,
AMCs absolutely posses good mechanical and physical properties such as light weight, high strength, high
specific modulus, low coefficient of thermal expansion and good wear resistance. Based on the type of
reinforcement, size and morphology, the AMCs are fabricated by different methods such as Stir Casting,
Squeeze Casting, Spray Deposition, Liquid Infiltration and Powder Metallurgy [Altinkok N et al., Kaczmar JW
et al.]. The processing method influences the mechanical and the tribological behaviour of the AMCs.
Enhancement of AMC properties requires the successful incorporation of ceramic particles into the
aluminium matrix and obtaining good bonding between them. The above listed processing methods can be
categorized into solid state processing and liquid state processing. Liquid method of processing is preferred
because of its simplicity, ease of adoption and applicability to mass production [Michael Rajan HB et al.]. Stir
casting is the widely used liquid method of processing to prepare AMCs where the aluminium matrix is
completely melted and ceramic particles are added into the molten metal in a vortex created using a
mechanical stirrer [Kok M et al.].

A limited research work has been carried out on Aluminium Matrix Composites (AMCs) reinforced with
B4C due to higher raw material cost. B 4C is a robust material having excellent chemical and thermal stability,
high hardness and low density. Hence, B4C reinforced aluminium Matrix Composite has gained more
attraction with low cost casting route [Toptan F et al., Shorowordi KM et al., Kerti I et al.]. It is used for
manufacturing bullet proof vests, armour tanks etc. [Abenojar J et al.]. In this paper fabrication,
characterization and evaluation of Mechanical properties of AMCs reinforced with B 4C are detailed.

2. Experimental Procedure

2.1. Fabrication Process

The fabrication of AA6061-B4C composite used in this study was carried out by using a Stir Casting method. In
this, firstly AA6061 alloy in the form of 25 mm diameter rods cut into 75mm length was placed in a clay graphite
crucible. It was then melted in a resistance heated muffle furnace to the desired temperature of 8500C. In the mean
time B4C particulates of size 25 m were heated in another crucible to a temperature of 250 0C to remove moisture,
and the die was preheated to a temperature of 6000C. Then the boron carbide particulates were mixed into the
molten metal. The crucible was covered with a flux and degassing agents to improve the quality of aluminium
composite casting. The mixture was stirred continuously by using mechanical stirrer for about 10-15 minutes at an
impeller speed of 400 rpm. The melt temperature was maintained at 8000C during addition of the particles. The
molten metal was then poured into the preheated die to cast plates of 100mmx100mmx10mm size. Same procedure
is followed to fabricate AMCs with 5 and 10 wt. % B4C. The chemical composition of aluminium alloy (AA6061)
used in this research work is shown in table 1.The process parameters used for stir casting is shown in table 2. The
stir casting set up used for producing composite plates and the composite castings were shown in figures 1 and 2
respectively.

Table 1. Chemical composition of Aluminium alloy (AA6061)

Elements Si Fe Cu Mn Mg Zn Cr Ti Al
% by 0.64 0.293 0.261 0.095 0.88 0.033 0.089 0.032 Balance
weight
2986 B. Ravi et al. / Materials Today: Proceedings 2 (2015) 2984 2990

Table 2. Process parameters used for Stir Casting

Parameters Units Value

Temperature of Melt 0C 850
Preheated temperature of B4C Particles 0C 250
Preheated temperature of die 0C 600
Spindle Speed rpm 400
Stirring time min 10-15
Powder feed rate g/s 0.8-1.2

Figure 1. Stir Casting Set-up used for fabrication of Composite Plates (AA 6061/B4C)

Figure 2. Casted Composite Plates (AA6061+B4C 0, 5, 10%)

 B. Ravi et al. / Materials Today: Proceedings 2 (2015) 2984 2990 2987

2.2. Microstructure characterization & Mechanical Testing

The specimens from the cast AMCs were prepared for microstructures study as per the standard metallographic
procedure. After thorough polishing using abrasive paper and velvet cloth, the specimens were etched using Kellers
reagent (HNO3 + HCL + HF). The etched specimens were observed under optical microscope.

The microhardness of polished samples was measured using Vickers hardness tester at different locations with a
load of 300g for 10 seconds.

The tensile specimens were prepared as per ASTM 08 [ASTM standard E8 et al. (2004)]. The dimensions of the
specimen are shown in figure 3.The Ultimate Tensile Strength (UTS) was measured using a computerized Universal
Testing Machine.

Figure 3. Dimensions of Tensile Specimen of AA6061-B4C Composite

3. Results and Discussions

3.1. Evaluation of Microstructure

The optical micrographs of the fabricated AMCs with different wt. % of B4C reinforcement of 25m size are
shown in figure 4 (a), (b) and (c). The micrographs reveal that B4C particles are uniformly distributed in the
aluminium matrix for 5 and 10 wt. % B4C particles, respectively. This behaviour can be attributed to the effective
stirring action and the use of appropriate process parameters, in addition to the greater wettability of the B 4C
particles with the aluminium alloy. The greater wettability of B4C particles with the aluminium alloy might be due
to formation of liquid B2O3 layer on the B4C particles. This liquid layer, which forms above certain temperature on
the surface of B4C, increases wettability as there is a liquid-liquid reaction, whereas the same pattern is resulted
[P.K. Jayashree et al]. It is also observed that the addition of B4C particles prevented the grains from growing as
large as the pure AA6061 alloy. Addition of reinforcement particles in the melt increased the number of nucleation
sites, by providing additional substrate during solidification, and decreased the grain size.
2988 B. Ravi et al. / Materials Today: Proceedings 2 (2015) 2984 2990

A B C

100X 100X 100X

Figure 4 a) AA6061 without reinforcement b) AA6061 matrix with 5% B4C c) AA6061 matrix with 10% B4C

3.2. Mechanical Properties

The mechanical properties such as hardness and tensile strength of the AA6061/B4C composites are discussed
briefly in the following sections.

3.2.1. Hardness of the Composites

The hardness results of the AA6061/B4C composites are shown in Figure 5 (b).The hardness value is increased
by increasing the wt % of B4C reinforcement particles in the composites, as the presence of hard reinforcement
particles on the surface resists the plastic deformation of the material. The strength of the grain boundaries increases
to maximum level and dislocation of atoms is decreased by increasing the wt% of reinforcement, which gives
strength to the matrix and thereby hardness of the composite gets increased. The same phenomenon is observed
[K. Kalaiselvan et al].

10 70
ASTM Grain Size

8 68
6 66
HV

4 64
2 62
0 60
0 5 10 0 5 10
B4C (wt. %) B4C (wt. %)

(a) (b)

Figure 5. The effects of percentage of B4C particulates on the a) grain size b) hardness of stir casted AMCs.
 B. Ravi et al. / Materials Today: Proceedings 2 (2015) 2984 2990 2989

3.2.2. Tensile Strength of the Composites

The tensile strength results of the AA6061/B4C composites are shown in figure 6. It is observed that ultimate
tensile strength is increased by increasing the percentage of the B4C particles in the composite. This is due to better
interfacial bonding between the matrix and the reinforcement which transfers and distributes the load from the
matrix to the reinforcement. Therefore the reinforcement particle tends to bear the entire load that has been acted
upon the matrix. The addition of B4C particles in the matrix induces much strength to matrix alloy by offering more
resistance to tensile stresses. It is well known that the thermal expansion coefficient of B4C particle is 5x10-6/0C and
for aluminium alloy is 23x10-6/0C. The thermal mismatch between matrix and the reinforcement causes higher
dislocation density in the matrix and load bearing capacity of the hard particles which subsequently increases the
composites strength [Toptan F et al.].

160
Ultimate Tensile Strength

150
140
(MPa)

130
120
110
100
0 5 10
B4C (wt. %)

Figure 6. The effects of percentage of B4C particulates on the Ultimate Tensile Strength of stir casted AMCs.

4. Conclusions

The AA6061/B4C composites were produced by stir cast route with different weight percentage of reinforcement
and the microstructure, mechanical properties were evaluated. From this study, the following conclusions are
derived.

1. Production of homogeneous AA6061/B4C composite could be achieved by using Stir Casting

Technique.

2. The optical metallographic study revealed the presence of B4C particles in the composite with
homogeneous dispersion.

3. Addition of B4C reinforcement particles decreased the grain size of the matrix.

4. The microhardness of the composites increased from 62 HV to 68 HV with incremental weight

percentage of B4C particles.

5. The B4C reinforcement has enhanced the tensile strength of Aluminium Matrix Composites (AMCs)
from 117 MPa to 145 MPa.
2990 B. Ravi et al. / Materials Today: Proceedings 2 (2015) 2984 2990

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