G B Veeresh Kumar et. al.

Letter

SYNTHESIS AND CHARACTERIZATION OF TiO2 REINFORCED Al6061 COMPOSITES

G B Veeresh Kumar1*, P S Shivakumar Gouda2, R Pramod1, C S P Rao3

1
Department of Mechanical Engineering, Amrita School of Engineering, Bengaluru, Amrita Vishwa Vidyapeetham, Amrita Uni-
versity, India.
2
Department of Mechanical Engineering, SDM College of Engineering & Technology, Visvesvaraya Technological University,
Dharwad - 580 002, India.
3
Department of Mechanical Engineering, National Institute of Technology, Warangal, Telangana State, India

*Author to whom correspondence should be addressed: E-mail: veeru232@gmail.com

Received 29 February 2016; accepted 13 December 2016

ABSTRACT
This article presents the investigative work carried out to study the relationship between the physical, mechanical and tri-
bological characteristics of aluminum matrix composites reinforced with Titanium dioxide (TiO2). The powder metallurgy
route of production was followed to produce the composites (Al6061 containing 3 wt% TiO2). The composites were subjected
to sequences of physical, mechanical and tribological investigations. The outputs of the experiments done indicate that the
increase in TiO2 fillers increase the density of the composite and the values accepted by the rule of mixtures. The result of
mechanical characterisation of Al6061-TiO2 composites was noticed to increase significantly with higher TiO2 content in the
matrix, with loss in ductility. The dry sliding wear studies of Al6061-TiO2 composite showed greater wear resistance than
Al6061 matrix and the composite containing higher filler content displayed the superior physical, mechanical and tribological
characteristics.

Key words: Metal Matrix Composites, Physical properties, Mechanical Properties, Wear.

1. INTRODUCTION extrudability and are widely applied in the engineering

Metal Matrix Composites (MMCs) are widely applied and
preferred materials for high technological applications
such as aeronautical, defence and in automobile sector due
to their improved characteristics in comparison with the
matrix alloy through weight advantages [1]. The non-fer-
rous materials are preferred over ferrous metals as matrix
materials like titanium, magnesium, aluminum and their
alloys, for the fabrication of MMCs. The secondary mate-
rials called reinforcements are classified with their shape
and size as particulates, whiskers and fibres. The particu-
late composites are preferred because of their form and
being cost effective [2]. Al-alloy based MMCs are gaining
recognition in several fascinating applications, and Al6061
is the best option as a matrix material to fabricate com-
posites with respect to their formability property and the
choice of tailoring the composites strength by heat treat-
ment, further the particulate reinforced composites display
upgraded scratch resistance and they are used as many me-
chanical components like pistons, cylinder blocks, piston
insert rings, calipers, brake disks, connecting rod, vibrator
component, contactors, microwave filters, space structures
and impellers [3, 4]. As the amount of filler material in-
creases in the base material, the MMCs strength found that
enhanced also with the reduced particulate size [5]. These
fine particulate reinforced Al-MMCs directed towards
newer materials produced for different engineering appli-
cations with better characteristics [6].
Out of different grades of Al-alloys, Al6061 is subjected
to extensive studies by numerous researchers due to their
good mechanical properties, anti-corrosiveness, easily
Advanced Composites Letters, Vol. 26, Iss.1, 2017
fields like high way, construction, automobile and in ship-
building sectors [7]. Ramesh et al, studied Al6061-TiO2
MMCs and confirmed the developed composites demon-
strated improved hardness with better coefficient of wear
in comparison with unreinforced alloy. From the investi-
gation they concluded that the composite with 8 wt% filler
content resulted lower coefficient of wear [8]. Straffelini et
al, [9] in their work stated that the hardness of the matrix
has greater influence on dry wear of Al6061-Al2O3 MMCs.
Yu et al, [10] indicated that the temperature and applied
load has greater effect on the dry sliding wear behaviour
of Al6061 - SiC MMCs and indicated reduction in the
amount of wear with the raise in applied load. How and
Baker [11], studied Al6061 with saffil (Al2O3) fibre rein-
forced composite and confirmed saffil reinforcement was
excellent in enhancing resistance to wear of composites.
It was specified that the MMCs with SiC filler exhibited
enhanced resistance to wear [12]. Basavarajappa et al, [13]
established that the parameters like microstructure, sliding
distance and speed, load and dry or wet sliding friction and
wear of MMCs, higher wear and silicon carbide particu-
lates cracking; and seizing of the composites occur through
dry sliding at higher loads. Researchers, described that the
most significant parameter was the sliding distance, which
has largest outcome on the wear characteristic than sliding
speed and applied normal load of MMCs [14]. Ramesh et
al, [15] examined the wear of Al6061 filled through Ce-
rium oxide, Al2O3 and SiC MMCs and confirmed that the
hot extruded MMCs with cerium oxide as filler content
showed least wear rates under similar experimental envi-
ronments. Carried out additional studies on Al6061-Si3N4
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MMCs and stated that the increased hardness & strength
attributed due to increase in Si3N4 content in matrix and
the improvement in Young’s modulus, also stated that the
progression in tensile and compressive strengths at the cost
of reduced hardness in Al6061-Gr MMCs with increase in
graphite content [16]. Further study on Al6061-albite re-
inforced MMCs, through the obtained results they noticed
that the increase in albite content resulted the reduction
of ductility and improvement in hardness, Young’s modu-
lus and tensile strength of MMCs [17]. The current study
is intended at the production of Al6061-TiO2 MMCs with
several weight fractions of TiO2 contents and to evaluate
their density, hardness, microstructure, ultimate tensile
strength, percentage elongation and wear properties.
2. SYNTHESIS AND INVESTIGATIONAL DETAILS
OF MMCS
2.1 Details of Materials selected
In the current work Al6061 as matrix and Titanium diox-
ide (TiO2) 50 µm as filler was selected. The MMCs were
produced by Powder Metallurgy (P/M) technique, the re-
quired alloying and other materials for MMCs in the pow-
der form were supplied by Shubmets and Carbideindia,
Mumbai, India. The Al6061 base alloy compositional de-
tails are given in Table 1 and Table 2 provides the informa-
tion about the properties of the selected materials.
Table 1: Compositional details of Al6061 alloy in weight frac-
tions.
Chemical
Fe Mn Si Cu Cr Ti Zn Mg Al
composition
Al6061 0.23 0.03 0.62 0.22 0.22 0.01 0.10 0.84 Balance
Table 2: Al6061 and Titanium dioxide materials properties.
Material Density Hardness Elastic Modulus Tensile Strength
(g/cc) (HB500) (GPa) (MPa)
Al6061 2.7 30 70-80 115
TiO2 4.23 89* 230 680**
* Kg/mm2;** Compressive Strength.
2.2 Synthesis of MMCs
The Al6061-TiO2 composites were synthesized by the P/M
route, which involves the powder mixing, cold pressing
and sintering. Matrix alloy powders were prepared by a
planetary ball mill and are then mixed along with different
various weight percentages of TiO2 reinforcement. After
mixing, the powders were compacted in a cylindrical die
and subjected to compaction at 160 MPa of pressure. The
compacts degassed, sintered in vacuum furnace at 400 °C
of temperature for 90 min duration and then decreased to
room temperature inside the furnace. The Cylinder-shaped
pins of dia 15 mm × 150 mm in length were acquired and
machined to conduct various tests.
2.3 Details of the experiments conducted
The Al6061-TiO2 composites test specimens were ma-
chined with respect to ASTM standards. The composite
Advanced Composites Letters, Vol. 26, Iss.1, 2017
G B Veeresh Kumar et. al. Letter
materials density was determined by the weight and vol-
ume of the composite pieces. The microscopic, hardness,
tensile and wear tests were conducted on the composite ex-
amples. Systematically polished and glass finished inves-
tigational samples were inspected under Scanning electron
microscope to get micrographs. The hardness tests were
carried out by Brinell hardness (MRB 250) tester with a
steel ball indenter of 10 mm at 500 kg load for 30 s. The
tensile and percentage elongation tests were evaluated us-
ing computerised UTM of Fine Spavy Associates model
TUE – 400C of 400 KN with 4 N least count. Compu-
terized pin-on-disc machine of Ducom, Bangalore was
used for conducting wear tests. The diameter of composite
pin samples of diameter 10 mm and 25 mm in length and
EN31 steel disc having a hardness of HRC 60 was used
as counter disc. By using 1.0 µm least count LVDT trans-
ducer, the loss of cylindrical pin material due to wear were
noted in microns. The volumetric loss of material due to
wear was evaluated from the height loss of the pin during
the pin-on-disc wear test. Composite pin was subjected to
10 to 40 N load and 3 km sliding distance was maintained.
The 0.1 µm Ra surface unevenness of the composite pin
and the disc surface was preserved.
3. RESULT AND DISCUSSIONS
3.1 Energy Dispersive Spectroscopy (EDX)
The various alloying elements in the powder form as per
standard composition of Al6061 base material were put
into a planetary ball mill, by mixing the powders as speci-
fied in the Table 1. The properly powdered mixtures were
subjected to EDAX examination and the Fig. 1 show the
result. The EDAX examination which is Fig. 1 illustrates
the occurrence of magnesium and silicon in the mixture
confirming to successful preparation of Al6061 alloy.
Fig. 1: Energy dispersive spectroscopy of ready Al6061-alloy.
3.2 Density
A comparison of densities of composites obtained by ex-
periments and rule of mixture values are presented in Fig.
2, with the composites containing different reinforcement
contents. From Fig. 2, it can be appreciated that the theo-
retical and experimental values are in close agreement
with each other and approves successful composite fab-
rication. Also as the percentage TiO2 content increases
in the Al6061 matrix, it was noticed that the densities of
composites are increasing and are greater than the Al6061
19

Fig. 2: Experimental and Theoretical densities of Al6061-TiO2
MMCs.
matrix alloy [18, 19]. The higher readings in density of
Al6061-TiO2 composites are due to the greater density of
TiO2 reinforcement.
3.3 Scanning Electron Micrograph studies
The SEM photographs of Al6061 and its TiO2 MMCs are
shown in Figs 3 a-d. From the SEM photographs, it is no-
ticed that the distributions of filler contents in the matrix
alloy are appropriately uniform. Further these Figs. it can
be discovered that the homogeneousness of the cast com-
posites. The micrograph also shows the increased filler
contents in the composites. It is also evident from the mi-
crographs that minor degree of porosity is discovered. It
is reported that higher hardness is always associated with
lower porosity of metal matrix composites [16]. Further,
in the micrographs it is revealed that there is a satisfactory
bonding between the matrix and the reinforcement mate-
rial, this leads to improved load transmission from the base
Al6061 to TiO2 strengthening the composite material.
Fig. 3: SEM photographs of Al6061 alloy and its TiO2filled
composites, a) Al6061 alloy, b) Al6061-1% TiO2, c) Al6061-
2% TiO2, d) Al6061-3% TiO2 MMCs.
Advanced Composites Letters, Vol. 26, Iss.1, 2017
G B Veeresh Kumar et. al. Letter
In the above Fig. 3, micrograph 3a, shows that the occur-
rence of very small dendrites of Al-solid solution, whereas
the microstructures 3b to 3d reveals that the presence of
small dendrites of Al-solid solution with some arbitrarily
distributed reinforcement elements.
3.4 Hardness studies of Al6061-TiO2 MMCs
The hardness is the basic physical and mechanical charac-
teristic of materials by which the properties like strength,
resistance to wear and bonding among the matrix and
strengthening particulates may be approximated [20]. The
hardness tests were conducted according to ASTM E10-
07a standard at ambient temperature. The hardness of
Al6061 and composites with 0-3 wt% TiO2 are illustrated
in Fig. 4. From the illustration, it was witnessed that the
hardness of the Al6061-TiO2 composites was higher than
Al6061 alloy. The composite with greater TiO2 filler con-
tent displays greater hardness. The hardness of composites
Al6061-TiO2 rises by 70% with the increase in TiO2 filler
content from 0 to 3 wt%. The enhancement in the hardness
can be accredited to the presence of TiO2 and its occur-
rence in the alloy enhances hardness [21]. Overall, the ma-
terials with the higher hardness are the most wear resistant
and it was in agreement with the other investigations who
also recommended that resistance to wear of composites
related directly to its hardness [22].
Fig. 4: Hardness of Al6061–TiO2 composites with variation in
reinforcement content.
3.5 Ultimate Tensile Strength
In this section, variation in ultimate tensile strength with
increasing TiO2 contents are discussed and shown in Fig.
5.
The ultimate tensile tests were conducted agreeing to
ASTM – E8/E8M-08 standard. There was a progress of
83% tensile strength of the composites with the TiO2 con-
tent increase from 0 to 3 wt%. The trend is comparable
to outcomes of other investigators [23]. In common, the
particulates filled Al-MMCs were acknowledged for more
enhanced elastic, tensile and fatigue property compared to
unreinforced materials [24]. The sturdiness of particulate
filled Al-MMCs were noticed to improve by higher content
20

Fig. 5: Ultimate tensile strength of Al6061 alloy and its TiO2
composites.
of filler phase and reduced particulate dimensions in the
MMCs, at the expense of percentage of elongation [25].
3.6 Ductility
Fig. 6, is presented with the effectiveness of TiO2 over per-
centage elongation of cast Al6061-TiO2 composites. It can
be noticed from the Fig., that the composites ductility re-
duces monotonically and significant amounts with the in-
creased TiO2 content. The ductility drops by 46% with the
content of TiO2 varied from 0 to 3 wt%. The found results
were in-line with the other scientists [26] who also noticed
that the reduced ductility with higher TiO2 particulate con-
tent. The reduction in the percentage elongation (ductility)
in contrast to the base alloy is a most frequently encoun-
tered drawback of particulate strengthened MMCs [27].
Fig. 6: Ductility of Al6061 alloy and its TiO2 filled MMCs.
Fractured, SEM micrographs of the Al6061 alloy and its
TiO2 filled composites are shown in Fig. 7, from the Fig.
it was noticed that there is a good closeness among matrix
and strengthening fillers and further, it is evident from the
Fig. that there is declining in the ductility property, this can
be credited to the absence of dimples in the micrographs
with the rise in the TiO2 filler content in the Al6061 base
alloy.
3.7 Dry sliding wear studies
The dry sliding wear tests are conducted at ambient tem-
perature in agreement with ASTM-G99 standard. The
Advanced Composites Letters, Vol. 26, Iss.1, 2017
G B Veeresh Kumar et. al. Letter
Fig. 7: SEM pictures of the fractured planes of a) Al6061 alloy,
b) Al6061-1% TiO2, c) Al6061-2% TiO2, d) Al6061-3% TiO2
MMCs.
composite pin specimens of diameter 10 mm and length of
25 mm was used for the tribological test. Dry-sliding wear
experimentations were done using a computerised pin-on-
disc wear monitor at a fixed rubbing velocity of 2.62 ms−1.
Fig. 8: Volumetric wear of composites through a sliding dis-
tance of 3 km at different loads.
The Figs. 8 a-d, are presented with the volumetric wear of
MMCs over sliding distance. The rise in volumetric wear
loss of matrix and its composites was noticed with rise
in sliding distances. At greater sliding distances, the slid-
ing surfaces temperature becomes very difficult to main-
tain. Due to this the matrix and composite pin surfaces
become soft and undergo substantial distortion at greater
sliding distances. This pays to greater loss of base matrix
and composite due to wear. From Fig. 8, the wear loss of
21

composites was much lesser when compared with the base
matrix at all the sliding distances studied and decrease
with higher TiO2 content in the composites. This may be
reasoned to improvement in hardness [28].
The deviations of wear loss with load applied are pre-
sented in Fig. 8. The amount of wear of Al-base alloy and
composites significantly enlarged by applied load and the
supreme aspect regulating the wear [29]. At higher loads,
there is increase in wear loss of Al6061 and its compos-
ites. Nevertheless, the resistance to wear of composites
remained greater to the Al6061 alloy at all applied loads.
Higher loads will lead to the delamination and greater
wear loss of the base alloys and composites as witnessed
by numerous investigators [30].
Fig. 9: Outcome of load on the wear loss of Al6061–3 wt%
TiO2 composites with increase in sliding distance.
Fig. 10: Deviations in volumetrical wear loss with rise in rein-
forcement of Al6061-TiO2 composites.
The deviation of volumetrical wear loss of Al6061 alloy
and TiO2 filled composites with the escalation in the rein-
forcement material are displayed in Fig. 10. It is noticed
that the volumetrical wear loss of the composites declines
by higher TiO2 filler content in the Al6061 alloy. Never-
theless, for given filler content, the composites results in
lower volumetrical wear loss then its base matrix. The en-
hancement in the refusal to accept wear of the composites
with higher TiO2 filler content can be accredited to the en-
hancement in the hardness values of the composites.
The SEM micrographs of worn out exteriors of Al6061
Advanced Composites Letters, Vol. 26, Iss.1, 2017
G B Veeresh Kumar et. al. Letter
Fig. 11: SEM micrographs of a) Al6061 alloy, b) Al6061-1%
TiO2, c) Al6061-2% TiO2, d) Al6061-3% TiO2 MMCs worn-out
surfaces at 40 N and 3 km sliding distance.
matrix and TiO2 filled composites on 40 N load and 3
km sliding distance are presented in Fig. 11. The exist-
ence of wear particles are adhesive wear indications, with
elastic and plastic shearing of the asperities, due to wear.
The composites with 3 wt% TiO2 at 40 N load, exhibits
lesser wear. At 40 N load, larger grooves are formed at
the worn out surface of the base matrix and composites
comprising lower volumetrical fractions of TiO2 are some-
what bigger and undergo serious plastic distortion leading
to extreme wear. The SEM photos display the occurrence
of dense worn subdivisions on their wear boundaries. This
happening is obvious from SEM graphs from Figs. 11 a-d.
The quantity of grooves in the composites worn surface is
lowered with higher TiO2 content in the matrix signifying
lower wear loss of material.
4. CONCLUSIONS
The inferences of the experimental work on Al6061-TiO2
MMCs are mentioned below.
The Al6061-TiO2 composites reinforced upto 3 wt% was
fabricated successfully by powder metallurgy technique.
The density readings of Al6061-TiO2 composites were
found to improve than their base Al6061 alloy. The SEM
micro-graphical studies discovered the even spreading of
the TiO2 particles in the Al6061 alloy. The Hardness stud-
ies of the composites improved with increased TiO2 par-
ticulates. The tests on tensile strength of composites were
greater than that of base alloy and composite Al6061-3
wt% TiO2 filler showed greater tensile strength then other
composites considered, at the expense of ductility. The re-
sistance to wear of composites was higher than that of base
matrix. At higher loads and higher sliding distances caused
in higher wear loss. The TiO2 filler materials subsidized
22

considerably in enhancing Al6061-TiO2 composites wear
opposition. From the present work it can be determined
that the Al6061-3 wt% TiO2 composite exhibited superior
physical, mechanical and resistance to wear properties.
ACKNOWLEDGEMENTS
The authors precise their thankfulness to the administra-
tion of School of Engineering, Amrita Vishwa Vidyap-
eetham University, Bangalore Campus, Bengaluru for
their constant support and motivation towards the above
research work.
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