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Volume 10, Issue 05, May 2019, pp. 143-159. Article ID: IJMET_10_05_015
Available online at http://www.iaeme.com/ijmet/issues.asp?JType=IJMET&VType=10&IType=5
ISSN Print: 0976-6340 and ISSN Online: 0976-6359
© IAEME Publication
Vishnu K. R
Department of Mechanical Engineering, PESU-EC, Bangalore
ABSTRACT
For thermal management in applications like automobiles, aviation, marine etc. we
need materials with high thermal conductivity, low coefficient of thermal expansion and
at the same time the materials should have high strength, high corrosion resistance and
low density. Aluminum alloys are excellent choices as the alloys possess all these
properties. In order to improve the properties of the alloys further to make them more
suitable for the applications, alloys are reinforced with different materials. This review
focuses on influence on thermal properties of LM25 and some common light metal
alloys reinforced with different materials, effect of heat and solution treatments on
LM25/SiC MMC, effect of aging treatment on thermal fatigue of LM-25 alloy and the
most common synthesis technique used.
Keywords: LM25 (A356), thermal conductivity, coefficient of thermal expansion,
thermal fatigue, reinforcement.
Cite this Article: Ishfaq Ahmad Ganaie, Adarsha Hiriyanniah, Kaushik Vijaya Prasad,
V. Ravinarayan and Vishnu K. R, Review on Effect of Various Reinforcements on the
Thermal Properties of Lm-25 Al Alloy and Some Common Light Metal Alloys,
International Journal of Mechanical Engineering and Technology, 10(5), 2019, pp.
143-159.
http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=10&IType=5
1. INTRODUCTION
Among the hypoeutectic aluminium silicon alloys, LM-25 also called A 356 or Al-Si7-Mg is
one of them. This is picking up far reaching fame and discovers applications in vehicle, aviation,
marine, defense, sports, bio-medical, electrical, food, chemical and other industries. Because of
its magnificent mix of properties, for example, good casting characteristics, machinability, high
strength to weight ratio, low density, low coefficient of thermal expansion and corrosion
resistant in sea-water and marine atmosphere [1,2]. A356 aluminum alloy is utilized to create
numerous parts in car industry in light of the more noteworthy interest for light weight and high
quality materials which decrease the fuel consumption [3]. Adequate thermal conductivity is an
important physical property for alloys used in motor components. In case of pistons it is
necessary that the heat generated in the course of the compression process is removed as quickly
as possible to avoid thermal stresses and hot spots on the piston surface. High thermal
conductivity will therefore play a major role in determining the life time of certain motor
components [4].
Key necessities of the alloys created for the uses of thermal management in electronics,
optoelectronics, automobiles, aerospace, etc. are a high thermal conductivity (TC) and an
adequately low coefficient thermal expansion (CTE) [5,6]. Therefore alloys used for thermal
management should have as high thermal conductivity as possible for the high rate of heat
transfer and as low coefficient of thermal expansion as possible to avoid the volume expansion
of the component due to high temperatures.
It is important to note that thermal conductivity is reduced by the addition of alloying
components, where components in solid mixture result in a higher thermal resistance than a
similar measure of components used as reinforcements in the composite materials. The last
mentioned regularly decreases thermal conductivity relative to the increment of volume fraction
[7]. In order to enhance the thermal conductivity and reduce the coefficient of thermal
expansion composite materials are being developed. There are different types of composites
like metal matrix composites (MMCs), ceramic matrix composites and polymer matrix
composites. Thermal properties of matrix composite materials of metals are influenced by many
parameters, for example, size and shape of particles, reinforcement distribution in the matrix,
volume fraction and matrix/reinforcement particle interface interaction [8, 9]. Not all thermal
properties but TC of MMC is mostly influenced by the microstructural parameters like void,
porosity and matrix/reinforcement interface interaction [10, 11].
In this review LM 25 alloy is discussed regarding the effect of various reinforcements on
its thermal properties (TC & CTE), commonly used synthesis technique for LM 25 alloy
composites, aging effect on thermal fatigue of the alloy and the relationship between the thermal
properties of composites.
For a homogeneous isotropic material, the relationship between thermal properties is given
by the well-known equation;
α = k / ρc
Where, α = thermal diffusivity
k= thermal conductivity
ρ= density of the material and
c= specific heat capacity of the material.
G. J. Pearson et al. [13] showed that this equation does not hold for heterogeneous
anisotropic materials like matrix composite materials; α ≠ k / ρc.
3. SYNTHESIS TECHNIQUE
Essential processes for synthesis of AMC's at commercial or large scale can be arranged into
the following three primary categories [14];
1. Liquid state techniques
a. Stir casting
b. Infiltration process
c. Reactive preparing technique and
d. Spray statement
2. Solid state techniques:
a. PM preparing
b. Diffusion holding
3. Vapor deposition technique:
a. Physical vapor deposition
acknowledged due to its simplicity, capability of commercial production and being economic.
The cost of synthesis of composites material utilizing the technique is around 33% to a half
portion of that of other techniques, and for high volume synthesis, it is anticipated that the cost
will tumble to one-tenth [17]. It permits a conventional composites synthesis course to be
utilized, hence limits the last cost of the item. MMCs are typically synthesized by Liquid
Metallurgy method or stir casting technique [18].
The synthesis of MMCs includes preparation of chosen molten matrix in a crucible kept
inside a furnace for heating. Then pouring of reinforcement particles or short fibers into the
molten matrix is done which is kept inside the crucible and getting a proper matrix-
reinforcement mixture by stirring with the help of mechanical stirrer powered by an electric
motor. The following stage is the solidification of the mixture containing suspended dispersed
particles under chosen conditions to get the proper mixture particles in the matrix.
In order to synthesize the MMCs by the stir casting technique, there are several factors
which need to be taken into account some of them are; reinforcement particles distribution in
the matrix material; reinforcement-matrix physical contact (wettability), porosity in the MMCs
and chemical reaction between the two components of MMC [19]. To get improved properties
of the MMCs, there should be proper distribution of reinforcement particles in the matrix
material because distribution tends to disturb during molten stage and during casting process.
This occurs due to density difference between the two materials.
For proper MMC synthesis, molten matrix should wet the solid reinforcement particles. The
essential means used to enhance wetting are (a) enhancing energy of the surface of
reinforcement particles (b) diminishing the surface tension of the molten matrix material, and
(c) decreasing the energy at the reinforcement-matrix interface [20, 21]. A few methodologies
have been taken to enhance the wetting of the particles with a molten matrix, including the
reinforcement coating, introducing of alloying components to the liquid matrix compound, the
particle treatment, etc. [22]. Porosity is a measure of void spaces in a material which is
undesirable and should be minimized. The ratio of the volume of this void space to the total
volume of the MMC, size of this void space and its distribution in the MMCs greatly decides
the mechanical properties of the MMCs. Porosity and other defects emerge from improper
casting process [23, 24]. It was found that the measure of gas porosity in casting depends more
on the ratio of volume of particles to the total volume of MMC than on the measure of hydrogen
gas present [25]. Chemical interactions must not happen between the reinforcement particles
and the matrix material for proper synthesis of the MMCs. For synthesis of composite material
by the technique, learning of its various working parameter are exceptionally fundamental. If
these process parameters are correctly handled, we can get the cast MMCs with improved
properties.
Figure 1 Schematic diagram of liquid phase fabrication technique (stir casting method) [56].
Figure 2 Variation of average TC with time for a) 1%, 3% and 5% of nanoparticles of size 60nm b)
1%, 3% and 5% of nanoparticles of size 120nm (c) A356 alloy[26].
Type of synthesis technique employed and its processing conditions also affects the thermal
conductivity of the synthesized MMC. If process parameters are selected properly, this can
reduce the porosity and agglomeration of the particles.
Figure 3 Variation of thermal conductivity and percent thermal conductivity change with volume
fraction of all MMC samples [26].
4.2. Effect of silicon carbide (SiC) on LM25 alloy (by powder metallurgy)
4.3. Effect of silicon carbide (SiC) on LM25 alloy (liquid pressing method)
4.3.1. Thermal conductivity (TC)
Lee et al. [28] worked on the silicon carbide particulates as a reinforcement material for the
A356 alloy and used 45% volume fraction of SiC particulates. Cast MMC was fabricated by
liquid pressing method.
The value of TC of the MMC was found to be 155W/mK with amount of pore 0.4% which
is higher than the alloy. It was also shown that porosity greatly affects the TC of the MMC. The
variation of TC with porosity is shown in the figure-4 (a) [28] along with the predicted values
by Hasselson-Johnson modal [29].
(a) (b)
Figure 4 Variation of thermal conductivity (k) and coefficient of thermal expansion (CTE) with
porosity in the MMC[28].
Figure 5 Variation of (a) measured thermal conductivity values with Ni content (b) measured TC
values with calculated values and (c) comparison between measured TC values and the two
models[31].
4.5. Effect of silicon carbide (SiC) on LM25 alloy ( vaccum hot pressing)
Jayakumar et al. [34] worked on SiC particulate reinforcement with volume fraction of
5%,10%,15% and 20%. The CTE of the alloy is around 19.3 Χ 10 ̄⁶ /˚C and the corresponding
values for CTE were calculated and was found that CTE decreases with increase in volume
fraction of SiC particulates. The CTE values of the experiment are tabulated and shown in the
table-4.The CTE depends on matrix percentage, reinforcement percentage and porosity in the
MMC. For constant porosity CTE decreases with increase in SiC content. It was also observed
that MMC with 5% vol of SiC particulates has most porosity and hence from the table it is clear
that porosity also tend to decrease CTE.
4.6. Effect of bonding thermal cycle, solution and aging treatment on SiC MMC
Xu Zhiwu et al. [35] worked on an MMC in which matrix material was A 356 alloy and the
reinforcement particulates were of SiC. CTE of A 356/ SiC composites and their joints was
dealt after subjecting to thermal bonding cycle (BTC) and heat treatment processes. The MMC
was synthesized using stir casting technique where 20% vol and 12.6μm average particle size
of SiC was used. The MMC was then subjected to VLP diffusion bonding process for 15
seconds in air at different temperatures. Solution treatment was given to the samples before and
after the bonding process and also aging treatment was given after the bonding process. In 20-
100˚C temperature range, CTE values were measured at 5 ˚C/min. Various processes through
which the samples were subjected are shown in the figure-6.
(a)
(b)
Figure 6 Flow charts (a) Heat treatment for base metal (b) Bonding and heat treatment of the VL
bonded joints as discussed in ref.[35]
Table 5 CTE of the MMC after (a) bonding thermal cycle (b) BTC, solution & aging treatment
(a)Peak temperatute of bonding thermal cycle (˚C) CTE (μm/m ˚C)
20 16.015
460 16.026
500 15.854
530 15.951
(b)Peak temperature of Bonding thermal cycle (˚C) CTE (μm/m ˚C)
460 15.551
500 15.556
530 15.561
There is a slight change in CTE of the MMC after subjecting to solution treatment and heat
treatment as shown in the table-5 (a). And little effect on CTE values due to bonding thermal
cycle as shown in the table-5 (b). CTE of the VLP bonded joints of the MMC decrease with
increasing bonding temperature and is lower than that of the MMC material itself.
Figure 7 Variation of TC with Temperature for the alloy and the composite[36].
Figure 8 Experimental data and theoritical curves from values obtained using Maxwell–Eucken
equation[44].
Figure 9 Variation of thermal conductivity with volume fraction of SiC fine particles using Maxwell`s
expression and experimental values[49].
(a) (b)
Figure 10 Variation of (a) k and (b) CTE of Al2024/graphite MMC with vol. % of graphite[52].
to 100 hr has less effect on increasing fatigue life than from 0 to 10 hr. So, due to T6 heating
followed by aging, fatigue life is increased but strength is decreased.
(a) (b)
Figure 8 (a) Total strain vs no. of cycles to fatigue failure (b) no. of cycles to failure vs aging time
plots[39].
6. CONCLUSION
Among the various methods of synthesis of MMCs of LM-25 alloy, the stir casting method is
simple, economical, allows wide range of shapes of particulates and causes no damage to
reinforcement. Alumina particulates reinforcement in general decrease TC of the LM-25 alloy.
In P/M synthesis method of LM-25/SiC system, vol. % and sintering time affects the TC of the
system. At constant sintering temperature and sintering time vol. % increases the TC of the
alloy. In liquid pressing synthesis method of LM-25/SiC system with vol. % of 45% enhances
the TC and reduces the CTE of the MMC. The reinforcement of Ni reduces the TC of the alloy
as its wt. % is increased and the experimentally measured values are more close to HS model
than Maxwell`s model. CTE of LM-25/SiC system, synthesized through vaccum hot pressing
method, decreases with increase in SiC content at constant porosity in the MMC. Heat and
solution treatments slightly change CTE of the LM-25/SiC system and increasing bonding
temperature reduces the CTE of the joints of MMC even lower than the MMC itself. TC of the
alloy reduces with increase in quarry dust content. This is due to scattering of heat carriers,
porosity and different sizes of the particles. TC of the alloy reinforced with 4% volume fraction
of the borassus flyash enhances with increase in temperatures across the MMC. The TC of Al-
12 wt.% Si composite decreases largely due to the presence of CNT clusters. The maximum
thermal conductivity of 5056 type Al-Mg alloy reaches to 403W/mK at 45.5% volume fraction
of diamond particles and then again decreases. Interfacial thermal resistance increases with
increase in volume percentage of reinforc ement which happens because adhersion of particles
at higher percentage becomes weak. TC of 2024 Al alloy increases with increase of graphite
flake percentage and its CTE decreases. Due to T6 heating followed by aging treatment
lengthens the thermal fatigue life but reduces the strength. Increasing the aging time lengthens
the fatigue life of the alloy.
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