IMPROVEMENT OF MECHANICAL

PROPERTIES OF AL6082 BASED MMC

K S V S SARATH CHANDRA
MACHINE DESIGN
1220714112
Under the guidance of
Dr M .AMRITA
Assistant Professor
Department of Mechanical
Engineering

CONTENTS

Abstract
Introduction
Literature Survey
Al6082 Properties
Procedure
Ilmenite Powder
Tests and their procedure
References
Results

ABSTRACT
In this aluminum alloy Al6082 was reinforced with the ilmenite
powder (FeTiO3) by stir casting method. In this experiments were
conducted by varying weight fraction of ilmenite powder (0% , 5% ,
10% , 15% ).
The mechanical properties of material can be studied by using
tensile, fatigue and wear tests. Microstructure of the Al6082 composite
can be studied to investigate the grains in alloy and good dispersion of
reinforcements in the matrix for the composite.

INTRODUCTION
Aluminum based metal matrix composite has emerged as an important class
of high performance material for use in Aerospace, Automobile because of its
improved strength.
In liquid state methods, the ceramic particulates are incorporated
into a molten metallic matrix and casting of the resulting MMC is done. Stir
Casting is a liquid state method of composite materials fabrication, in which a
ceramic particle is mixed with a molten matrix.
Aluminum 6082 is a metal alloy with high hardness, thermal conductivity but it has
poor corrosion resistance. So in this we reinforce FeTiO3 with this alloy to increase
in mechanical properties, such as Tensile, Fatigue, Microstructure, Wear resistance.
Ilmenite is an oxide mineral with bulk density of 4.55gm/cc. It is a nonfluorescent and submetallic, black colored mineral. It crystallizes in trigonal
system.

LITERATURE SURVEY

composites as an engineering materials normally refer to the

material with the following characteristics
1. These are artificially made ( excluding natural material
such as wood).
2. These consist of at least two different materials.
3. There properties are influenced by the volume
percentage of ingredients.
4. These have at lest one property not possessed by the
individual constituents.

Performance of composite depends on :

1. Properties of matrix and reinforcement ,
2. Size and distribution of constituents ,
3. Nature of interface between the constituents.
The aluminum based composites are increasingly being used in the
transport, aerospace, marine, automobile and mineral processing
industries, owing to their improved strength, stiffness and wear
resistance properties.
The 6061 alloy is primarily composed of aluminum, magnesium and
silicon. Its other metallic elements include iron, copper, chromium, zinc,
manganese and titanium, in descending order of quantity.

Al6082 PROPERTIES
Typical material properties for 6082 aluminum alloy include:[2]
Density: 2.71 g/cm3, or 169lb/ft3 .
Young's modulus: 71 Gpa , or 10 Msi .
Ultimate tensile strength: 140 to 330 MPa, or 20 to 48 ksi.
Yield strength: 90 to 280 MPa, or 13 to 41 ksi.
Thermal Expansion: 23.1 m/m-K.
Solidus: 575C or 1070F.

Applications of Aluminum alloy 6082

High stress applications
Trusses
Bridges
Cranes
Transport applications
Ore skips
Beer barrels
Milk churns

PROCEDURE
CASTING PROCESS:
First we take BASE METAL, taking 600g of Al2014 and must be
melted in the Stir Casting machine(capacity 1050c).
Now the melted form is poured in the die we had taken.
Second we take 5% of ilmenite powder and 570g of Al6082 metal.
The Ilmenite powder is heated in the Muffle Furnace for about
600c.
The heated powder is wrapped into aluminum coil sheet piece.
Mean while the Al6082 metal must be heated in the Stir Casting
machine.
After the completion of stirring in the Stir Cast Machine, the melted
form is poured in the die for the model.
This is repeated for 10% and 15% also.

Electrical Heater

TABULAR FORM:
AL6082

Wt of Wt of
AL
ilmenite
(g)
powder(g)

Stir
castingm/c
temp.(0c)

Time of
heating
rods(hr)

Muffle
furnace
temp.
(0c)

Time of heating
powder(hr)

BASE
METAL

600g

900

1 hr

5%

570g

30g

900

1hr

600

hr

10%

540g

60g

900

1 hr

600

hr

15%

510g

90g

900

1 hr

600

hr

ILMENITE POWDER(FeTiO3)

Ilmenite is the titanium-iron oxide mineral with the idealized

formula FeTiO3.
Ilmenite crystallizes in the trigonal system. The ilmenite crystal
structure consists of an ordered derivative of the corundum
structure; in corundum all cations are identical but in ilmenite
Fe2+ and Ti4+ ions.

TESTS
TENSILE TEST
Tensile strength is the capacity of a material or structure to withstand
loads tending to elongate, as opposed to compressive strength, which
withstands loads tending to reduce size. In other words, tensile
strength resists tension (being pulled apart), whereas compressive
strength resists compression. Ultimate tensile strength is measured by
the maximum stress that a material can withstand while being
stretched or pulled before breaking.

Specimen

Tensile Testing Machine

FATIGUE TEST
Fatigue is the weakening of a material caused by repeatedly applied
loads Fatigue strength used to describe a property of materials: the
amplitude of cyclic stress that can be applied to the material without
causing fatigue failure. The ASTM defines fatigue strength, SNf, as
the value of stress at which failure occurs after Nf cycles, and fatigue
limit, Sf, as the limiting value of stress at which failure occurs as Nf
becomes very large. Fatigue occurs when a material is subjected to
repeated loading and unloading. If the loads are above a certain
threshold, microscopic cracks will begin to form at the stress
concentrators such as the surface, persistent slip bands (PSBs), and
grain interfaces. Eventually a crack will reach a critical size, the crack
will propagate suddenly, and the structure will fracture.

WEAR TEST
Wear is related to interactions between surfaces and specifically the
removal and deformation of material on a surface as a result of
mechanical action of the opposite surface. Wear is erosion or sideways
displacement of material from its "derivative" and original position on a
solid surface performed by the action of another surface. Wear can also
be defined as a process where interaction between two surfaces or
bounding faces of solids within the working environment results in
dimensional loss of one solid, with or without any actual decoupling and
loss of material.

Wear testing machine

MICROSTRUCTURE
Microstructure is defined as the structure of a prepared surface of
material as revealed by a microscope above 25 magnification. The
microstructure of a material (such as metals, polymers, ceramics or
composites) can strongly influence physical properties such as
strength, toughness, ductility, hardness, corrosion resistance, high/low
temperature behavior or wear resistance.

VICKERS HARDNESS TEST

The Vickers hardness test as an alternative to the Brinell method to
measure the hardness of materials . The Vickers test is often easier to use
than other hardness tests since the required calculations are independent
of the size of the indenter, and the indenter can be used for all materials
irrespective of hardness.The unit of hardness given by the test is known
as the Vickers Pyramid Number (HV) or Diamond Pyramid Hardness
(DPH).
The hardness number can be converted into units of pascals, but should
not be confused with pressure, which also has units of pascals. The
hardness number is determined by the load over the surface area of the
indentation and not the area normal to the force, and is therefore not
pressure.

VICKERS HARDNESS TESTER

SCANNING ELECTRON MICROSCOPE

A scanning electron microscope (SEM) is a type of electron
microscope that produces images of a sample by scanning it with a
focused beam of electrons. The electrons interact with atoms in the
sample, producing various signals that contain information about the
sample's surface topography and composition. The electron beam is
generally scanned in a raster scan pattern, and the beam's position is
combined with the detected signal to produce an image. SEM can
achieve resolution better than 1 nanometer. Specimens can be observed
in high vacuum, in low vacuum.
The most common SEM mode is detection of
secondary electrons emitted by atoms excited by the electron beam.
The number of secondary electrons that can be detected depends,
among other things, on the angle at which beam meets surface of
specimen , i.e. on specimen topography.

SCANNING ELECTRON MICROSCOPE MACHINE

RESULTS:
TENSILE TEST
FOR AL6082 PURE

FOR AL6082 5%

FOR AL6082 10%

FOR AL6082 15%

Comparision of Tensile Test values

Specimen
Label

Maximum Load
(KN)

Load at break
(KN)

UTS (MPa)

Tensile stress at
yield
offcet(0.2%)

1Modules (MPa)

Load at 2%
strain (KN)

0%

9.36

7.32

186.21

107.79

16634.37042

7.09

5%

2.62

1.64

52.10

52.07

14364.80255

10%

3.82

2.48

75.90

69.18

12779.10919

15%

2.90

2.01

57.76

53.05

9796.09528

6082

WEAR TEST
FOR AL6082 PURE

FOR AL6082 5%

FOR AL6082 10%

FOR AL6082 15%

COMPARISION OF WEAR TEST RESULTS

MICROSTRUCTURE RESULTS
0% 5X

5% 5X

10% 5X

15% 5X

0% 10X

5% 10X

10% 10X

15% 10X

0% 20X

5% 20X

10% 20X

15% 20X

0% 50X

5% 50X

10% 50X

15% 50X

HARDNESS TEST RESULTS

6082

ILMENITE%

TRAIL 1

TRAIL 2

TRAIL 3

AVERAGE

101.7

102.9

109

105.53

189.5

225.3

275.1

229.96

10

237.6

232.8

251

240.46

15

217.3

271.1

238.3

242.23

HARDNESS GRAPH

250

200

150
Average value

100

50

Scanning Electron Microscope

6082 0%
X430
X750

X370

X500

X250

X330

6082 10%
X230

X700

X400

X270

X300

X230

SEM with EDS

Al6082 0%

Quantitative Result
Quantitative results
0.6

W e ig h t %

0.5
0.4
0.3
0.2
0.1
0.0
-0.1
O

Mg

Al

Ti

Cr

Mn

Fe

Zn

Al6082 10%

Quantitative result
Quantitative results
0.6

W e ig h t %

0.5
0.4
0.3
0.2
0.1
0.0
-0.1
O

Mg

Al

Cr

Mn

Fe

Zn

As an application to the Al6082 and ilmenite we

designed a Drive Shaft.
Drive Shaft drawn in Catia.

Total Deformation of Drive Shaft in Ansys

Equivalent Elastic Strain

Equivalent Stress

Maximum Shear Stress

Normal Stress

Maximum Principal Stress

Conclusion
By comparing

all the values of tensile test 10% of

Al6082 is very much better compared to all other
percentages pieces.
From the comparision of all the values of Al6082 in
wear test 10% is better than others.
Microstructure images have been obtained.
In Hardness the values have been obtained and
compared the values in that 10% has better values
than other values.
Sem test has been done and the images are obtained.

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