311819114306 -AL6063 PROJECT FINAL REPORT PPT.docx.pptx

Aluminium mechanical behavior

1. INVESTIGATION OF MICROSTRUCTURAL AND MECHANICAL BEHAVIOR OF ALUMINIUM 6063/Gr POLYMER COMPOSITES DEPARTMENT OF MECHANICAL ENGINEERING PRESENTED BY SUPERVISOR Mr. M.SURESH, M.E ., Assistant Professor, Department of Mechanical Engineering M.Gokul (311819114005) A.Sheik Hussain (311819114020) S.Salaudeen badusha (311819114306)

2. ABSTRACT In the present day, Aluminium metal are widely used in the field of engineering applications, especially in automobile, aerospace, marine, and processing industries, because of their improved higher specific strength, wear resistance, low density, high strength, and good structural rigidity. Presently hybrid composites play a vital role in engineering applications. In this present work, Aluminium alloy 6063 has been used as the matrix and recycled polymer as the reinforcement. The Aluminium composite is produced by liquid metallurgical route (stir casting). This method is less expensive and very effective. The objective of this work is to predict the tensile strength, compression, impact, and Microstructure Corrosion behavior of the Composites.

3. OBJECTIVES To Develop the new aluminium alloy composite. To Use stir casting setup facilities to fabricate aluminium 6063 reinforced with PET (Polyethylene Terephthalate). To Use a CNC wire EDM machine to cut the casting material into no. of pieces with the desired cutting standard. To Study the tensile, impact, compression, and Microstructure Test.

4. PROJECT SCOPE Identifying new materials Break caliper Net of Lacrosse sticks Camping gadgets Vehicle Exhaust manifold casing Upper and lower receiver of M16 Rifle parts

5. LITERATURE REVIEW Jawalkar , C.S ., et.al 2017, The research on aluminum6063 metal matrix composites with particle reinforcement is summarised in this paper. Due to its small weight, high strength-to-weight ratio, corrosion resistance, and workability, the aluminum metal matrix is becoming more and more popular in aviation, automotive, and other industries. The current work analyses the issues raised and conclusions reached by many writers who have made contributions in the field of stir-cast aluminum metal matrix composites with particulate reinforcement . The reported works reveal that decrease in particle size and increase in precentage addition of reinforcement increase hardness and tensile strength of the composite

6. Kumar, G. V., Pramod, R .,(2017).In order to achieve a high strength-to-weight ratio, recent work on reinforcing polymer into aluminium foil is presented in this study. In addition to being resistant to corrosion, lightweight, and ductile, aluminium also exhibits increased strengths that are desirable for high-tech applications when alloyed with other metals. Babrekar, H.A ., et. al (2010), Polystyrene is employed as a polymer matrix and aluminium is used as a filler. We used aluminium particles with varying morphologies that were both micro meter and nanoscale-sized. When coarse grains and flakes of aluminium were employed as fillers, the values of emissivity’s decreased, but when Nano-aluminium was included in the composite, there was no discernible difference.

7. METHODOLOGY Selection of material Mold making as per specimen Composite preparation with Al6063/Recycled Polymer Casting of aluminium6063 by stir casting process by using Recycled polymer as reinforcements Pouring and Solidification Testing

8. SELECTION OF MATERIAL Aluminium alloys are alloys in which Al is the predominant metal. The typical alloying elements are copper, magnesium, manganese, silicon, and zinc. There are 2 principal classifications, namely cast alloys and wrought alloys We Choosed Aluminium 6063 Grade. This AL 6063 is aluminium, with magnesium and silicon as the alloying elements. The standard controlling its composition is maintained by The Aluminium Association. It has generally good mechanical properties and is heat treatable and weldable. Reinforcement particle : A reinforcement is a constituent of composite material which increases the composite's stiffness and tensile strength. Here we used the PET (Polyethylene Terephthalate) bottle as reinforcement. It is the most common thermoplastic polymer resin of the polyster family and is used in fibers for containers for liquids and foods. Plastic bottles made from PET are widely used for soft drinks .

9. Al 6063 length rod Al 6063 length rod 6mm dia Aluminium 6063 metal Al 6063 Metal Cut 1inch size for Stir Casting Process

10. REINFORCEMENT PARTICLE The reinforcement is placed in the Metal plate and burned and it’s melted with the help of the Butane gas torch. And then the reinforcement is added to the molten metal. Melting of reinforcement

11. STIR CASTING Stir Casting Furnace Heating of Al6063 Stirrer Al 6063 and recycled polymers are mixed and melted. The melted is stirred slightly above the liquid us temperature (800-850 °c) Stir casting is a type of casting process in which a mechanical stirrer is introduced to form vortex to mix reinforcement in the matrix material

12. The molten mixture is then poured in preheated mold and kept for natural cooling and solidification. After the solidification the surface cleaning and finishing is done. Graphite Crucible Cup Pouring of mixture in the mold Casting material Material cutting process

13. METHODS OF TESTING Impact testing machine Compression testing machine Tensile testing machine Microstructure Testing

14. TENSILE TEST Sample 1 Sample 2 Final Result of Tensile specimen test SPECIMEN LOAD Fmax (KN ) TENSILE STRENGTH ( MPa ) T1-1 3.07 95.09 T1-2 3.04 107.55 T1-3 3.02 100.24 T2-1 4.29 152.31 T2-2 4.13 146.75 T2-3 3.25 114.47

15. IMPACT TEST SAMPLE Zone-1, Joules Zone-2, Joules Zone-3, Joules 1 8.9 13.6 11.7 2 13.6 13.7 11.4 Final Result of Impact specimen test Sample 1 Sample 2

16. COMPRESSION TEST Sample 1 Sample 2 SPECIMEN LOAD (KN) COMPRESSIVE STRENGTH ( MPa ) C1-1 31.6 643.42 C1-2 30.53 624.05 C1-3 31.66 644.04 C2-1 32.35 687.67 C2-2 28.38 603.02 C2-3 30.38 637.55 Final Result of Impact specimen test

17. MICROSTRUCTURE TEST SPECIMEN NO. Al6063 PET (Polyethylene Terephthalate) 1 97% (834g) 3% ( 6g) 2 94% (738g) 6% (8g) WEIGHT PERCENTAGE OF THE COMPOSITE MATERIALS :

18. TENSILE TEST Sample 1 Sample 2 T1-1 T1-3 T1-2 T2-1 T2-2 T2-3

19. COMPRESSION TEST Sample 1 C1-1 C1-2 C1-3 C2-1 C2-2 C2-3 Sample 2

20. MICROSTRUCTURE TEST Sample 1 Sample 2 Magnification: 100X, 200X Etchant: H.F Soln. Magnification: 100X, 200X Etchant: H.F Soln.

21. CONCLUSION The Selection of matrix base material. Casting of metal matrix composites by stir casting process by using Al6063 / PET (Polyethylene Terephthalate) as reinforcements. We have undergone Mechanical testing like Tensile, Impact, Compression and Microstructure. In tensile testing there are totally six specimens T2-1 was found to high strength and T1-1 was found to be low strength. Also in Compression test there are six specimens out of the two specimens the C2-1, was found to high strength & C2-2, was found to low strength. In Impact testing there are totally six specimens out of the two high impact is 13.7J & low impact is 8.9J

22. REFERNCES Jawalkar , C. S., Verma , A. S., & Suri , N. M. (2017). Fabrication of aluminium metal matrix composites with particulate reinforcement: a review. Materials Today: Proceedings , 4 (2), 2927-2936 . Dickson, A. N., Barry, J. N., McDonnell, K. A., & Dowling, D. P. (2017). Fabrication of continuous carbon, glass and Kevlar fibre reinforced polymer composites . 16 , 146- 152. Stöbener , K., & Rausch, G. (2009). Aluminium foam–polymer composites: processing and characteristics. Journal of Materials Science , 44 (6), 1506- 1511. Surappa , M. K. (2003). Aluminium matrix composites: Challenges and opportunities. Sadhana , 28 (1), 319-334. Kumar, G. V., & Pramod , R.(2017, July). Investigation of mechanical properties of aluminium reinforced glass fibre polymer composites. In AIP Conference Proceedings (Vol. 1859, No. 1, p. 020084). AIP PublishingLLC .

23. THANK YOU