SEMESTER PROGRESS (Vth Sem)_Devendra.pptx

LM6 Alloy

1. Semester Progress Presentation on “Parametric Evaluation of Al 2 O 3 -LM6 Semi-Solid Cast Composite Fabricated under Self-pouring Temperature” Presented by: Devendra Pratap Singh Ph.D. Scholar (M.E.) Roll No. 209121006 Under the Supervision of : Dr. Vijay Kumar Dwivedi Supervisor Professor (ME), GLAU, Mathura Dr. Mayank Agarwal Co-Supervisor Associate Professor (ME), RMLAU, Ayodhya

2. Table of Contents

3. Introduction Chemical Composition of LM-6 ( wt %) Mg Si Fe Cu Pb Mn Zn Ti Ni Sn Al 0.1 10-13 0.6 0.1 0.1 0.5 0.1 0.2 0.1 0.05 Rest What is LM-6? LM6 is aluminum casting alloy of composition as shown in Table-1 [2] high impact strength and ductility high resistance to corrosion and excellent castability but is of medium strength and Its strength falls off rapidly at high temperatures.

4. Introduction Why Semi-Solid Metal Casting (SSMC)? A near net shape variant of die casting Suitable for higher temperature alloys for which no currently suitable die materials are available Reduced shrinkage due to the lower casting temperature of the melt Low gas porosity enabling heat treating of the castings High mechanical properties due to the uniquely fine microstructure of the resulting castings Extremely fine surface finish

5. Traditional Processing Routes of SSMC Schematic representation of two major categories of SSMC processes. (in rheo-casting, A refers to continuous cooling and stirring, and B illustrates isothermal stirring). [1]

6. Research Gap 01 02 Various studies reported a range of pouring temperature in between liquidus and solidus temperature but no or very few literature is found for the self-pouring temperature. Most of the authors have reported their work using conventional heating methods for casting. However heating can be done inside the muffle furnace in inert gas atmosphere to reduce porosity further. 03 There is possibility of use of metal or alloy in powder form instead of bulk for casting.

7. Objective Micro-Structural Evaluation Impact of the properties on the grains of cast microstructure. Self-Pouring Temperature Identification of Self Pouring temperature of the mixed powder per-form of Al2O3-LM6 for variable compositions. 01 02 03 Mechanical Properties Processing effect and influence of self-pouring temperature on the mechanical properties of the cast.

8. Novelty Statement In semi-solid casting process, pouring temperature plays an important role on the cast microstructure and mechanical properties. Various studies reported a range of pouring temperature in between liquidus and solidus temperature but no or very few literature is found for the self-pouring temperature. However, following points reflect the possible novelty of the work: Impact of self-pouring temperature Possibility of powder use in casting in place of bulk

9. Work Progress

10. Experimental Work Flow

11. Mixing and Pre-Heating Mixing Via Ball Milling Pre-Heating Ball Size 10 mm Oven Type Electric RPM 50 rpm Temp. 50 °C Time 40 min [mixing] -20 min [cool off] (3 sets) Time 2 Hrs. Purpose Uniform mixing of LM6 and Al2O3 powder Purpose To remove moisture

12. Pre-Form Fabrication Compaction using a die (as shown) in STM by applying Load of 1.8 kN. Sample Wt % of LM6 Wt % of Al2O3 No. of Samples A 98% 2% 10+25 B 97% 3% 10+25 C 96% 4% 10+25

13. Identification of self-pouring Temperature and casting 10 Pre-Form of each sample types (Sample A, B, and C) are tested to obtained self-pouring temperature and average value of obtained readings is considered for final casting. Sample A-7 Identified Self Pouring Temperature- 650°C Sample B-3 Identified Self Pouring Temperature- 670°C Sample C-8 Identified Self Pouring Temperature- 686°C

14. Current Status of Experimental Work Process Status Material Procurement Completed Mixing via Ball milling Completed Pre-Form Fabrication Completed Identification of self-pouring temperature Completed Casting of final specimen block Completed Specimen preparation Completed Testing and Analysis Completed

15. Key Findings Development of cast composite under self-pouring temperature has been successful conducted after several iterations and it has been found that compaction pressure should be very low for the successful melting and flow of the metal rather than sintering. Mixing of Al 2 O 3 via ball milling process with LM6 alloy played an important role in successful melting due to the refined size of the powder particles with increased surface area and progressive heat transfer rate . A successful incorporation of Al 2 O 3 addition and development of cast composite without using conventional liquid slurry showing some specific better results for a possible processing route. Obtained results for the density and hardness confirm a consolidated effect of process pouring temperature and Al 2 O 3 addition . But this consolidated effect is limited to the impact strength of the developed composite while a fine and equal distribution of reinforcement particulates with some silicon particles along with the microstructure of the developed composite.

16. Publications

17. S. No. Paper Title Journal Name Index Status 1 Processing Characteristics for Self-Pouring Temperature of Al2O3 – LM6 Cast Composite. MRS Advances SCOPUS & ESCI Published [Online] DOI: 10.1557/s43580-022-00450-9 2 Development and microstructural evaluation of Al2O3-LM6 powder cast composite under self-pouring temperature. Composite theory & Practice SCOPUS & ESCI Accepted for publication 3 Influence of self-pouring temperature on metallurgical and mechanical properties of Al2O3/LM6 cast composite. National Academy Science Letters SCI Under Review [Major Revision Submitted] S. No. Paper Title Conference Name Status 1 The key attributes of processing parameters on semi-solid metal casting: An Overview. 12th International Conference on Materials Processing and Characterization, NITTTR Chandigarh Paper Presented 2 Synthesis, microstructural evaluation and mechanical characterization of Al2O3-LM6 cast composite with use of mixture DoE approach 1st International Conference on Aspects of Materials and Mechanical Engineering (ICMME 2022), GLA Mathura Paper Presented

18. Work Plan for Upcoming Semester Publications planned Technical Letter A letter or short communication for the novelty statement. Book Chapter A book chapter is planned for the interfacial and temperature effect on the cast composite. Thesis Writing: in progress

19. References Nafisi, S., Ghomashchi , R. (2016). Semi-Solid Metal (SSM) Technologies. In: Semi-Solid Processing of Aluminum Alloys. Springer, Cham. https://doi.org/10.1007/978-3-319-40335-9_2 M.N. Ervina Efzan  et al (2016). Microstructure and Mechanical Properties of Fly Ash Particulate Reinforced in LM6 for Energy Enhancement in Automotive Applications, IOP Conf. Ser.: Mater. Sci. Eng. 133 012046. DOI: 10.1088/1757-899X/133/1/012046 Liu, Z., Mao, W., Wan, T. et al. Study on Semi-Solid A380 Aluminum Alloy Slurry Prepared by Water-Cooling Serpentine Channel and Its Rheo-Diecasting. Met. Mater. Int. (2020). https://doi.org/10.1007/s12540-020-00672-2 Agarwal, M., Srivastava, R. Friction, Wear and Mechanical Properties of Al-Si LM6 Cast Alloy Processed in Semi-solid Stage. Silicon 11, 355–366 (2019). https://doi.org/10.1007/s12633-018-9849-5 Ł. Rogal  (2017) Critical assessment: opportunities in developing semi-solid processing: aluminium, magnesium, and high-temperature alloys, Materials Science and Technology, 33:7, 759-764, DOI: 10.1080/02670836.2017.1295212 Shehata, M.M., El- Hadad , S., Moussa, M.E. et al. Optimizing the Pouring Temperature for Semisolid Casting of a Hypereutectic Al–Si Alloy Using the Cooling Slope Plate Method. Inter Metalcast  (2020). https://doi.org/10.1007/s40962-020-00465-8

20. References Kapranos , P., Kirkwood, D. H., & Sellars, C. M. (1993). Semi-Solid Processing of Aluminium and High Melting Point Alloys. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 207(1), 1–8. doi:10.1243/pime_proc_1993_207_05 Aguilar, J., Fehlbier , M., Grimmig , T., Bramann , H., Afrath , C., & Bührig-Polaczek , A. (2004). Semi-Solid Processing of Metal Alloys. Steel Research International, 75(8-9), 492–505. doi:10.1002/srin.200405802 Li, L., Li, D., Feng, J., Zhang, Y., & Kang, Y. (2020). Effect of Cooling Rates on the Microstructure and Mechanical Property of La Modified Al7SiMg Alloys Processed by Gravity Die Casting and Semi-Solid Die Casting. Metals, 10(4), 549. doi:10.3390/met10040549 Talangkun , S., Potisawang , C., & Saenpong , P. (2020). Thixoforming and Rheo-Die-Casting of A356/ SiC Composite. Metals, 10(2), 251. doi:10.3390/met10020251 Gadakh , V. S., Badheka , V. J., & Mulay , A. S. (2021). Solid-state joining of aluminum to titanium: A review. Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications, 235(8), 1757–1799. doi:10.1177/14644207211010839 

21. THANK YOU ! Any Questions?