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@ IJTSRD | Available Online @ www.ijtsrd.com
ISSN No: 2456
International
Research
Characterization of Al/WC/Fly ash Metal Matrix Composites
Assistant Professor, Kelappaji College of
Engineering
ABSTRACT
Metal matrix composites are formed by combination
of two or more materials (at least one of the materials
is metal) having dissimilar characteristics. In this
present investigation, aluminium (Al 6061) as base
matrix metal and tungsten carbide (WC) particulate,
fly ash as reinforcements. Fabrication of MMCs was
done by stir-casting process. The Tungsten Carbide
particulate was added in proportions of 1%, 2%, and
3% and Fly ash was added in proportions of 2%, 4%,
and 6% on mass fraction basis to the molten metal.
The different combination sets of composites were
prepared. Mechanical properties like tensile strength
and hardness were studied for both reinforced and
unreinforced Al 6061 samples. Microstructure
examination was carried by using Scanning Electron
Microscope (SEM) to obtain the distribution of
tungsten carbide particulate and fly ash in base
matrix. From the results, it was found that the tensile
strength and the hardness of the prepared metal matrix
composites increased with increase in tungsten
carbide and fly ash content. The Scanning Electron
Micrographs of the samples indicated uniform
distribution of tungsten carbide and fly ash particles in
the base matrix without voids before testing and with
voids after testing.
Keywords: Aluminium metal matrix composite,
Tungsten Carbide, Fly ash, Stir-casting, Mechanical
properties, SEM
I. INTRODUCTION
Metal matrix composites (MMCs), like most
composite materials, provide enhanced properties
over monolithic materials, such as higher strength,
stiffness, hardness and weight savings. Aluminium
based metal matrix composites are concentrating more
for engineering applications since it is the class of
@ IJTSRD | Available Online @ www.ijtsrd.com | Volume – 2 | Issue – 3 | Mar-Apr 2018
ISSN No: 2456 - 6470 | www.ijtsrd.com | Volume
International Journal of Trend in Scientific
Research and Development (IJTSRD)
International Open Access Journal
Characterization of Al/WC/Fly ash Metal Matrix Composites
Nithin K
Assistant Professor, Kelappaji College of Agricultural
Engineering and Technology, Tavanur, Kerala, India
Metal matrix composites are formed by combination
of two or more materials (at least one of the materials
having dissimilar characteristics. In this
present investigation, aluminium (Al 6061) as base
matrix metal and tungsten carbide (WC) particulate,
fly ash as reinforcements. Fabrication of MMCs was
casting process. The Tungsten Carbide
late was added in proportions of 1%, 2%, and
3% and Fly ash was added in proportions of 2%, 4%,
and 6% on mass fraction basis to the molten metal.
The different combination sets of composites were
prepared. Mechanical properties like tensile strength
ardness were studied for both reinforced and
unreinforced Al 6061 samples. Microstructure
examination was carried by using Scanning Electron
Microscope (SEM) to obtain the distribution of
tungsten carbide particulate and fly ash in base
sults, it was found that the tensile
strength and the hardness of the prepared metal matrix
composites increased with increase in tungsten
carbide and fly ash content. The Scanning Electron
Micrographs of the samples indicated uniform
ten carbide and fly ash particles in
the base matrix without voids before testing and with
Aluminium metal matrix composite,
casting, Mechanical
Metal matrix composites (MMCs), like most
composite materials, provide enhanced properties
over monolithic materials, such as higher strength,
stiffness, hardness and weight savings. Aluminium
tal matrix composites are concentrating more
for engineering applications since it is the class of
light weight and high performance aluminium centric
materials system.
Al6061 is the form of aluminium alloy containing
magnesium and silicon as major alloying elements,
commonly used for aerospace, marine applications,
cycling and automotive applications and to make gas
cylinders. Al6061 is heat treatable, can be easily
welded, with very good corrosion resistance and
finishing characteristics. It has medium strength,
hardness.
Particulate composites are widely used in composites
development because they are cheap and of
manufacturing ease. Particulate reinforced MMCs
have recently found special interest because of their
specific strength and specific
elevated temperatures. Ceramic particles or fibers are
commonly used as reinforcement. The basic reason of
metals reinforced with hard ceramic particles or fibers
are improved properties than its original material like
strength, stiffness, wear resistance etc. It can also
improve strength to weight ratio of the composites.
Fabrication of composites is commonly done by the
stir- casting among the different processing
techniques available, because it is simplest and
cheapest form, references [7][8][9].
In recent days, considerable work has been done on
tungsten carbide reinforced metal matrix composites
as well as fly ash reinforced metal matrix composites.
The tungsten carbide is used as reinforcement in
Al6061 matrix composites with different weight
percentages, references [1][2
done by stir casting process, reference [2]. It was
found that increasing the WC content within the
Apr 2018 Page: 465
6470 | www.ijtsrd.com | Volume - 2 | Issue – 3
Scientific
(IJTSRD)
International Open Access Journal
Characterization of Al/WC/Fly ash Metal Matrix Composites
light weight and high performance aluminium centric
Al6061 is the form of aluminium alloy containing
magnesium and silicon as major alloying elements,
commonly used for aerospace, marine applications,
cycling and automotive applications and to make gas
cylinders. Al6061 is heat treatable, can be easily
welded, with very good corrosion resistance and
shing characteristics. It has medium strength,
Particulate composites are widely used in composites
development because they are cheap and of
manufacturing ease. Particulate reinforced MMCs
special interest because of their
specific strength and specific stiffness at room or
elevated temperatures. Ceramic particles or fibers are
commonly used as reinforcement. The basic reason of
rd ceramic particles or fibers
are improved properties than its original material like
strength, stiffness, wear resistance etc. It can also
improve strength to weight ratio of the composites.
is commonly done by the
casting among the different processing
techniques available, because it is simplest and
cheapest form, references [7][8][9].
In recent days, considerable work has been done on
ide reinforced metal matrix composites
as well as fly ash reinforced metal matrix composites.
The tungsten carbide is used as reinforcement in
Al6061 matrix composites with different weight
percentages, references [1][2][3]. The fabrication is
done by stir casting process, reference [2]. It was
found that increasing the WC content within the
International Journal of Trend in Scientific Research and Development (IJTSRD) ISSN: 2456-6470
@ IJTSRD | Available Online @ www.ijtsrd.com | Volume – 2 | Issue – 3 | Mar-Apr 2018 Page: 466
matrix material, resulted in significant improvement
in mechanical properties like hardness, tensile
strength. Density also increases with increase in
tungsten carbide content, in reference [1]. Wear
resistance increases with increase in WC content, in
reference [2].
In references [4][5][6], fly ash is used as
reinforcement in aluminium composites. Fabrication
is done by stir-casting method. It was found that as
increase in fly ash content, resulted in increase in
tensile strength, hardness and decrease in density.
II. EXPERIMENTAL DETAILS
Aluminium alloy (Al6061) is taken as base matrix
metal, tungsten carbide (WC) particulate of 2-3µm
size and fly ash are taken as reinforcements. WC was
taken in 1%, 2%, and 3% on mass fraction and fly ash
was taken 2%, 4%, and 6% on mass fraction.
A. Composite Fabrication
Fabrication of composites is done by stir-casting
method. Al6061 alloy ingots are kept in crucible
and melt in electric resistance furnace at 850˚C.
The melt was degassed by adding solid dry
hexachloroethane (C2Cl6), called degasser. The
stirring setup is brought near the furnace, stirrer is
dipped inside crucible and stirred at 500rpm. The
calculated amount of the preheated reinforcement
particles of WC and fly ash were added slowly into
the melt. As the impeller rotates it generates a
vortex that draws the reinforcement particle into
the melt from the surface. The stirring action was
carried out about 10-15min. After by removing
stirrer setup, the mixed melt is poured to the
required preheated metallic mould of 22mm
diameter and 220mm length. The molten metal is
made to solidify and the prepared casting is
removed from the mould.
The casted composites were sectioned and made to
prepare tensile testing, hardness and dry wear
testing specimens asper ASTM standards.
B. Testing for Mechanical Properties
The specimens were prepared and tensile testing
was carried out as per ASTM E8 standard in
computerized UTM. Hardness testing by Brinell
Hardness tester was carried to the prepared
specimen as per ASTM E10 standard, where steel
ball indenter of dia. 10mm and applied load of
500kgf were used.
Fig. 1: Tensile test specimens
Fig. 2: Tensile test specimens after test
Fig. 3: Brinell Hardness test specimens
International Journal of Trend in Scientific Research and Development (IJTSRD) ISSN: 2456-6470
@ IJTSRD | Available Online @ www.ijtsrd.com | Volume – 2 | Issue – 3 | Mar-Apr 2018 Page: 467
Fig. 4. Brinell Hardness tested specimens
III. RESULTS AND DISCUSSION
A. Tensile properties
TABLE I. shows the variation of tensile strength of
the composites with the different weight fractions of
tungsten carbide and fly ash particles. It can be noted
that the tensile strength increased with an increase in
the weight percentage of tungsten carbide and fly ash.
This is due to the reinforcement particles acts as
barrier to dislocation movement in microstructure.
TABLE I: THE TENSILE TEST RESULTS
Serial No. Reinforcement content (%) Peak load
(KN)
Tensile Strength
(N/mm2
)
%
Elongation
1 WC-0% and flyash-0% 16.41 130.778 16.02
2 WC-1% and flyash-2% 16.32 132.349 09.96
3 WC-1% and flyash-4% 18.05 148.036 08.90
4 WC-1% and flyash-6% 17.60 148.598 07.48
5 WC-2% and flyash-2% 18.40 150.906 06.84
6 WC-2% and flyash-4% 21.05 167.756 05.28
7 WC-2% and flyash-6% 20.56 169.430 04.90
8 WC-3% and flyash-2% 21.15 171.241 04.54
9 WC-3% and flyash-4% 20.58 173.776 03.74
10 WC-3% and flyash-6% 21.98 179.110 02.66
Fig. 5: Graph of tensile strength v/s reinforcement
content (%) with Al6061
Fig. 6: Graph of tensile strength v/s WC content
(wt. %) with varying fly ash content
International Journal of Trend in Scientific Research and Development (IJTSRD) ISSN: 2456-6470
@ IJTSRD | Available Online @ www.ijtsrd.com | Volume – 2 | Issue – 3 | Mar-Apr 2018 Page: 468
Fig. 7. Graph of tensile strength v/s fly ash content
(wt. %) with varying WC content
B. Hardness
TABLE II shows the variation of hardness of the
composites with different weight fractions of tungsten
carbide and fly ash particles. It can be noted that the
hardness of the composite increased with the increase
in weight fraction of the fly ash particles.
TABLE II: HARDNESS TEST RESULTS
Sl No Reinforcement content
(%)
Ball diameter,
D (mm)
Load, P
(Kgf)
Mean diameter of
indentation
„d‟ (mm)
Brinell
Hardness
Number, BHN
1 WC-0% and flyash-0% 10 500 4.30 32.92
2 WC-1% and flyash-2% 10 500 4.21 34.35
3 WC-1% and flyash-4% 10 500 4.15 35.30
4 WC-1% and flyash-6% 10 500 4.00 38.13
5 WC-2% and flyash-2% 10 500 3.90 40.20
6 WC-2% and flyash-4% 10 500 3.70 44.85
7 WC-2% and flyash-6% 10 500 3.57 48.31
8 WC-3% and flyash-2% 10 500 3.49 50.62
9 WC-3% and flyash-4% 10 500 3.40 53.43
10 WC-3% and flyash-6% 10 500 3.37 54.42
Fig 8: Graph of Hardness (BHN) v/s reinforcement
content (wt. %) with Al6061
Fig. 9: Graph of Hardness (BHN) v/s WC content
(wt. %) with varying fly ash content
International Journal of Trend in Scientific Research and Development (IJTSRD) ISSN: 2456-6470
@ IJTSRD | Available Online @ www.ijtsrd.com | Volume – 2 | Issue – 3 | Mar-Apr 2018 Page: 469
Fig. 10: Graph of Hardness (BHN) v/s fly ash content
(wt. %) with varying WC content
C. Microstructure
As the microstructure plays an important role in the
overall performance of a composite and the physical
properties depend on the microstructure,
reinforcement particle size, shape and distribution in
the alloy, prepared samples were examined using a
Scanning Electron Microscope (SEM) to study the
distribution pattern of tungsten carbide and fly ash in
the matrix. The micrographs of composites before and
after testing can be seen below.
Fig. 11: SEM micrograph of Al6061+WC1%+fly
ash2%.
Fig. 12: SEM micrograph of Al6061+WC2%+fly
ash2%.
Fig 13: SEM micrograph of tensile fractured surface
of Al6061+WC 1%+fly ash 2%.
Fig 14: SEM micrograph of tensile fractured surface
of Al6061+WC 2%+fly ash 4%.
International Journal of Trend in Scientific Research and Development (IJTSRD) ISSN: 2456-6470
@ IJTSRD | Available Online @ www.ijtsrd.com | Volume – 2 | Issue – 3 | Mar-Apr 2018 Page: 470
Fig. 15: SEM micrograph of tensile fractured surface
of Al6061+WC 3%+fly ash 6%.
III. CONCLUSION
Al6061 matrix composites were easily and
economically fabricated by stir-casting method with
tungsten carbide and fly ash particulates as
reinforcements. The mechanical properties are
enhanced.
From the tensile test results, it is found that the tensile
strength increased, as reinforcement content in weight
percentage increases, Increase in reinforcement
content in matrix, decreased in ductility of
composites.
From brinell hardness test results, increase in
reinforcement content in matrix, there is increase in
hardness of composites.
The enhancement effect of tungsten carbide
reinforcement is more compared to fly ash
reinforcement in tensile strength and hardness
properties.
From SEM micrograph studies, equal distribution of
reinforcement content (tungsten carbide and fly ash
particulates) in Al6061 matrix composites without any
voids formation. In tensile fractured surface, observed
that formation of voids observed. As reinforcement
content increases, the size of the voids are decreased,
indicating less ductility.
REFERENCES
1. S Jerry Andrews Fabian, B. Selvam,
“Densification behaviour of Aluminium
reinforced with Tungsten Carbide particulate
Metal Matrix Composite processed by P/M”,
IOSR Journal of Mechanical and Civil
Engineering (IOSR-JMCE), PP 24-29.
2. Amarnath.G, K.V. Sharma, “Microstructure and
tribological properties of nanoparticulate WC/Al
metal matrix composites”, International journal of
mechanical engineering and technology (ijmet),
Volume 4, Issue 2, pp. 178-188 March - April
2013.
3. Hari Prasada Rao Pydi, Balamurugan Adhithan,
A.Syed Bava Bakrudeen ,“Microstructure
Exploration of the Aluminum-Tungsten Carbide
Composite with different Manufacturing
circumstances”, International Journal of Soft
Computing and Engineering (IJSCE) ISSN: 2231-
2307, Volume-2, Issue-6, January 2013.
4. Arun Kumar M. B, R. P. Swamy, “Evaluation of
mechanical properties of Al6061, Flyash and E-
glass fiber reinforced hybrid Metal matrix
composites”, ARPN Journal of Engineering and
Applied Sciences, VOL. 6, NO. 5, pp. 40-44, May
2011.
5. Deepak Singla, S.R. Mediratta, “Evaluation of
mechanical properties of Al 7075-fly ash
composite material”, International Journal of
Innovative Research in Science, Engineering and
Technology, Vol. 2, Issue 4, April 2013.
6. H.C. Anilkumar, H.S. Hebbar, K.S. Ravishankar,
“Mechanical properties of fly ash reinforced
aluminium alloy (al6061) composites”,
International Journal of Mechanical and Materials
Engineering (IJMME), Vol.6, No.1, 41-45, 2011.
7. Lloyd D.J. and Brotzen F.R., “Particle reinforced
aluminium and Mg matrix composites” Int. Mater.
Rev; 39,1-39, 1994.
8. Rajeshkumar Gangaram Bhandare, Parshuram M.
Sonawane, “Preparation of Aluminium Matrix
Composite by Using Stir Casting Method”,
International Journal of Engineering and
Advanced Technology (IJEAT) ISSN: 2249 –
8958, Volume-3, Issue-2, December 2013.
9. G.N.Lokesh, M.Ramachandra, K.V.Mahendra,
T.Sreenith, “Effect of Hardness, Tensile and Wear
Behavior of Al-4.5wt%Cu Alloy/Flyash/SiC
Metal Matrix Composites”, International Journal
of Modern Engineering Research (IJMER) ,
Vol.3, Issue.1, pp-381-385, Jan-Feb. 2013.

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Characterization of Al/WC/Fly ash Metal Matrix Composites

  • 1. @ IJTSRD | Available Online @ www.ijtsrd.com ISSN No: 2456 International Research Characterization of Al/WC/Fly ash Metal Matrix Composites Assistant Professor, Kelappaji College of Engineering ABSTRACT Metal matrix composites are formed by combination of two or more materials (at least one of the materials is metal) having dissimilar characteristics. In this present investigation, aluminium (Al 6061) as base matrix metal and tungsten carbide (WC) particulate, fly ash as reinforcements. Fabrication of MMCs was done by stir-casting process. The Tungsten Carbide particulate was added in proportions of 1%, 2%, and 3% and Fly ash was added in proportions of 2%, 4%, and 6% on mass fraction basis to the molten metal. The different combination sets of composites were prepared. Mechanical properties like tensile strength and hardness were studied for both reinforced and unreinforced Al 6061 samples. Microstructure examination was carried by using Scanning Electron Microscope (SEM) to obtain the distribution of tungsten carbide particulate and fly ash in base matrix. From the results, it was found that the tensile strength and the hardness of the prepared metal matrix composites increased with increase in tungsten carbide and fly ash content. The Scanning Electron Micrographs of the samples indicated uniform distribution of tungsten carbide and fly ash particles in the base matrix without voids before testing and with voids after testing. Keywords: Aluminium metal matrix composite, Tungsten Carbide, Fly ash, Stir-casting, Mechanical properties, SEM I. INTRODUCTION Metal matrix composites (MMCs), like most composite materials, provide enhanced properties over monolithic materials, such as higher strength, stiffness, hardness and weight savings. Aluminium based metal matrix composites are concentrating more for engineering applications since it is the class of @ IJTSRD | Available Online @ www.ijtsrd.com | Volume – 2 | Issue – 3 | Mar-Apr 2018 ISSN No: 2456 - 6470 | www.ijtsrd.com | Volume International Journal of Trend in Scientific Research and Development (IJTSRD) International Open Access Journal Characterization of Al/WC/Fly ash Metal Matrix Composites Nithin K Assistant Professor, Kelappaji College of Agricultural Engineering and Technology, Tavanur, Kerala, India Metal matrix composites are formed by combination of two or more materials (at least one of the materials having dissimilar characteristics. In this present investigation, aluminium (Al 6061) as base matrix metal and tungsten carbide (WC) particulate, fly ash as reinforcements. Fabrication of MMCs was casting process. The Tungsten Carbide late was added in proportions of 1%, 2%, and 3% and Fly ash was added in proportions of 2%, 4%, and 6% on mass fraction basis to the molten metal. The different combination sets of composites were prepared. Mechanical properties like tensile strength ardness were studied for both reinforced and unreinforced Al 6061 samples. Microstructure examination was carried by using Scanning Electron Microscope (SEM) to obtain the distribution of tungsten carbide particulate and fly ash in base sults, it was found that the tensile strength and the hardness of the prepared metal matrix composites increased with increase in tungsten carbide and fly ash content. The Scanning Electron Micrographs of the samples indicated uniform ten carbide and fly ash particles in the base matrix without voids before testing and with Aluminium metal matrix composite, casting, Mechanical Metal matrix composites (MMCs), like most composite materials, provide enhanced properties over monolithic materials, such as higher strength, stiffness, hardness and weight savings. Aluminium tal matrix composites are concentrating more for engineering applications since it is the class of light weight and high performance aluminium centric materials system. Al6061 is the form of aluminium alloy containing magnesium and silicon as major alloying elements, commonly used for aerospace, marine applications, cycling and automotive applications and to make gas cylinders. Al6061 is heat treatable, can be easily welded, with very good corrosion resistance and finishing characteristics. It has medium strength, hardness. Particulate composites are widely used in composites development because they are cheap and of manufacturing ease. Particulate reinforced MMCs have recently found special interest because of their specific strength and specific elevated temperatures. Ceramic particles or fibers are commonly used as reinforcement. The basic reason of metals reinforced with hard ceramic particles or fibers are improved properties than its original material like strength, stiffness, wear resistance etc. It can also improve strength to weight ratio of the composites. Fabrication of composites is commonly done by the stir- casting among the different processing techniques available, because it is simplest and cheapest form, references [7][8][9]. In recent days, considerable work has been done on tungsten carbide reinforced metal matrix composites as well as fly ash reinforced metal matrix composites. The tungsten carbide is used as reinforcement in Al6061 matrix composites with different weight percentages, references [1][2 done by stir casting process, reference [2]. It was found that increasing the WC content within the Apr 2018 Page: 465 6470 | www.ijtsrd.com | Volume - 2 | Issue – 3 Scientific (IJTSRD) International Open Access Journal Characterization of Al/WC/Fly ash Metal Matrix Composites light weight and high performance aluminium centric Al6061 is the form of aluminium alloy containing magnesium and silicon as major alloying elements, commonly used for aerospace, marine applications, cycling and automotive applications and to make gas cylinders. Al6061 is heat treatable, can be easily welded, with very good corrosion resistance and shing characteristics. It has medium strength, Particulate composites are widely used in composites development because they are cheap and of manufacturing ease. Particulate reinforced MMCs special interest because of their specific strength and specific stiffness at room or elevated temperatures. Ceramic particles or fibers are commonly used as reinforcement. The basic reason of rd ceramic particles or fibers are improved properties than its original material like strength, stiffness, wear resistance etc. It can also improve strength to weight ratio of the composites. is commonly done by the casting among the different processing techniques available, because it is simplest and cheapest form, references [7][8][9]. In recent days, considerable work has been done on ide reinforced metal matrix composites as well as fly ash reinforced metal matrix composites. The tungsten carbide is used as reinforcement in Al6061 matrix composites with different weight percentages, references [1][2][3]. The fabrication is done by stir casting process, reference [2]. It was found that increasing the WC content within the
  • 2. International Journal of Trend in Scientific Research and Development (IJTSRD) ISSN: 2456-6470 @ IJTSRD | Available Online @ www.ijtsrd.com | Volume – 2 | Issue – 3 | Mar-Apr 2018 Page: 466 matrix material, resulted in significant improvement in mechanical properties like hardness, tensile strength. Density also increases with increase in tungsten carbide content, in reference [1]. Wear resistance increases with increase in WC content, in reference [2]. In references [4][5][6], fly ash is used as reinforcement in aluminium composites. Fabrication is done by stir-casting method. It was found that as increase in fly ash content, resulted in increase in tensile strength, hardness and decrease in density. II. EXPERIMENTAL DETAILS Aluminium alloy (Al6061) is taken as base matrix metal, tungsten carbide (WC) particulate of 2-3µm size and fly ash are taken as reinforcements. WC was taken in 1%, 2%, and 3% on mass fraction and fly ash was taken 2%, 4%, and 6% on mass fraction. A. Composite Fabrication Fabrication of composites is done by stir-casting method. Al6061 alloy ingots are kept in crucible and melt in electric resistance furnace at 850˚C. The melt was degassed by adding solid dry hexachloroethane (C2Cl6), called degasser. The stirring setup is brought near the furnace, stirrer is dipped inside crucible and stirred at 500rpm. The calculated amount of the preheated reinforcement particles of WC and fly ash were added slowly into the melt. As the impeller rotates it generates a vortex that draws the reinforcement particle into the melt from the surface. The stirring action was carried out about 10-15min. After by removing stirrer setup, the mixed melt is poured to the required preheated metallic mould of 22mm diameter and 220mm length. The molten metal is made to solidify and the prepared casting is removed from the mould. The casted composites were sectioned and made to prepare tensile testing, hardness and dry wear testing specimens asper ASTM standards. B. Testing for Mechanical Properties The specimens were prepared and tensile testing was carried out as per ASTM E8 standard in computerized UTM. Hardness testing by Brinell Hardness tester was carried to the prepared specimen as per ASTM E10 standard, where steel ball indenter of dia. 10mm and applied load of 500kgf were used. Fig. 1: Tensile test specimens Fig. 2: Tensile test specimens after test Fig. 3: Brinell Hardness test specimens
  • 3. International Journal of Trend in Scientific Research and Development (IJTSRD) ISSN: 2456-6470 @ IJTSRD | Available Online @ www.ijtsrd.com | Volume – 2 | Issue – 3 | Mar-Apr 2018 Page: 467 Fig. 4. Brinell Hardness tested specimens III. RESULTS AND DISCUSSION A. Tensile properties TABLE I. shows the variation of tensile strength of the composites with the different weight fractions of tungsten carbide and fly ash particles. It can be noted that the tensile strength increased with an increase in the weight percentage of tungsten carbide and fly ash. This is due to the reinforcement particles acts as barrier to dislocation movement in microstructure. TABLE I: THE TENSILE TEST RESULTS Serial No. Reinforcement content (%) Peak load (KN) Tensile Strength (N/mm2 ) % Elongation 1 WC-0% and flyash-0% 16.41 130.778 16.02 2 WC-1% and flyash-2% 16.32 132.349 09.96 3 WC-1% and flyash-4% 18.05 148.036 08.90 4 WC-1% and flyash-6% 17.60 148.598 07.48 5 WC-2% and flyash-2% 18.40 150.906 06.84 6 WC-2% and flyash-4% 21.05 167.756 05.28 7 WC-2% and flyash-6% 20.56 169.430 04.90 8 WC-3% and flyash-2% 21.15 171.241 04.54 9 WC-3% and flyash-4% 20.58 173.776 03.74 10 WC-3% and flyash-6% 21.98 179.110 02.66 Fig. 5: Graph of tensile strength v/s reinforcement content (%) with Al6061 Fig. 6: Graph of tensile strength v/s WC content (wt. %) with varying fly ash content
  • 4. International Journal of Trend in Scientific Research and Development (IJTSRD) ISSN: 2456-6470 @ IJTSRD | Available Online @ www.ijtsrd.com | Volume – 2 | Issue – 3 | Mar-Apr 2018 Page: 468 Fig. 7. Graph of tensile strength v/s fly ash content (wt. %) with varying WC content B. Hardness TABLE II shows the variation of hardness of the composites with different weight fractions of tungsten carbide and fly ash particles. It can be noted that the hardness of the composite increased with the increase in weight fraction of the fly ash particles. TABLE II: HARDNESS TEST RESULTS Sl No Reinforcement content (%) Ball diameter, D (mm) Load, P (Kgf) Mean diameter of indentation „d‟ (mm) Brinell Hardness Number, BHN 1 WC-0% and flyash-0% 10 500 4.30 32.92 2 WC-1% and flyash-2% 10 500 4.21 34.35 3 WC-1% and flyash-4% 10 500 4.15 35.30 4 WC-1% and flyash-6% 10 500 4.00 38.13 5 WC-2% and flyash-2% 10 500 3.90 40.20 6 WC-2% and flyash-4% 10 500 3.70 44.85 7 WC-2% and flyash-6% 10 500 3.57 48.31 8 WC-3% and flyash-2% 10 500 3.49 50.62 9 WC-3% and flyash-4% 10 500 3.40 53.43 10 WC-3% and flyash-6% 10 500 3.37 54.42 Fig 8: Graph of Hardness (BHN) v/s reinforcement content (wt. %) with Al6061 Fig. 9: Graph of Hardness (BHN) v/s WC content (wt. %) with varying fly ash content
  • 5. International Journal of Trend in Scientific Research and Development (IJTSRD) ISSN: 2456-6470 @ IJTSRD | Available Online @ www.ijtsrd.com | Volume – 2 | Issue – 3 | Mar-Apr 2018 Page: 469 Fig. 10: Graph of Hardness (BHN) v/s fly ash content (wt. %) with varying WC content C. Microstructure As the microstructure plays an important role in the overall performance of a composite and the physical properties depend on the microstructure, reinforcement particle size, shape and distribution in the alloy, prepared samples were examined using a Scanning Electron Microscope (SEM) to study the distribution pattern of tungsten carbide and fly ash in the matrix. The micrographs of composites before and after testing can be seen below. Fig. 11: SEM micrograph of Al6061+WC1%+fly ash2%. Fig. 12: SEM micrograph of Al6061+WC2%+fly ash2%. Fig 13: SEM micrograph of tensile fractured surface of Al6061+WC 1%+fly ash 2%. Fig 14: SEM micrograph of tensile fractured surface of Al6061+WC 2%+fly ash 4%.
  • 6. International Journal of Trend in Scientific Research and Development (IJTSRD) ISSN: 2456-6470 @ IJTSRD | Available Online @ www.ijtsrd.com | Volume – 2 | Issue – 3 | Mar-Apr 2018 Page: 470 Fig. 15: SEM micrograph of tensile fractured surface of Al6061+WC 3%+fly ash 6%. III. CONCLUSION Al6061 matrix composites were easily and economically fabricated by stir-casting method with tungsten carbide and fly ash particulates as reinforcements. The mechanical properties are enhanced. From the tensile test results, it is found that the tensile strength increased, as reinforcement content in weight percentage increases, Increase in reinforcement content in matrix, decreased in ductility of composites. From brinell hardness test results, increase in reinforcement content in matrix, there is increase in hardness of composites. The enhancement effect of tungsten carbide reinforcement is more compared to fly ash reinforcement in tensile strength and hardness properties. From SEM micrograph studies, equal distribution of reinforcement content (tungsten carbide and fly ash particulates) in Al6061 matrix composites without any voids formation. In tensile fractured surface, observed that formation of voids observed. As reinforcement content increases, the size of the voids are decreased, indicating less ductility. REFERENCES 1. S Jerry Andrews Fabian, B. Selvam, “Densification behaviour of Aluminium reinforced with Tungsten Carbide particulate Metal Matrix Composite processed by P/M”, IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE), PP 24-29. 2. Amarnath.G, K.V. Sharma, “Microstructure and tribological properties of nanoparticulate WC/Al metal matrix composites”, International journal of mechanical engineering and technology (ijmet), Volume 4, Issue 2, pp. 178-188 March - April 2013. 3. Hari Prasada Rao Pydi, Balamurugan Adhithan, A.Syed Bava Bakrudeen ,“Microstructure Exploration of the Aluminum-Tungsten Carbide Composite with different Manufacturing circumstances”, International Journal of Soft Computing and Engineering (IJSCE) ISSN: 2231- 2307, Volume-2, Issue-6, January 2013. 4. Arun Kumar M. B, R. P. Swamy, “Evaluation of mechanical properties of Al6061, Flyash and E- glass fiber reinforced hybrid Metal matrix composites”, ARPN Journal of Engineering and Applied Sciences, VOL. 6, NO. 5, pp. 40-44, May 2011. 5. Deepak Singla, S.R. Mediratta, “Evaluation of mechanical properties of Al 7075-fly ash composite material”, International Journal of Innovative Research in Science, Engineering and Technology, Vol. 2, Issue 4, April 2013. 6. H.C. Anilkumar, H.S. Hebbar, K.S. Ravishankar, “Mechanical properties of fly ash reinforced aluminium alloy (al6061) composites”, International Journal of Mechanical and Materials Engineering (IJMME), Vol.6, No.1, 41-45, 2011. 7. Lloyd D.J. and Brotzen F.R., “Particle reinforced aluminium and Mg matrix composites” Int. Mater. Rev; 39,1-39, 1994. 8. Rajeshkumar Gangaram Bhandare, Parshuram M. Sonawane, “Preparation of Aluminium Matrix Composite by Using Stir Casting Method”, International Journal of Engineering and Advanced Technology (IJEAT) ISSN: 2249 – 8958, Volume-3, Issue-2, December 2013. 9. G.N.Lokesh, M.Ramachandra, K.V.Mahendra, T.Sreenith, “Effect of Hardness, Tensile and Wear Behavior of Al-4.5wt%Cu Alloy/Flyash/SiC Metal Matrix Composites”, International Journal of Modern Engineering Research (IJMER) , Vol.3, Issue.1, pp-381-385, Jan-Feb. 2013.
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