Thesis Abstract

Metal Matrix Composites (MMC’s) have evoked a keen interest in recent times for potential applications. Composite materials like Particle-reinforced Aluminium Silicon carbide (Al/SiC) Metal-Matrix Composite is gradually becoming very important materials in manufacturing industries e.g. aerospace, automotive and automobile industries due to their superior properties such as light weight, low density, high strength to weight ratio, high hardness, high temperature and thermal shock resistance, superior wear and corrosive resistance, high specific modulus, high fatigue strength etc. In this study, Connecting rods made from commercial pure aluminum alloy (about 99.1% purity) / Silicon carbide (SiC) reinforced particles metal-matrix composites (MMCs) are fabricated by green sand casting. The MMCs connecting rods (Big end ø 68 mm, pin end ø 32 mm, 136 mm Center to Center height) are prepared by varying the reinforced particles by weight fraction ranging from 0%, 5%, 10%, 15% and 20 %. The average reinforced particles size of SiC are 75 microns (µm), 125 microns (µm) and 300 microns (µm) respectively. The microstructure and mechanical properties like Ultimate tensile strength (MPa), Breaking strength (MPa), Elastic Modulus (Mpa), % Elongation, Hardness (HRB), are investigated on prepared specimens of MMCs. It was observed that the hardness of the composite is increased with increasing of reinforced particle weight fraction. The tensile strength is increased with rising of reinforced weight fraction. Different mechanical tests were conducted and presented by varying the particle size and weight fractions of the Silicon carbide (SiC) particulates.

Thesis Overview

1.0: INTRODUCTION

The rapid development in the automobile and aircraft industries requires among other things, the integration of unique materials for design purposes that reduce fuel consumption to preserve the dwindling hydrocarbon resources without compromising other attributes such as safety, performance, recyclability and cost. Similarly, the current trend of materials in car industry is towards replacing metal parts more and more by these unique materials in order to improve the fuel economy and reduce the weight of the vehicles. These categories of unique materials include composite materials which are widely used in aerospace, automotive, electronics and medical industries. Composites are materials in which the desirable properties of separate materials are combined by mechanically or metallurgically binding them together. Each of the components retains its structure and characteristic, but the composite generally possesses better properties. Composite materials offer superior properties to conventional alloys for various applications as they have high strength, low weight, high modulus, low ductility, high wear resistance, high thermal conductivity and low thermal expansion.

1.2: PROBLEM STATEMENT

1.3: OBJECTIVE OF STUDY

The main purposes in accomplishing of this project are:

1. To synthesis silicon carbide particle reinforced aluminum metal matrix composite connecting rods using green sand casting process process.
2. To study the effect of weight percentage of silicon carbide on mechanical behavior of aluminum metal matrix composite.

• To characterize the properties of aluminum metal matrix composite on hardness and microstructure.

1. To investigate the viability of Sand Cast Particle reinforced Aluminium Silicon carbide Connecting rods.

1.4: JUSTIFICATION OF THE STUDY

1.5: SCOPE OF THE PROJECT

This study is limited to green sand cast Particle reinforced Aluminium Silicon carbide Metal Matrix composite connecting rods. Commercially pure Aluminium alloy (up to 99.1% Purity) was used as the matrix and Silicon Carbide reinforcements of 75, 125 and 300 microns sizes were used respectively. The casting, tensile and hardness tests were done at Foundary Workshop and Materials Science lab at the Federal University of Technology Owerri. The metallographic test was carried out at TCR Engineering Services PVT Limited India. Only materials and calculations considered relevant to this work are included