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Materials Today: Proceedings 18 (2019) 2563–2572 www.materialstoday.com/proceedings

ICMPC-2019

Microstructural and Mechanical Characterization of Al-4032 based

Metal Matrix Composites
Deepak Kumara, Pradeep K. Singhb*
a
Ph.D. Scholar, Dept. of Mechanical Engineering, Sant Longowal Institute of Engineering & Technology, Longowal, 148106, India
b
Professor, Dept. of Mechanical Engineering, Sant Longowal Institute of Engineering & Technology, Longowal, 148106, India

Abstract

This paper presents an alternative material to the aluminum-silicon alloys used in automotive applications with focus on
investigation of the morphological and mechanical behavior of the metal matrix composites formed. The silicon carbide
reinforced aluminium alloy (Al-4032) metal matrix composites have been produced through the stir casting technique. Four
different compositions, i.e. 0, 3, 6 and 9% (by weight) silicon carbide reinforcement with the particle size 37-54μm have been
used. Also, 1% magnesium powder (by weight) has been used for better interfacial bond between the matrix and reinforcement.
In general, all the mechanical properties, the tensile strength, hardness, and impact strength have been observed to improve with
the reinforcement over the base metal. These properties have also been found to improve with increase in the weight percentage
of the reinforcement
© 2019 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the 9th International Conference of Materials Processing and Characterization, ICMPC-2019

Keywords: Composites, Al-4032, Silicon carbide, Microstructure, Mechanical testing

1. Introduction

A composite material is produced by mixing two or more physically and chemically distinct phases whose
combination produces aggregate properties that are different from those of its constituents (Johnson, 1989; Harris,
1999; Kaw 2006). Among all composites, the metal matrix composites (MMCs) are an important class of
engineering materials. The MMCs are rapidly replacing many conventional materials in automotive, aerospace,

* Corresponding author. Tel.: +91-941-746-2320; fax: +91-167-225-3123.

E-mail address: [email protected]

2214-7853 © 2019 Elsevier Ltd. All rights reserved.

Selection and peer-review under responsibility of the 9th International Conference of Materials Processing and Characterization, ICMPC-2019
2564 D. Kumar and P.K. Singh / Materials Today: Proceedings 18 (2019) 2563–2572

marine, and sports industries due to their light weight, superior mechanical and tribological properties (Schwartz,
1984; Prasad & Rohtagi, 1987; Torralba et al., 2003). In MMCs, metal acts as the matrix, and its main function is to
transfer and distribute the load to the reinforcements. This transfer of load depends on the interface bonding between
the matrix and the reinforcement (Hamuoda and Hashmi, 1996).

By far most of the metal matrix composites, both in research and development, as well as in industrial
applications, are based on aluminium and its alloys. This is because aluminium is light in weight, which is the basic
requirement in most of the applications of metal matrix composites. Additionally, it is economical as compared to
other light metals, such as copper, titanium and magnesium (Rohtagi, 1991; Yilmaz et al., 2001). Over past few
years, the aluminum matrix composites have been gaining more and more attention in industrial applications because
of changing operational requirements, low density, high fluidity, good cast-ability, low thermal expansion, high
damping limit, high wear & corrosion resistance (Rohtagi, 1991; Eliasson & Sandstrom, 1995; Yilmaz et al., 2001).
Among all the available types of composite materials, the particle reinforced composites appear to be the most
promising ones owing to their isotropic material properties and low cost (Bandyopadhyay et al., 2007). Perhaps
because of this reason, several researchers reported the studies on the incorporation of different hard ceramic
particles like SiC, Al2O3, TiO2 etc., into a soft matrix – the aluminum alloys (Kaczmar et al., 2000; Prasad &
Asthana, 2004, Pawar & Utpat, 2014).

The aluminium matrix based composites can be fabricated through various processes such as squeeze casting,
investment casting, stir casting, powder metallurgy, pressure and pressure less infiltration, diffusion bonding,
deposition techniques, vortex method, compo casting, gas injection, metal injection molding, and in-situ formation
(Seshan et al. 1996, Kaczmara et al. 2000, Kandpal et al., 2014). Out of these, the stir casting and powder metallurgy
are the most widely used processing methods for fabrication of metal matrix composites (Torralba et al. 2003). The
stir casting of metal matrix composites was initiated in 1968 (Narashima et al. 2013; Kala et al. 2014). Surappa &
Rohatgi (1981) developed the vortex-mixing technique for preparation of the ceramic particle dispersed aluminium
matrix composites. The major advantage of the stir casting process is its applicability to mass production for its
simplicity and economy of operation.

2. Literature Review

Fabrication and testing of MMCs for improvement of various properties over the base metal and obtain the best
material for a given application has been an interesting topic for decades. A few important studies reported in
literature are presented below.

Yu et al. (2006) fabricated metallic glass particle-reinforced Al-based metal matrix composite. The 30% Ni-
70Nb-30 metallic glass powders was reinforced in the pure aluminium through powder metallurgy route, sintering at
773K, below the melting temperature of aluminium. The composite so obtained has been found to exhibit the
improved Young’s modulus, yield strength and ultimate tensile strength over the pure aluminium.

Kerti & Toptan (2008) fabricated the aluminium based metal matrix composite with the reinforcement of the B4C
(particle size 10μm and 20μm) at different weight fraction – 5%, 10%, and 15%, through casting process. The
K2TiF6 flux was used to avoid the formation of undesirable phases. The addition of B4C with bigger particle size
appears to have resulted in better and homogeneous microstructure with free of agglomerated particles, using the
K2TiF6 flux by casting method. For higher particle ratios (i.e. 15%) and bigger size B4C particles (20 μm), the
amount of flux should be at least equal to the amount of B4C particles, for the better bonding effect between matrix
and reinforcement.

Manna et al. (2011) fabricated the aluminum (Al-6070)/ alumina (Al2O3) and Al-6070/ graphite (Gr) reinforced
metal–matrix composites by melt-stirring technique, with varying 5% to 15% volume fraction of reinforcement. The
average reinforcement particle size of alumina (Al2O3) and graphite (Gr) has been 23 and 53 mm, respectively. The
 D. Kumar and P.K. Singh / Materials Today: Proceedings 18 (2019) 2563–2572 2565

hardness of the composite was observed to increase with the increase in reinforcement. On the other hand, both the
tensile strength and impact strength appear to decrease with increase in reinforcement.

Gangwar & Patnaik (2013) studied the physical and mechanical properties for the micro TiO2 (1, 3, 5, 7 and 9%
by weight) reinforced Al-380 alloy composites. The mechanical properties of the composites have been observed to
be satisfactory except for the flexural strength and impact strength. The physical properties, such as void fraction
was found to increase (2.22 to 3.02%) with increase in reinforcement. The hardness of the composites increases
from 35.5Hv to 62.5Hv, but the impact strength decreases from 6.11J to 4.22J. The tensile strength also improves
with the addition of reinforcement content in the alloy composites from 225MPa to 300MPa.

Moorthy et al. (2015) fabricated a hybrid composite of Al-2218 with the 5, 10, 15 wt% of fly ash and 4 wt% of
talc by stir casting method. It was found that the accumulation of both fly ash and talc particles into the matrix
improves the wear resistance of the composite with increasing volume of fly ash.

Wang et al. (2016) studied the microstructure and mechanical behavior of metal matrix composite, containing Al-
7075 matrix reinforced with Zr-based metallic glass fibers, using spark plasma sintering process with low porosity.
It was found that the reinforcing phase improves the mechanical properties of the composite and inhibits the plastic
deformation and retards the crack propagation. The deformation behavior of the composite material indicates that
local plastic deformation occurs in the matrix near the glassy reinforcements, followed by the initiation and
propagation of cracks mainly through the matrix.

Ravikumar et al. (2017) investigated the mechanical properties of aluminum alloy (Al-6082) based metal matrix
composites, reinforced with tungsten carbide (WC) particles (2, 4, 6, 8 and 10% by weight). The composites were
produced through stir casting process. It was found that the hardness of composites increases, but the density, impact
strength and elongation decrease with increase in tungsten carbide particles content.

Selvakumar et al. (2017) characterized the metal matrix composite, formed by reinforcing molybdenum particles
(0, 6, 12, 18 vol.%) in Al-6082 aluminum alloy, using friction stir processing. A homogenous distribution of the Mo
particles in the composite was formed. The improvement in tensile strength of the composite without compromising
on ductility was observed. The mechanical tests reveal that the ultimate tensile strength obtained 222 MPa at 0
vol.% and 305 MPa at 18 vol.%. And, the ductility was tested to be 24% and 14% at 0 vol.% and 18 vol.% of Mo
particles respectively. The microstructure study showed that the Mo particles were well bonded with the aluminum
matrix without any pores and reaction compounds at the interface.

Sharma et al. (2018) investigated the effect of particle size on the dry sliding wear behavior of the aluminum-
based metal matrix composites, fabricated through the stir casting, by reinforcing the sillimanite particles in LM-30.
The composites reinforced with sillimanite in different composition (3–18% by weight) and particle size range (fine:
1–20 μm, medium: 32–50 μm, and coarse: 75–106 μm) were produced. From the microstructural studies, it was
revealed that the sillimanite particles were uniformly distributed in composites. The nanoindentation taken at
different phases indicated the good bonding between reinforced particles and matrix. Fine particles (1–20 μm)
reinforced composites containing 15 wt% sillimanite exhibited higher wear resistance which is 55% more compared
to base LM30 alloy. Beyond this reinforcement level, wear resistance deteriorated because of agglomeration of the
fine particles.

This paper presents the effect of silicon carbide particles on the microstructure and mechanical properties of the
Al-4032. The aluminum alloy Al-4032 has been used as the metal matrix and the silicon carbide powder as the
reinforcement, for fabrication of the composites. A series of composites reinforced with different weight fraction (0,
3, 6 and 9%) of silicon carbide powder have been fabricated using a high temperature bottom pouring stir casting
machine. This followed the investigation of the morphological and mechanical properties of the composites so
obtained.
2566 D. Kumar and P.K. Singh / Materials Today: Proceedings 18 (2019) 2563–2572

3. Experimental Study

3.1. Materials

For preparing metal matrix composite, the alloy Al-4032 has been used as the matrix and the silicon carbide
particles with fraction 0, 3, 6 and 9% (by weight) as the reinforcement. The particle size of the silicon carbide
powder has been in the range 37-54 μm. Chemical composition of the aluminium alloy (Al-4032) is shown in Table
1. The designation of the composites as per fraction of the reinforcement is shown in Table-2.

Table 1. Chemical composition (fraction – percentage by weight) of the Al-4032

Component Si Cu Mg Cr Ni Zn Mn Al

wt% 11.53 0.9 1.00 0.10 0.8 0.25 0.415 Rest

Table 2. Designation used for the AMC’s sample

Wt% of the SiC 0 3 6 9

Designation A0 A1 A2 A3

3.2 Processing of Composites

The stir casting has been adopted for fabrication of the aluminium metal matrix composites (AMC) using the
bottom pouring stir casting machine (Figure-1). The silicon carbide particles are preheated at 350-4000C for 30
minutes. The base metal is melted at temperature 700-7500C and stirred with the stirrer in the crucible for 5-10 min
at the 650 RPM. The silicon carbide powder is mixed slowly into the molten base metal at reduced stirring speed.
The magnesium powder (1 wt%) is mixed for better interfacial bond between the matrix and the reinforcement. The
mixture is further stirred at a speed of 650 RPM for 8-10 min, followed by pouring into the cast iron mould for
casting under air cooling.

Fig. 1. Bottom Pouring Stir Casting Machine, at the Advanced Welding and Casting Lab,
PEC University, Chandigarh
 D. Kumar and P.K. Singh / Materials Today: Proceedings 18 (2019) 2563–2572 2567

3.3 Testing of the AMC’s

3.3.1 Microstructure Analysis
The samples are prepared for microstructural characterization and various mechanical tests as per the ASTM
standards. The microstructural study, the samples (10x10x5 mm3) were cut and polished at the paper grit size up to
3000micron, followed by polishing with diamond paste on the velvet paper. The Keller’s etchant was applied on the
samples to study the microstructure. The chemical composition of the Keller’s etchant is shown in the Table 3.
Finally, the microstructural study has been carried out at the Light Microscope A-LM machine.

Table 3. Chemical Composition of the Keller’s etchant

Chemicals Distilled water Nitric acid Hydrochloric acid Hydrofluoric acid

Quantity (ml) 190 5 3 2

3.3.2 Mechanical Characterization

The mechanical characterization of the AMCs has been attempted through the tensile test, micro-hardness test and
the impact test.
(a) Tensile test
The tensile test has been carried out to obtain the ductility of the material (percentage elongation) and ultimate
tensile strength of the material. The tensile test specimen was prepared as per the ASTM E-08 standards (Figure 2)
on wire-cut electron discharge machine. The tensile tests were performed on the Universal Testing Machine.
(b) Micro-hardness Test
The samples for the micro-hardness test were prepared as per the ASTM E-92 standards. The samples were polished
up to 1500 grit size to make the surface free from irregularities. A vicker micro hardness tester was used.
(a) Impact Test
The Charpy impact test was performed on the aluminium metal matrix composite. A sample size 10x10x55 mm3
was prepared with a notch of depth of 2mm at 450 according to the ASTM A-370 standards (Figure 3).

Fig. 2. Tensile Test Specimen as per the ASTM E-08 standards

Fig. 3. Charpy Impact Test Specimen as per the ASTM A-370 standards
2568 D. Kumar and P.K. Singh / Materials Today: Proceedings 18 (2019) 2563–2572

4. Results and Discussions

4.1 Microstructural study
The microscopic study of the samples of the AMC composites reveal that the reinforcement particles are uniformly
distributed in the base metal. As the weight percentage of the reinforcement is increased, the particles start to
coagulate and disturb the uniformity of particle distribution. The white circle in the microstructure images, as shown
in Figure 4 (a-d), reveals the SiC particles distributed in the Al-4032 matrix.

Fig. 4. Microstructral Image of the Al-4032 matrix composite at 100X magnification for different compositions
(a) A0 (b) A1 (c) A2 (d) A3

4.2 Mechanical Properties – Effect of SiC Particles

4.2.1 Tensile Strength

The tensile test reveals that the ultimate strength of the Al-4032 based composites is increases as the weight
percentage of the SiC particles up to 6%, followed by a decrease, as shown in the Table 4. The decrease in the
ultimate strength at the higher weight percentage of the silicon carbide particles occurs possibly because at higher
percentage the particles tend to coagulate to form a mesh, weakening weakens the region. The uniform distribution
of the ceramic particles and the bonding between matrix and the reinforcement results in the increase in the ultimate
strength of the composites. The same happens with the ductility (percentage elongation). As the weight percentage
of the reinforcement increases, the ductility of the composite materials will decrease.
 D. Kumar and P.K. Singh / Materials Today: Proceedings 18 (2019) 2563–2572 2569

4.2.2 Hardness and Impact Energy

The Vicker micro-hardness test reveals that the hardness value of the Al-4032 based composites increases with the
increase in weight percentage of reinforcement up to 6%, followed by a decrease. Similarly, the Charpy test for
impact energy indicates that the impact energy of the Al-4032 based composites increases with the increase in
weight percentage of reinforcement up to 6%, followed by a decrease as shown in below Fig 5 (a-c) .

Table 4. Tensile test results of the Al-4032 based MMCs

Composition Designation Modulus (MPa) Ultimate Strength (MPa) % Elongation
Al-4032 A0 1960 69.4 13.3

Al-4032 +3% SiC A1 2290 100 16.1

Al-4032 +6% SiC A2 2540 138 18.4

Al-4032 +9% SiC A3 2320 124 14.3

Tensile Test Tensile Test

160 3000
ULTIMATE STRENGTH (MPA)

140 138 2540

2500
120 124 2290 2320
2000 1960
MODULUS (MPA)

100 100
80 1500
69.4
60 1000
40 500
20
0
0 A0 A1 A2 A3
A0 A1 A2 A3
SAMPLE DESIGNATION
SAMPLE DESIGNATION
A B

Tensile Test
20
% ELONGATION (DUCTILITY)

18.4
16.1
15 14.3
13.3
10

0
A0 A1 A2 A3
SAMPLE DESIGNATION

Fig. 5. Graphical representation of the tensile test of the Al-4032 based metal matrix composites
(a) Ultimate strength MPa (B) Modulus MPa (c) Percentage elongation
2570 D. Kumar and P.K. Singh / Materials Today: Proceedings 18 (2019) 2563–2572

The improvement in the hardness and the impact energy with the increase in the reinforcement can be due to the
strong bond formation between the matrix and the reinforcement. However, the decrease beyond 6% reinforcement,
can possibly be due to coagulation tendency of the reinforcement particles resulting in formation of mesh, a weak
region in the composites as shown in below Fig 6 and Table 5.

Table 5. Micro-hardness and Impact test results of the Al-4032 based MMCs

Composition Designation Hardness (VHN) Impact Energy (J)

Al-4032 A0 137 22

Al-4032 +3% SiC A1 172 27.5

Al-4032 +6% SiC A2 216 38

Al-4032 +9% SiC A3 189 32

Micro-Hardness Test (VHN) Charphy Impact Test

250
40
HARDNESS VALUE (VHN)

216 38
IMPACT ENERGY (JOULE)

200
189 30 32
172 27.5
150
137 20 22
100
10
50
0
0 A0 A1 A2 A3
A0 A1 A2 A3 SAMPLE DESIGNATION
SAMPLE DESIGNATION

A B
Fig. 6. Variation of (A) micro-hardness (B) Charpy’s Impact energy, of Al-4032 based MMCs

5. Conclusion

In this study, an attempt has been made to fabricate the SiC (particle size 37-54μm) reinforced Al-4032 matrix-
based metal matrix composites through stir casting. After microstructural analysis, mechanical tests have been
conducted to study the effect of addition/ variation of SiC particles on the properties of the base metal and the
composites. The main outcomes of this study are as follows.
a. The uniform distribution of the silicon carbide particles in the Al-4032 metal matrix has been achieved, as
revealed through the microstructure study.
b. The mechanical properties of the composite materials appear to have been improved than those of the base
metal.
c. The sample A2 (i.e. Al-4032+6% SiC) yields the highest mechanical properties – tensile strength, hardness
value and impact strength.
d. The mechanical properties of the MMCs appear to be increasing with increase in the weight fraction of the
reinforcement material up to 6%, followed by a decrease with further increase in the reinforcement.
 D. Kumar and P.K. Singh / Materials Today: Proceedings 18 (2019) 2563–2572 2571

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