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ICTMES 2020 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 1189 (2021) 012019 doi:10.1088/1757-899X/1189/1/012019

Evaluation of Mechanical Properties of Ceramic Reinforced

Aluminium-7029 Hybrid Composite
K S Madhu*, B N Sharath, C V Venkatesh, D G Pradeep

Department of Mechanical Engineering, Malnad College of Engineering, Hassan,

affiliated to VTU, Belagavi, Karnataka, India

*Corresponding author e-mail address: [email protected]

Abstract. Composites are often chosen for structural applications because they have tailored
material properties. The production of hybrid metal matrix composites has become a major
research area in materials science. With this interest, present paper deals with fabrication of
aluminium alloy (Al-7029), boron carbide (B4C) and graphite (Gr) hybrid composite using
conventional stir casting is investigated. Evaluation of mechanical properties such as tensile
hardness and impact strength of base alloy with reinforcement [B4C (2%, 4%, 6%, 8%) with
constant 2% Gr] was performed on the samples. After solidification, the samples are prepared
according to ASTM standards and tested to find the various mechanical properties like tensile,
hardness and impact. It was observed that the hybrid composite tensile strength was increased,
with decrease in elongation rate of unreinforced aluminium alloy. The impact strength and
hardness property for a hybrid composite was increased compared to base alloy. The
composite's microstructure was studied using a Scanning Electron Microscope (SEM).

Keywords: Metal matrix composites; Boron carbide; graphite; Hardness; Impact test;
Tensile strength.

1. Introduction

Over the past few years, industries have focused on materials with multiple applications, which are
lightweight, durable, and cost effective. Hybrid composites are more popular recently, and they cover
multiple material properties. We have a broad range of aluminium alloys to choose from when
developing material for automotive applications. Mechanical properties of the aluminium based
composite can be enhanced with the addition of reinforcement, when compared to the base alloy.
Addition of ceramic reinforcements to aluminium metal matrix composites (AMMCs) exhibit superior
strength and rigidity, resistance to creep and wear. Addition of boron carbide (B4C) improve tensile
strength, impact strength, toughness and show stronger interface bonding with the aluminium matrix.
Addition of graphite reduces the wear rate of the composite due to its self-lubricating property [1].
The properties of AMCs can be tailored to the requirements of various industrial applications by
appropriate combinations of matrix, reinforcement, and processing routes [2-4]. The most used
industrial method of producing aluminium-based composites is traditional stir casting. Because of its
applicability to mass production and cost-efficiency [5]. Ceramic particle reinforced aluminium
composites have shown a significant improvement in their mechanical properties [6]. Al6061 and
Al7015 alloy with TiB2 particulates reinforced composite produced by hot extrusion were studied to
evaluate the mechanical properties. Tests were done for room and high temperature condition (500
°C) for both the composites. Al7015+ TiB2 composites show the better result with hardness up to
148HV and UTS till 400 MPa at room temperature [7]. Mechanical behaviour of B4C reinforced with
Al-7075 matrix composite were studied. It was found that the ultimate tensile strength, compressive
strength, and the hardness of the composite increased linearly with increase in volume percentage of
B4C. Also, the wear effect found minimum in the composite with 10 % B4C [8]. Keeping 3% weight
fraction of Gr and by varying the weight percentage (3-12 %) of B4C Aluminium alloy (LM25)
composites were characterised for wear and hardness test. Vicker’s hardness value increased with
increase in B4C reinforcement. Aluminium alloy with 12% B4C+3%Gr found with better
characteristics [9]. Dry sliding friction behaviour Al-SiC-Gr particles was studied. Concluded that the
load is the most important factor affecting the friction coefficient of the hybrid composite followed by

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ICTMES 2020 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 1189 (2021) 012019 doi:10.1088/1757-899X/1189/1/012019

sliding speed. The coefficient of friction increased with increase in load and sliding distance. The
author also revealed that the average friction coefficient of the hybrid composite is quite low
compared to pure alloy [10]. It was found that wear behaviour of Al 7075/Bagasse ash/Gr hybrid
composite the percentage of ceramic phase weight increased and finally suggested wear behaviour of
hybrid composites containing graphite showed superior wear resistance [11].
In the present paper, fabrication of aluminium alloy (Al-7029), boron carbide (B4C) and graphite
(Gr) hybrid composite using conventional stir casting is carried. The prepared composites were
subjected to mechanical properties such as tensile hardness and impact strength of base alloy with
reinforcement [B4C (2%, 4%, 6%, 8%) with constant 2% Gr]. The composite's micro structure was
studied using a Scanning Electron Microscope (SEM).

2. Experimentation

2.1 Material selection

Aluminum-7029 alloy, containing zinc and magnesium as its main alloy elements, selected as the base
material due to its good mechanical properties, such as high corrosion resistance, re-crystallization
capability and the most economical thermal aluminium alloy. Table 1 and 2 shows the chemical
composition of the Al7029 alloy and material composition used for this study.
Table 1. Chemical composition of Al7029 alloy (mass fraction%) [3]
Si Fe Cu Mn Mg Zn Ti V Al
0.10 0.12 0.5-0.9 0.03 1.3-2.0 4.2-5.2 0.05 0.05 Remaining
Table 2. Material composition in percentage
Sample Al7029 Boron carbide Graphite
A 100 0 0
B 96 2 2
C 94 4 2
D 92 6 2
E 90 8 2
Commercially available boron carbide (partial size average 50 μm [1]) and graphite reinforcements
were used for preparing the composites with Al7029 matrix material. The chemical composition of
master alloys used in the present study is reported in Table 1. Al7029 alloys was procured from M/s
Fen fee Metallurgical, Bangalore, India. Boron carbide was procured from Parshwamani metals,
Mumbai, India, and graphite was procured from Graphite India, Bangalore, India.

2.2 Material preparation

Hybrid Al7029-B4C-Gr composites were fabricated by stir casting technique using electrical furnace
of 5 kW capacity. Figure.1a and figure.1c shows photograph of casting furnace and cast specimen
used in the present study. Graphite crucible is used because Al7029 matrix material melt was held for
90 minutes at a temperature between 600 and 700 ºC, at this temperature graphite crucible does not
react with Al7029. Magnesium (3%) was added to the molten metal as the Al7029 ingot material
reached a liquent condition to enable the dispersion of particles inside the molten metal. 2% boron
carbide has been preheated at temperature of 500 °C to remove moisture or any other gases. Boron
carbide fine-reinforcing particles (50μ) has been applied to a molten metal, which can have
heterogeneous nuclei. Stirring is carried for 15-20 minutes at 150 rpm to acquire consistent
distribution of B4C particulate in Al7029. Graphite (2%) was pre-heated and poured into the premixed
molten metal (Al7029 with B4C). Stirring is further carried up to 10-15 minutes to ensure proper
mixing of Gr with molten metal. Degasification agent hexa-chloroethane (C2Cl6) is used to eliminate
porosity, voids, and casting defects. Progressive solidification will begin when hot molten metal has
been poured into the pre-heated die. The molten pool is then allowed to solidify and are extracted at
room temperature [1].

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ICTMES 2020 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 1189 (2021) 012019 doi:10.1088/1757-899X/1189/1/012019

Figure 1a. Preheated Die Figure 1b. Pouring

Figure 1. Stir casting setup Figure 1c. Cast sample

2.3 Test procedure
Cast samples are machined as per ASTM standards accordingly. Tensile behaviour of the sample is
conducted as per ASTM E8 standard. As per ASTM E10 standard, Brinell hardness test was carried
out by applying load of 50 g for a period of 10 seconds. Readings were taken at five various places on
the sample and an average value was used for study. Charpy impact test was carried to measure the
samples’ ability to resist high rate loading and samples were prepared according to the ASTM E23
standard. Metallographic investigation was carried out through scanning electron microscope
(SEM). Etching was done using 10% NaOH solution on the surface of polished sample.

3. Results and Discussions

3.1 Tensile strength

Purpose of this study is to investigate tensile strength of Al7029 and HMMc (Al7029-B4C-Gr).
Tensile test is carried out in Universal testing machine. Tensile strength increases progressively with
a rise of up to 6% in the composition of B4C. Results of the tensile tests also revealed significant
improvement in (2 % wt of B4C & Gr) reinforced hybrid composite. Increase in tensile strength
(reinforcement up to 6% B4C & 2%Gr) is also attributed to increase in grain boundary area due to
grain refinement and effective propagation of applied tensile load to well-bound reinforcement with a
standardized distribution. Strength of ceramic materials lies much higher than metallic materials and
higher than that of the matrix alloy. Under the applied stress, grain boundaries serve as an obstruction
to the dislocation movement and ultimately results in a dislocation stack on the grain boundaries.
Again, multi-directional stress induced during elongation easily starts multi-gliding system under
applied stress so that dislocations were found developing and moving in several directions. These
multi glide planes agglomerate with reinforcement particles under the applied stress forms grain
boundary ledges. As applied load increases, these ledges act as obstacle to dislocation movement
resulting in pile-ups. The cumulative impact of these two barriers enhances the hybrid composite 's
strength.

Figure 2. Stress v/s strain Figure 2a. Tensile strength

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ICTMES 2020 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 1189 (2021) 012019 doi:10.1088/1757-899X/1189/1/012019

3.2 Hardness test

Experiments are done with the constant Gr (2%), changing weight fraction B4C (2%, 4%, 6%, 8%).
The graph reveals that Al7029 alloy surface hardness rises steadily, with rise in the weight percentage
of strengthening particulates (B4C & constant 2 % Gr). The results of hardness test conducted on
unreinforced Al7029 and hybridised Al7029 samples have shown that matrix hardness levels are
growing with reinforcement material up to 6% (Figure 3.). Effects of hardness measurements shows
that the increase in reinforcement content results in a considerable increase in hardness which can be
mainly due to; the existence of hard ceramic B4C & Gr particles scattered in the matrix, the
deformation restricted due to their inclusion during indentation and the reduced size of grain due to
the chilling phase.

Figure 3. Hardness
3.3 Impact test
Figure 4 portrays the variation in the impact strength of the specimen for varying wt. % of
reinforcements. Energy observed by the 6 wt. % primary reinforced composite is superior to the other
composites. The increase in impact strength is due to the reduction in the porosity. Experiment is
carried out on Al7029 Alloy with different weight divisions B4C (0%, 2%, 4%, 6%, 8%) and Gr (2%).
At the beginning, the impact strength increases with increase in percentage composition of B4C and
Gr. It has been concluded that (Al7029+6%B4C-2%Gr) hybrid composite has the highest impact
capacity. It is concluded that highest impact strength is for Al6082 hybrid composite with 8% B4C
and 2% Al203 reinforcements, this indicates that maximum amount of energy is absorbed during
fracture.

Figure 4. Impact energy

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ICTMES 2020 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 1189 (2021) 012019 doi:10.1088/1757-899X/1189/1/012019

3.4 SEM Analysis

A B C

D E

Figure 5. SEM images of cast samples

SEM micrographs of base alloy and hybrid composites is shown in figure 5. The distribution of the
B4C and Gr particles in the Al7029 is noticeably uniform. Micrographs discloses the uniform particles
distribution of the cast composites. The uniform particles distribution enhances the mechanical
properties of the reinforced Al7029. B4C particles are observed to be accumulated within the grain
boundary regions and geometrical trapping by dendrites is observed [1]. B4C and Gr particles have
located at grain boundary region, so that it increases the bonding between matrix and the
reinforcement. Hence there is increase in the grain strength, which results in increase in mechanical
properties as revealed from mechanical tests. Also, both the reinforcements act as obstacles to the
dislocations, at the boundary region which improves the mechanical properties.

4. Conclusions

1. Mechanical properties of hybrid composites increase with an increase in wt. % of B4C & Gr.
Tensile strength maximization is obtained by 6% B4C and 2% Gr.
2. From hardness test, the better effects will be seen if the B4C is used at 6 % with 2 % Gr.
3. It is inferred that for (Al7029+6 % B4C+2 % Gr) hybrid composite has highest impact strength
which indicates that maximum energy is absorbed during fracture.
4. B4C and Gr were found to be distributed reliably. It was confirmed, the interfacial analysis
indicated that the reinforcement particulate is related closely to the matrix strengthening.

References

[1] Sharath, B.N., Madhu, K.S. and Venkatesh, C.V., 2019. Experimental Study on Dry sliding
Wear Behaviour of Al-B4C-Gr Metal Matrix Composite at Different Temperatures. J. Applied
Mechanics and Materials, 895, pp. 96-101.
[2] Jones, R. M., Mechanics of Composite Materials, Tailor Francis, 2nd Edition, 1999.
[3] Davis, Joseph R. Aluminum and aluminum alloys. ASM international, 2001: p351-416.
[4] Surappa, M.K., Aluminium matrix composites: Challenges and opportunities. Sadhana, 28
(1-2), 2003: pp.319-334.
[5] Surappa, M.K. and Rohatgi, P.K., Preparation and properties of cast aluminium-ceramic
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stir cast aluminum matrix composites. Procedia Materials Science, 6, 2014: pp.1951-1960.
[7] Onoro, J., Salvador, M.D. and Cambronero, L.E.G., High-temperature mechanical properties

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ICTMES 2020 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 1189 (2021) 012019 doi:10.1088/1757-899X/1189/1/012019

of aluminium alloys reinforced with boron carbide particles. Materials Science and
Engineering: A, 499(1-2), 2009: pp.421-426.
[8] Baradeswaran, A.E.P.A. and Perumal, A.E., Influence of B4C on the tribological and
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2013: pp.146-152.
[9] Thirumalai, T., Subramanian, R., Kumaran, S., Dharmalingam, S. and Ramakrishnan, S.S.,
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hybrid composites. J. Materials & Design, 34, 2012: pp.576-583.
[11] Imran, M., Khan, A.A., Megeri, S. and Sadik, S., 2016. Study of hardness and tensile strength
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composites. Resource-Efficient Technologies, 2(2), pp.81-88.