EXPERIMENTAL EVALUATION OF ALUMINIUM –CU COMPOSITE MATERIAL TO INCREASE THE MECHANICAL PROPERTIES

WITH DIFFERENT COMPOSITION

PRESENTED BYPRESENTED BY

EDWIN.AEDWIN.AUnder the guidance of

Mr.G.SURENDHAR M.E

(Assistant professor)

DEPARTMENT OF MECHANICAL ENGINEERING E.G.S.PILLAY ENGINEERING

COLLEGENAGAPATTINAN

COMPOSITE MATERIAL TECHNOLOGY

Composites Materials are engineered materials combining two or more materials to obtain the desired combination of properties for specific applications

Composites are Exciting Materials which are finding Increasing Applications in Aerospace, transportation, Communication, Power, Electronics recreation sporting and numerous other commercial and Consumer products

COMPOSITE MATERIALS IN OUR DAY TO DAY LIFE

Glass Fabric reinforced composites are perhaps that most commonly used ranging in applications from Helmets, container boxes, fishing boats, Automobile bodies and aircraft structures.

OBJECTIVE

In our point of view all these drawbacks can be over come by replacing composite materials instead of heavy metals in manufacturing. High specific stiffness and near-zero coefficient of thermal expansion is being experienced in Metal Matrix Composites (MMC’S).These are a new class of materials that combine two or more separate components into a form suitable for structural applications. While each component retains its identity, the new composite material displays macroscopic properties superior to its parent constituents, particularly in terms of mechanical properties and economic value.

In our project Copper and Aluminum Oxide mixed the following categories.

Sample 1 : 90% Cu 10% Al2O3

Sample 2 : 80% Cu 20% Al2O3

Sample 3 : 70% Cu 30% Al2O3

Mixing ratio-90%&10% (Copper and Aluminium)Volume of copper=180*0.90=162 gm Volume of Aluminum=180*.10=18 gmDensity of copper=8.9gm/ccWeight of copper 162*8.9=1441.8 gm =1.441kgDensity of aluminum=2.7gm/cc Weight of Aluminum =18x2.7= 48.6 gm30 % for excess (Runner&riser,slag) Total weight of mixtureCopper=1441.8 gm +410 gm= 1851.8 gmAluminum=48.6+15=63.6 gm

MATERIAL REQUIREMENT CALCULATION

SAMPLE : 1

Mixing ratio-80%&20%(Copper and Aluminium)Volume of copper=180*0.80=144 gm Volume of Aluminum=180*.20=36 gmDensity of copper=8.9 gm/ccWeight of copper 144*8.9=1281.6 gm/cc=1.281kgDensity of aluminum=2.7gm/cc Weight of Aluminum =36x2.7=97.2 gm30 % for excess (Runner&riser, slag) Total weight of mixtureCopper=1281.6Kg+360 g= 1641.6gmAluminum=97.2+30=127.2 gm

MATERIAL REQUIREMENT CALCULATION

SAMPLE : 2

Mixing ratio-70%&30%(Copper and Aluminium)Volume of copper=180*0.70=126 gm Volume of Aluminum=180*.30=54 gmDensity of copper=8.9gm/ccWeight of copper 126*8.9=1121.4 gm =1.121kgDensity of aluminum=2.7gm/cc Weight of Aluminum =54x2.7=145.8 gm30 % for excess (runner &riser, slag) Total weight of mixtureCopper=1121.4g+300 g= 1421.4gm=1.421kgAluminum=145.8+45=190.8gm

MATERIAL REQUIREMENT CALCULATION

SAMPLE : 3

CASTNGCASTNG

In this project we have used sand mold casting for produce the requirement size. Sand casting, also known as sand molded casting, is a metal casting process characterized by using sand as the mold material.

Importance of Powder Metallurgy

Advantages of Powder Metallurgy

Basic processThere are six steps in this process:Place a pattern in sand to create a mold.Incorporate the pattern and sand in a gating system.Remove the pattern.Fill the mold cavity with molten metal.Allow the metal to cool.Break away the sand mold and remove the casting.

PIT FURNACEPIT FURNACE

Pit furnace are those furnace that are applied for heating various metals or alloys of metals. They are available in various sizes and are either gas fired or fuel fired. They can operate at various temperatures and are designed in such a way that the heat loss is minimum.

Importance of Powder Metallurgy

Advantages of Powder Metallurgy

Importance of Powder Metallurgy

Advantages of Powder Metallurgy

SALIENT FEATURES

Following are the features of pit furnace:

They can withstand continuous operation.

Some of the pit furnace have plug in type of door/retort cover.

Temperature is distributed uniformly.

For longer element life heating elements operate on low surface load.

Types

There are different types of pit furnace that are used

Element Pit FurnaceElectric Pit FurnaceFuel-Fired Pit FurnaceElectric Retort Pit FurnaceGas-Fired Retort Pit FurnaceNitriding Pit FurnaceTempering Pit Furnace

In our project copper & aluminum composite material melted by fuel fired pit furnace.

Destructive test

In this project the following types of destructive test are conducted

Hardness Impact Strength Micro Structure Analysis Resistivity

HARDNESS TEST

Importance of Powder Metallurgy

Advantages of Powder Metallurgy

TYPES : Rockwell HardnessMajor Load Applied : 100KgfTypes of Indenter used : 1/16”(Ball)Verification of Raw Materials

S.No

Material

Trial 1

Trial 2

Trial 3

Trial 4

Trial 5

Mean

1

Pure Alumini

um (LM4)

39 41 48 40 40 39.5

2Pure

Copper81 79 78 83 83 81

APPLICATION OF THE Cu-Al2O3 COMPOSITE

Cam Shaft Main Journal Bushes Connecting Rod small end bearing bushes.Used extensively in refrigeration and air conditioning equipment Electrical machines, especially electromagnetic motors, generators and transformers

REFERENCES

[1] H.E. Boyer, T.M. Gall, Metals Handbook, Desk Ed., American Societyfor Metals, Metals Park, OH, 1991, pp. 20.16–20.21.[2] G. Gusmano, A. Bianco, R. Polini, J. Mater. Sci. 36 (2001) 901–907.[3] J.L. Johnson, R.M. German, Int. J. Powder Metall. 30 (1) (1994) 91–102.[4] W.F. Wang, Powder Metall. 40 (4) (1997) 295–300.[5] R. Jedamzik, A. Neubrand, J. Rodel, J. Mater. Sci. 35 (2000) 477–486.[6] T.H. Ihn, S.W. Lee, S.K. Joo, Powder Metallurgy, vol. 37, No. 4, 1994,pp. 283–288.[7] V.N. Eremenko, R.V. Minakova, M.M. Churakov, Sov. Powder Metall.Met. Ceram. 15 (1976) 283.[8] K. Byoong, Mechano-chemical process for production of high densityand ultrafine W/Cu composite material, US Patent no. 5842108 (1998).

THANK YOU