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International Journal of Mechanical Engineering and Technology (IJMET) Volume 8, Issue 6, June 2017, pp. 190–199, Article ID: IJMET_08_06_020 Available online at http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=8&IType=6 ISSN Print: 0976-6340 and ISSN Online: 0976-6359 © IAEME Publication Scopus Indexed

DEVELOPMENT OF POLYMER MATRIX

COMPOSITES REINFORCING WITH Al2CuMg

Gopidesi Radha Krishna

Research Associate, School of Mechanical Engineering, VIT University, Vellore, Tamilnadu, India

K Mohan Kumar

Associate professor, Department of Mechanical Engineering, St Mary's Engineering College, Guntur, Andhra Pradesh, India

N Madhu Venkatesh

Assistant professor, Department of Mechanical Engineering, St Mary's Engineering College, Guntur, Andhra Pradesh, India

Gouse Basha Mohammed

M.Tech Student, Department of Mechanical Engineering, St Mary's Engineering College, Guntur, Andhra Pradesh, India

ABSTRACT

The research criterion for material processing is increasing continuously with

emerging advanced material characteristics like high strength to weight ratio, high-

temperature stability and good wear resistance for automotive, aerospace and marine

industries etc. Generally, composites are having high specific properties like strength,

modulus of elasticity, hardness, wear and abrasion resistance, etc., and the polymer

matrix materials are prioritized on top with reference to the ease of manufacture and

assembly, low cost of infrastructure and establishment, ability to reprocess,

environment friendly production parameter and etc. Reinforcing these materials with

high strength and environment - friendly materials yield composites of the future

generation.

Most of the global researchers put their effort on the Polymer Matrix Composites

with reinforcing natural fiber, glass fiber, graphite and carbon fibers. Reinforcing

these polymers with Bulk metallic glass (BMG) materials where high strength to

weight ratio materials can be developed. Based on literature review BMG owing high

strength, high hardness compares to the commercial Al alloys and stiffness with

different polymer matrix compositions.

The present research work involves in manufacturing of Polymer Matrix

Composites (PMC) reinforcing with Al2CuMg particulates and characterization.

Key words: Alloy, Composites, polymer matrix composites, Reinforcing.

Gopidesi Radha Krishna, K Mohan Kumar, N Madhu Venkatesh and Gouse Basha Mohammed


Cite this Article: Gopidesi Radha Krishna, K Mohan Kumar, N Madhu Venkatesh and Gouse Basha Mohammed. Development of Polymer Matrix Composites Reinforcing with Al2CuMg. International Journal of Mechanical Engineering and

Technology, 8(6), 2017, pp. 190–199. http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=8&IType=6

1. INTRODUCTION

1.1. Composite Material

The word "composite" refers to a combination of two or more separate materials are physically bound together. Generally, a material having the multi-phase system in the form of matrix material and reinforced material, matrix materials are always in continuous phase and reinforcing materials are in a dispersed phase. Matrix materials are categorized into i) Metal matrix composite material ii) inorganic non-metallic matrix composite materials iii) polymer matrix composites by various matrix materials. A composite matrix Particle-reinforced composite material consists of a particle of high strength and modulus embedded in or bonded to a matrix with distinct interfaces (boundary) between them. In this form, both particle and matrix with retaining their physical and chemical identities, at this point they produce a combination of properties that cannot be achieved with constituent acting alone. Generally, particles are the principal load-carrying members, while the surroundings matrix keeps them in the desired location and orientation. Then a load transfer medium between them and protects them from environmental damages due to eminent temperatures and humidity etc.

2. MATERIALS AND METHODS

The experimental work was carried out in two stages. In this first stage involved in the preparation of alloy with a characterization of alloy, it consists of melting and casting of alloys with different compositions in the aluminum- copper- magnesium system covering the region of standard, but also higher copper contents, of alloys. The second stage carried out the fabrication and conducts the various tests for finding out the material properties.

2.1. Alloy Preparation

The term alloy refers the mixture of metal or metal with different elements by a metallic bond character. Here alloy is prepared by a commercially pure aluminum (99.5+ % EC grade) was procured from M/s HINDALCO as 20 kg ingots, bus-bars of conductivity grade copper (99.95% Cu) and high purity magnesium ingot (99.9%) are purchased from local market. In this explain mainly two types of alloys preparation they are the i) Binary Alloy ii) Ternary Alloy

Binary Alloy Preparation

Cut ingots of pure aluminium were melted in a stationary spot type electric heating furnace in clay graphite crucible at 700°C. In order to prevent excess oxidation of the metal Coverall (0.1 wt% of metal) proprietary covering agent is used. Copper pieces wrapped in aluminium foil were added to the aluminium melt at 850°C and the same temperature was maintained till copper completely melts. The top layer was skimmed and metal was cast into 140 mm x 18mm Ф cylindrical finger molds.

Ternary Alloy Preparation

Cut ingots of pure aluminium were melted in a stationary spot type electric heating furnace in clay graphite crucible at 700°C. In order to prevent excess oxidation of the metal Coverall

Development of Polymer Matrix Composites Reinforcing with Al2CuMg


(0.1 wt% of metal) proprietary covering agent is used. Copper pieces wrapped in aluminium foil, were added to the aluminium melt at 850°C and the same temperature was maintained till copper completely melts. And then Magnesium in the form of thin slices wrapped with aluminium foil was added to the Al-Cu alloy melt after the furnace temperature was reduced to 700°C. Magnesium oxidation was minimized by plunging the slices to the bottom of the melt and allowed to melt then itself. The melt was well mixed with a graphite sheathed tube for uniformity in the composition a small amount of Coverall was once again added to the melt. The top layer was skimmed and metal was cast into 140 mm x 18mm Ф cylindrical finger molds. Cast ingots were homogenized at 100°C for 24 hrs.

Figure 1 Fabrication procedures for Al-Cu-Mg ternary alloys Figure 2 the casted pieces by mould

2.2. Characterization of Reinforcement

Hardness

Vickers micro hardness studies are carried out for the investigated alloys were evaluated using UHL IMS 4.0 VMHT with a 1kg load. The indentation time for the hardness measurement was 15sec. An average of six readings was taken for each hardness value. The Vickers hardness results are shown in below graphically. The changes in chemical composition of the alloy cause changes in the structure that are reflected in the Vickers hardness. By increasing the content of Cu & Mg the hardness also increases.

Figure 3 Vickers micro hardness tester Graph 1 Alloys Vs Hardness

2.3. Microstructures of Investigated Alloys

Specimens for metallographic observations were prepared by standard polishing techniques. The microstructures of the specimen were investigated by means of optical microscopy (Model: Olympus, C – 5060 - G x 4- Japan). Keller’s reagent with composition of HF = 1.0cm3, HCL = 1.5cm3, HNO3 = 2.5cm3 and water=95cm3 was used as etching reagent.

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Al-10Cu Al-10Cu-10Mg Al-20Cu-10Mg

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Scanning electron microscopy (Model: SEM – Hitachi S-3400N - Japan) was used in order to evaluate the morphological changes observed in the investigated alloys.

Figure 4 Optical microscopy

2.4. XRD of Alloys

The X-ray diffraction (XRD) pattern of investigated ternary alloys is carried out using IGAKU, ULTIMA-IV H-12-JAPAN for identification of phases present in the alloys.

Figure 5 XRD of binary alloy Figure 6 XRD ternary alloy

The X-ray diffraction (XRD) pattern of both binary alloy and ternary alloys is shown in Fig. 5, 6 which shows the phases present in the alloy and are largely Aluminium and Al2Cu in binary alloy and Aluminium and Al2CuMg in ternary alloys.

2.5. Selection of Reinforcement

Among the investigated alloys Al-20%Cu-10%Mg is selected as reinforcement due to its high hardness. Powders of Al-20%Cu-10%Mg are produced by filing a rotating rod at high speeds with different grades of files. Powders in different sizes are produced by using different rotation speeds and files. Powders are classified by sieving methods.

2.6. Fabrication of Composite Specimen for Tensile Test

Composite samples are prepared using open molding Hand-layup method for the tensile test. For this test, we followed the ASTM D 638, ISO 527 (Tensile test for plastics). First of all, we will make the mold on Rubber sheet according to the dimensions taken from the ASTM D 638.The following figure shows the tensile test mold

A special code for the Tensile Testing of Polymer Matrix Composite Materials ASTM D3039 ASTM D 638 tensile testing is used to measure the force required to break a polymer composite specimen and the extent to which the specimen stretches or elongates to that breaking point. Tensile tests produce a stress-strain diagram, which is used to determine



tensile modulus. The obtained results are used to state a material, to design parts to withstand application force and a quality control check of materials. There are totally five types of ASTM D 638 specimen for our project we used type1.

Figure 7 Types of ASTM D 638

The mould is prepared on a smooth ceramic tile with rubber shoe sole to the required dimension. Initially, the ceramic tile is cleaned with shellac (NC thinner) a spirituous product to ensure clean surface on the tile. The space between the rubber and the tile was covered with a mansion hygienic wax. A thin coating of PVA (polyvinyl alcohol) is applied on the contact surface of the specimen, using a brush. The resulting mould is cured for 24 hours.

Figure 8 Mixing processing

Hand layup technique was choose to plug the prepared mould with general purpose polyester resin of ECMALON 4413 grade, supplied by ECMAS RESINS PVT. LTD. Vijayawada, as matrix and various particles as reinforcement. ECAMALON 4413 is an unsaturated polyester resin of ortho-phathalic acid grade with clear colorless or pale yellow colour. Its viscosity is 500 - 600 CPS (BROOKFIELD VISCOMETER) and specific gravity is 1.13 gms/cc at25°c. Acid number (mg KOH/g) is 22 and monomer content is 35%. Cobalt accelerator and MEKP catalyst are added for curing the resin at room conditions. The quantity of each of these materials, added is 1.5% of the volume of the resin. The gel time is found to be about 25 minutes. The accelerator is mixed thoroughly with the resin and the catalyst is added later to avoid the explosion. Add 2%, particles to the weight of the mixer. Mix properly distribution of particles around the mixer. Before solidification of the mixer poured into the mould, each rubber sheet has six moulds. After 24 hours remove specimens slowly, then it repeats the experiment change the percentage of adding particles. 4%, 6%, 8%, 10%, 12%, and 14% of particles added to fabricated the specimen



Figure 9 Tensile specimens of polymer matrix composites with different wt. fractions. (0% to 14% bottom to top).

2.7. Fabrication of Composite Specimen for Compression Test

For this test, we followed the 12×12mm (compression test for plastics). First of all, we will make the mold on the wooden block according to the dimensions. The following figure shows the compression test mould.

Table 1 Preparation of wooden mould

First, we are taken the two wooden blocks dies of sizes 300×30mm. those two blocks are combined equally then drill 12 holes (14×140mm) maintain equal spacing on the joined part. The gap between the two wooden filled with mansion hygienic wax

Figure 10

Hand layup technique was choose to plug the prepared mould with general purpose polyester resin of ECMALON 4413 grade, supplied by ECMAS RESINS PVT. LTD. Vijayawada, as matrix and various particles as reinforcement. ECAMALON 4413 is an unsaturated polyester resin of ortho-phathalic acid grade with clear colorless or pale yellow colour. Its viscosity is 500 - 600 CPS (BROOKFIELD VISCOMETER) and specific gravity is 1.13gms/cc at 25°c, acid number (mg KOH/g) is 22 and monomer content is 35%. Cobalt accelerator and MEKP catalyst are added for curing the resin at room conditions. The quantity

Composites Compositions

0% 0% particles + polymer










of each of these materials, added is 1.5% of the volume of the resin. The gel time is found to be about 25 minutes. The accelerator is mixed thoroughly with the resin and the catalyst is added later to avoid the explosion. Add 2% particles to the weight of the mixer.

3. RESULTS AND DISCUSSION

The mechanical properties of the fiber reinforced polyester composites prepared for this present investigation. Details of processing of these composites and the tests conducted on them have been described.

3.1. Tensile Tests

The tensile strength of base and composites was determined using 10T DAK universal testing machine as per ASTM D 638 standards. Online plotting of load versus extension was done continuously though a data acquisition system.

The development of successful applications for metal particles will be aided by an understanding of their mechanical properties. Selecting compatible matrix materials for particles will specifically require an understanding of Young’s modules of metal particles tensile strength were measured for replicate polymer matrix composite the specimen types and tested. The prepared samples are tested by using the Dak Test Bench at Andhra University. Specimens are placed in the grips of the instrument at a specified grip separation and pulled until failure. Here shown various graphs of tensile tests for stress Vs strain with various reinforcement compositions.

Graph 2 Tensile Stress vs. Strain curve for 0%, 2%, and 4% reinforcement

Graph 3 Tensile Stress vs. Strain curve for 6%, 8%, 10% reinforcement

Graph 4 Tensile Stress vs. Strain curve for 12%, 14% reinforcement, matrix and Composites.

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Graph 5 Elongation Vs reinforcement, Load Vs reinforcement during tensile test

3.2. Compression Test

Compression tests were carried out on cylindrical specimens of composites. These cylindrical specimens of standard dimensions were prepared using conventional machining operations of turning and facing. Specimen edges were chamfered to minimize folding. The concentric v- groove of 0.05cm deep was made on the flat surface for a low friction connecting dies and work piece during compression. Standard specimens of sizes Ø 12mm×12mm (H/D=1) are upset by placing between the flat plates at a constant cross head speed of 0.2mm/min in dry conditions until failure, using a computer controlled 10T DAK universal testing machine.

Compressive properties of composites can be understood by studying load-displacement curves during compression testing shows the influence of Al2CuMg content on the compressive strength of polymer and also figure 4.12 - 4.18 shows the stress-strain curves of matrix and composites. The load requirement increased with increase in displacement for the composites. The composites show higher loads than the unreinforced polymer; and this increase in compression strength is more for higher the concentration of particle, as shown in Figure 8. The same is confirmed from the true stress and true strain results. This indicates that the Al2CuMg particle addition leads to improvement in the strength of the composites.

The development of successful applications for metal particles will be aided by an understanding of their mechanical properties. Selecting compatible matrix materials for particles will specifically require an understanding of the compression strength were measured for replicate polymer matrix composite the specimen types and tested. The prepared samples are tested by using the Dak Test Bench at Andhra University. Specimens are placed in the grips of the instrument at a specified grip separation and pushed until failure. Here shown the graphs for the stress Vs strain compression test result with various reinforcement

Graph 6 Stress Vs Strain for 2%, 4%, and 6% reinforcement

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Graph 7 Stress & Strain for 8%, 10% and 12% reinforcement

Graph 8 Stress & Strain for 14% reinforcement, curves of composites

Graph 9 Load vs. % of Reinforcement, Deformation vs. % of Reinforcement during compression test

4. CONCLUSIONS

This experimental investigation of the mechanical behavior of aluminum alloy particle reinforced epoxy composites leads to the following conclusions:

• In the present research work, successful fabrication of alloys with different compositions in the aluminum- copper- magnesium system with higher copper contents.

• It has been noticed that the micro-hardness of the alloys are greatly influenced by the addition of copper and magnesium contents.

• Particulates of Alloy Al-20(%wt) Cu-10(%wt) Mg are successfully produced.

• In the present research work, successful fabrication of particle reinforced polyester resin composites are fabricated by simple hand-lay-up technique.

• There was a uniform distribution of Al2CuMg particulates in the matrix phase and also existing a good bonding between matrix and reinforced particles.

• The results indicate that tensile strength of the Polymer composites is greatly influenced by the percentage of reinforcement.

• Compression behavior of Polymer composites reinforcing with Al2CuMg particulates are computed and are greatly influenced by the filler content.

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5. SCOPE FOR FUTURE WORK

There is a very wide scope for future scholars to explore this area of research. This work can be further extended to study on other aspects such as an effect of particle size and the different weight percentage of particles on the polymer matrix composites and characterization of composites such as Hardness, Piezoresistivity behaviour, wear behaviour etc.

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[4] Jochen Gassan. A study of bre and interface parameters acting the fatigue behavior of natural bre composites. Composites Part A: 2002;33(3):369–74.

[5] Ruys D, Crosky A, Evans WJ. Natural bast structure. Int J Mater Product Technol 2002;17(1–2):2–10.

[6] K. Chandra Padmakar and B. Sarath Chandra Kumar, An Experimental Study on Metakaolin and GGBS Based Geopolymer Concret. International Journal of Civil Engineering and Technology, 8(1), 2017, pp. 544–557

[7] Mishra S, Tripathy SS, Misra M, Mohanty AK, Nayak SK. Novel ecofriendly biocomposites: bio.ber reinforced biodegradable polyester amide composites – fabrication and properties evaluation. J Reinf Plast Comp 2002;21(1):55–70.

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[9] Balaraman R, Vinodh K.R, Nithiya R and Arunkumar S, Comparative Study of Geopolymer Concrete in Flyash with Conventional Concrete. International Journal of Civil Engineering and Technology, 7(4), 2016, pp.24–36

DEVELOPMENT OF POLYMER MATRIX COMPOSITES … · procured from M/s HINDALCO as 20 kg ingots, bus ......

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