ISSN: 2278 7798 International Journal of Science, Engineering and...

ISSN: 2278 – 7798 International Journal of Science, Engineering and Technology Research (IJSETR)

Volume 5, Issue 4, April 2016

1128

All Rights Reserved © 2016 IJSETR

ENHANCEMENT OF MICROSTRUCTURE AND MECHANICAL

PROPERTIES OF AL ALLOYS – REVIEW

M. MARUTHI RAO1, Dr. N.V.V.S SUDHEER

2,

Research Scholar, Acharya Nagarjuna University, Guntur, AP, India.

Associate Professor, Dept; of Mechanical Engineering, RVRJC, Guntur, AP, India.

Abstract:

This is article addresses the effects of Al alloys by using different quenching media(water,

distilled water, brine, soybean oil, palm oil, cotton seed oil, olive oil, palm kernel oil, apple

juice, polymer quenching, clay and caster oil etc;) quenching time, quenching temperature

and mechanical properties like (Ultimate tensile strength, yield strength and hardness) and its

micro structure studies. By using different quenching media the micro structure is refined,

mechanical properties were improved at certain percentage of quenching media, quenching

temperature and quenching time not only Al alloys and other metals also. Ultimately the

property of fatigue is enriched with the refinement of micro structure.

Key words: Quenching media, quenching temperature, quenching time and micro structure.

I. INTRODUCTION:

Piston head is the most crucial components of an automobile engine. Lot of research work

was reported in the literature on the design of piston head, materials and manufacturing of

piston heads, temperature distribution over the surfaces of the piston head etc; A detailed

damage analysis of engine parts was also reported in the literature. The damage mechanism

includes, wear, temperature and fatigue failures. Extensive work was reported in the

literature on the wear and wear mechanism on pistons. However, there were only discrete

references in the literature on the fatigue strength analysis of piston heads. An attempt is

made in the proposed work to study fatigue strength analysis of piston heads and to optimize

the design of piston head from fatigue strength considerations. The two important fatigue

failures of piston heads are thermal fatigue failure either at room temperature or at elevated

temperatures and mechanical fatigue failure. The operating temperatures during working

stroke and the thermal fatigue failure are considered. The main focus was on determining

the mechanical properties of piston head material and the quenching process used to obtain

the required mechanical properties and micro structure.



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M. Sakthivel et al.,(2013) did extensive work on Evaluation of EN8 steel in different quenching

medium.

They conducted experiment on EN8 MEDIUM Carbon steel using different quenching medium (oil,

water and air) in a gas carburizing furnace of heating temperature between 900o C -930

0 C. The

objectives of this experimentation was to improve hardness and wear resistance.

Based on the results, the hardness of the quenched materials was improved over the raw

materials and also improve the wear resistance of the quenched materials. Finally the water quenched

material has the best mechanical properties in hardness and wear resistance when compared to the

other quenched materials.

Table No.1: Hardness Reading.

S.No

TYPE OF

QUENCHA

NT

HARDNESS

(HRC)

MEAN

VALUE(HRC)

1. As received 12,13,12,14,13,14,

12,12,13,14,12,14,12

12

2. Air 19,20,20,22,19,20,

21,22,21,20,19,22,20

21

3. Oil (open)

4,33,30,33,35,32

34,32,30,32,33,30,31

34

4. Oil (closed) 42,40,40,41,39,41,

41,42,40,39,40,42,41

42

5. Water 42,45,42,44,43,45,

42,43,42,44,43,42,44

46

Effect of Heat Treatment On Microstructure

The microstructures of different quenched samples as well as received sample were taken

using optical microscope.

Fig. 1 Microstructure of Received material Fig.2 Microstructure of Air quenched material

Fig.3 Microstructure of Oil (open) quenched Fig.4 Microstructure of oil (Closed)quenched



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Fig.5 Microstructure of Water quenched material

O. E. Joseph et al., (2015) have done hardening and characterisation of 0.45%C steel using

Clay/water as quenchant.

From experimental work they were the morphologies and mechanical properties of

0.45%C steel when different amount of clay was added to water for quenching operation.

The result obtained from present work was compared with the earlier work, which showed a

great improvement in the mechanical properties. Poor mechanical properties obtained for

higher additions of clay to water, lower amount of clay in water was considered by them.

Table 2. Mechanical properties of the as-quenched 0.45%C steel.

Quenchants

Hardne

ss Value

BHN

Yield

Strength

(N/mm2)

Tensile

Strength

(N/mm2)

Izod

Impact

Energy

(J)

Specific

latent heat of

vaporization

((J/Kg)x106)

water 364 1204 1442 13.0 2.31

2% clay + 98%

water

432 1298 1582 12.0 2.00

4% clay + 96%

water

476 1338 1653 10.0 1.8

6% clay + 94%

water

388 1240 1500 11.0 1.67

8% clay + 92%

water

354 1201 1457 12.0 1.34

10% clay + 90%

water

290 1156 1349 14.0 1.22

12% clay + 88%

water

283 1103 1206 18.0 1.14

As-received 123 214 411 31.0 --

Joshua. T. O. Et al., (2014) have done pioneering work on effects of various quenching media

on the mechanical properties of Medium Carbon Steel.

Their experimental work consisted of finding mechanical properties of medium

carbon steel at critical temperatures 7600C, 770

0C, 780

0C, 790

0C, 800

0C and samples were

quenched in water, distilled water and palm kernel oil respectively. Finally microstructures



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of each specimen was evaluated. Grains were fine them when quenched in distilled water

with high strength and hardness value was obtained in quenched distilled water, while for

strength and toughness palm kernel oil will be the best. Hence palm kernel oil has proved

better hardness value, tensile strength value and microstructure.

Fig .6 Microstructure of Medium Carbon Steel rod at 8000C held for 1 hour and quenched in

coldwater at x 200

Fig.7 Microstructure of Medium Carbon Steel rod 7900C, held for 1 hour and quenched in

palm kernel oil at x 200

A. AbdulmuminA et al., (2012) investigate the effect of water temperature on the mechanical

properties of water quenched Mn steel.

Their experimental work estimated hardness and impact strength of water

quenched medium carbon steels. It contains 0.33wt%c and 0.42wt%c heated to 9000C and

quenched in water temperature range from 350C to 95

0C. The hard marten site structure

which is quenched steels highly brittle and low toughness was replaced by tempered marten

site structures better mechanical properties in the steel.

Graph 1:Effect of Water Temperature Hardness of the Quenched Steel Samples



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Graph 2 :Effect of Water Temperature Impact Strength of the Quenched Steel Samples

Graph 3:Effect of Water Temperature Tensile Strength of the Quenched Steel Samples

Alim sabur Ajibola et al., (2012) did extensive work on production and micro structural analysis of

as Cast and heat treated aluminium alloy (Al-20%wt Mg).

Their experimental work consisted of 16 samples were cast and heat treated at 4500C for 1

hr and the samples were annealed, and quenched in water and used engine oil. Also they estimated

tensile, fatigue and hardness values. In case of the used engine oil quenched sample, the cooling rate

is slower compared to that of water. This slow cooling rate reduces the possibilities of defect

formation. The rate of cooling experienced in annealing is the slowest of all the sluggishness gives

room for poor formation.

Dr. Jassim Mohammed Salman A. M et al.,(2014) did extensive work on the effect of heat

treatments, polymer quenching and additions (Zr & Ag) on mechanical properties of (6061)

aluminium alloy.

Based on the results on improvement on corrosion resistance in 3.5% Nacl solution

was seen when the alloys quenched in polymer solution. The alloys that were quenched in

polymer solution have exhibited higher thermal stability than these quenched in water.

Addition of 0.03% Zr with .18% Ag to the base alloy improves thermal age hardening

behaviour.

Graph 4:Variation of energy absorbed of alloy sample ( quenching in water medium and

35% polyethylene glycol medium ) with aging time at 180°C aging temperature for A and B

alloys.



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Fig 8:Microstructure of A alloy after aging treatment in 1800C alloy quenched in water.800X

Fig9: Microstructure of B alloy after ageing treatment in 1800C alloy quenched in polymer.

800X

M. Dauda et al., (2015) did experiments of effects of various quenching media on mechanical

properties of annealed 0.509wt % C – 0.178wt% Mn steel.

They evaluated palm kernel oil, cotton seed oil and olive oil as quenching media of

0.509Wt% C medium carbon steel. The machined specimen of the steel was heated at 8800C

and then quenched in water, engine oil, palm kernel oil, cotton seed oil and olive oil. They

also estimated strength properties and micro structure of the quenched samples were used to

determine the quench severity of the oils.

Based on results the following conclusions can be drawn.

(1)The olive oil, palm kernel oil and cotton seed oil have hardness values less than that of water and

SAE 40 engine oil.

(2) Palm kernel oil, cotton seed oil and olive oil can be used to improve the toughness and these

quench media gave higher impact energy values than water

Fig 10:Microstructure of as-received structure of 0.509% carbon steel showing pearlite (dark)

in ferric (white) matrix X200



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Fig 11: Microstructure of 0.509% carbon steel quenched in engine oil, showing full marten

site (dark) X200

Fig 12: Microstructure of water quenched microstructure of 0.509% carbon steel showing

marten site structure (dark) with retained austenite (white) X200

Fig 13:Micrograph of 0.509% carbon steel quenched in cotton seed oil, showing low

proportion of marten site structure (dark) in ferric (white) matrix X 200

Fig 14:Micrograph of 0.509% carbon steel quenched in palm kernel oil, showing low

proportion of marten site structure (dark) in ferric (white) matrix X200

Fig 15: Micrograph of 0.509% steel quenched in olive oil, showing low proportion of marten

site structure (white) with retained austenite(dark)



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O.K. Abubakre et al., (2009) have done Investigations of the Quenching properties

of selected media on 661 aluminium alloy.

From the result based alloy at 5300C water quenched has highest tensile strength and

yield strength as well as highest value in hardness. Toughness property of the alloy was

better at 5300C for specimen quenched in sheanut oil and low impact strength was observed

in specimen quenched in water at 4000C water among the quenching media proved to have

the highest cooling rate followed by sheanut oil

Table 3: Tensile test results of 6061 aluminum quenched in different media:

Quenching

Media

Heat

Treatment

Temp. (0C)

Solution

Time

(Hours)

UTS N/mm2 Yield

Strength

N/mm2

Percentage

Elongation

%

Water

450 2 85.77 63.12 7.0

450 2 87.69 67.73 6.11

530 2 109.70 70.89 4.00

Sheanut oil

450 2 78.12 59.63 6.35

450 2 86.37 62.73 6.00

530 2 88.00 66.72 3.75

Palm Kernel

oil

450 2 74.07 55.53 6.01

450 2 77.04 57.60 5.50

530 2 90.10 64.94 2.98

Control

sample

-- --- 83.80 64.44 5.0

Fig16:Aluminum 6061 quenched in Fig17: Aluminum 6061 quenched in palm

water at 5300C. Precipitates formed by kernel oil at 5300C, plate lets

Mn and Mg spherodised in Al-matrix of precipitates sharing partial

(mag x 300) spherodisation (mag x 300)



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Fig 18: Fig 19:

Aluminum 6061 quenched In 6061 quenched in water at

in Sheanut oil at 5300C showing 4500C less spherodisation of

growth of precipitates leading to sub precipitates (mag x 300)

grains of concentrated precipitates

(mag x 300)

Fig 20: Fig 21:

Aluminum 6061 quenched Aluminium 6061 quenched in

in sheanut oil at 4500C more palm kernel oil at 4300C shows ab-

spherodisation of precipitates as normal Segregation of secondary

compared to plate IIA (Mag x 300) phase (Mag x 300)

Nikolai I.K et al., (2010) have done experiments on vegetable oil quenchants: Calculation

and comparison of the cooling properties of a series of vegetable oils, was undertaken by

them.

Vegetable oils were taken as quenching medium (canola, soya bean, corn, cotton seed

and sunflower oils) by blending oils with minimum viscosity variations. The heat transfer

using the oils occurs only by convection. Vegetate oils have better heat conducting properties

than petroleum oil based quenchants.



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Graph:8 Cooling curves data at 60ºC bath temperature. a) time - temperature, b) cooling

rate –Temperature

Mr. Rajkumar shinde et al.,(2013) analysed the Influence of petroleum and Biodegradable

quench ants on properties of medium carbon steels.

Their observed that medium carbon alloy steel it microstructure and composition

dependent on the heat treatment and quenching process used i.e petroleum , vegetable oils

and soya bean oil. The result showed biodegradable quenchants used in place of petroleum

oils with improved mechanical properties.

From the results it is concluded that the heat treatment of steel using soy bean

quenchant gives the better mechanical properties and micro structure than petroleum

quenchants showed graphically.

First specimen heated to 8600 2 hours and then quenched indifferent quenchants. After

quenching specimen are tempered at 5600C and finally evaluated mechanical properties and

micro structure examined.

Graph:9 YS Vs Quenching media Graph:10 T S Vs Quenching media

Graph:11 Hardness Vs Quenching media Graph:12 Hardness Vs Quenching media



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Graph:13 % Reduction Vs Quenching media Graph:14 % Elongation Vs Quenching media

Fig :22 Fig :23

Microstructure of EN19 Microstructure of EN 19 is done by

is done by fast cooling oil. quench slow cooling oil.

Kahtan K.A et al.,(2011) did extensive work on the effect of poly metric quenching on wear

resistance of Eutectic modified aluminium silicon alloy.

In their study a master alloy of modified eutectic (Al-12% Si) was prepared and used

the specimens were quenched and heat treated in distilled water, food oil, machine oil (0.2 –

1.4_wt% concentrations of poly vinyl alcohol. The specimens were characterised for X-ray

diffraction, microstructure, hardness and wear rate.

From the results it has been concluded that he Al-Si alloy with (0.6)wt% PVA had

maximum hardness and slight decrease the wear rate. And maximum decrease in the wear

rate when (1.2)wt% PVA was compared to the reference cast alloy, polymer quench ants

affect positively decrease wear rate of eutectic Al-Si alloy over the traditional quenching

media.



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Table 4: explains the effect of different quenching media on the hardness and wear rate of the

eutectic Al-Si alloy.

Quenching Media Brinell Hardness

Number

(BHN)

Wear Rate

(*10-9)

(cm3/cm) Reference cast alloy 77.305 12.6

Distilled Water 90.42 22.482

Food oil 52.63 15.946

Machine oil 42.78 15.782

0.2 % PVA 88.693 34.189

0.4 % PVA 80.455 12.483

0.6 % PVA 96.286 11.323

0.8 % PVA 72.782 11.599

1.0 % PVA 74.596 25.849

1.2 % PVA 60.148 8.672

1.4 % PVA 91.835 15.741

M. Riaz et al.,(2014) have done A study on the mechanical properties of S45C medium type

carbon steel specimens under lathe machining and quenching conditions.

From experimental process they determined the nature and behaviour of many

materials under study. In the experimental work there were 2 sets (5 samples each) of

medium type steel specimens S45C of 0.45% carbon. Quench media both water and iso rapid

oil that were selected. Substantial change in mechanical properties when material quenched

in water as compared to isorapid oil.

Table5: Results for stress, strain, and percentage elongation (430 RPM & 860 RPM/Water

quenching)

No Machining speed

(RPM)

Temp (0C)

Stress (MPa)

Strain (%)

% Elongation

1 430 & 860

200 637

31.050

10.364

2 430 & 860

300 596

28.850

9.2285

3 430 & 860

400 599

28.525

9.8005

4 430 & 860

500 673

27.220

8.9875

5 430 & 860

600 657

30.100

10.467



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Graph: 15 Graph:16

STRESS Vs TEMPERATURE STRAIN Vs TEMPERATURE

S.B.Hassan et al., ((2013) Investigated the Evaluation of khaya seed oil (mahoganyoil) as

quenchant in the hardening process of plain carbon steel.

The main objective of their work was khaya seed oil as a quenchant for hardening

process of 0.34% C plain carbon steel was investigated. Compared to water and SAE engine

oil quenched properties of plain carbon steel in the annealed, normalized and quenched,

tempered conditions were also investigated. The samples heated to 8700C, soaked and

quenched different media and also mechanical properties investigated.

Based on results khaya seed oil hardness value less than that of water but higher

hardness value than that of SAE 40 engine oil. Khaya seed oil improved toughness of PCS

and high impact energy values than water. Khaya seed oil used for hardening process in

PCS properties in between that of water and SAE 40 engine oil.

Table 6: Details of Plain Carbon steel different heat treatment and its Micro structure

Heat treatment Microstructure

As-received Pearlite in ferrite matrix

Normalized A highly pearlitic matrix

Annealed An essentially ferritic matrix

Water quenched A martensitic with retained austenite

Khaya oil Higher level martensite present with some

retained



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Engine oil austenite and little bainite

Quenched in Khaya oil and tempered (350°) Martensite present, retain austenite and slight

increase in bainite Tempered martensite

structure

Fig24: Microstructure of As-received Fig25: Mirostructure Normalized PCS

Plain Carbon Steel. The structure Reveals The structure Consists of Ferrite (white) in

Pearlite (dark) in Ferrite (white) Martrix x500 Pearlite (dark) Matrix x500.

Fig 26: Microstructure of Annealed Fig 27:Microstructure of PCS

PCS. The structure Reveals a Ferrite (white) Quenched in water. The structure

Matrix x500. Reveals a Martensitic and

retained Austenite x500

Fig 28: Microstructure of PCS Fig 29 :Microstructure of PCS

Quenched in SAE 40 Engine oil.The structure Quenched in Khaya Oil. The Structure

Reveals Martensite, Retained Austenite, and Consists of little Bainite, with some

Slight increase in Bainite x500 Retained Austenite and a Higher % of

Martensite x500.



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Fig 30: Microstructure of Plain Carbon Steel Hardened in Khaya Oil and Tempered at 350°.

The Structure Reveals Tempered Martensite x500.

CONCLUSION:Based on the observations from various research papers the mechanical

properties and micro structures of the metal alloys can be improved with different quenching

media at varying temperature and time. These observations when implemented on I. C.

Engine piston head, the material could show better fatigue strength.

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Research Scholar, Acharya Nagarjuna University, Guntur, Andhra Pradesh

Associate Professor, Dept; of Mechanical Engineering, RVRJC, Guntur, AP

ISSN: 2278 7798 International Journal of Science, Engineering and...

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