Corrosion Behavior of 55mass%Al–1.6mass%Si–Zn Alloy in Wet ...
Mechanical properties and corrosion behaviour of Zn-27Al...
Transcript of Mechanical properties and corrosion behaviour of Zn-27Al...
Leonardo Electronic Journal of Practices and Technologies
ISSN 1583-1078
Issue 25, July-December, 2014
p. 58-71
Mechanical properties and corrosion behaviour of Zn-27Al based
composites reinforced with silicon carbide and bamboo leaf ash
Kenneth Kanayo ALANEME1, 2*, Sumaila Isaac ADAMA1, Samuel Ranti OKE1
1 Department of Metallurgical and Materials Engineering, Federal University of Technology,
Akure, PMB 704, Nigeria 2 Department of Mining and Metallurgical Engineering, University of Namibia, Ongwediva
Engineering Campus, Ongwediva, Namibia E-mail:* [email protected];
* Corresponding author, phone: +2348034228868
Abstract
The mechanical and corrosion behaviour of Zn27Al alloy based metal matrix
composites reinforced with silicon carbide and bamboo leaf ash (BLA) was
investigated. Double stir casting method was used to produce the composites
which contained 7 and 10wt% BLA-SiC particles consisting of 0, 20, 30 and
40% BLA, respectively. Microstructural examination, mechanical properties
and corrosion behaviour were used to characterize the composites produced.
The results show that the hardness and tensile strength of the composites
decreased with increase in the weight percent of BLA although less than 11%
for all experimental cases studied. The percent elongation (%E) improved
slightly with the addition of a maximum of 30% BLA content for both the 7
and 10 wt% composite grades while the fracture toughness increased
consistently with increase in the weight percent of BLA in both the 7 and 10
wt. % composite grades. The BLA-SiC containing Zn-27Al hybrid composites
were very stable in 3.5% NaCl solution and the corrosion resistance in 0.3M
H2SO4 solution was superior to that of the single SiC reinforced Zn-27Al
composite grade.
Keywords
Zn-27Al based composites; Mechanical properties; Bamboo leaf ash; Silicon
carbide; Corrosion
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Mechanical properties and corrosion behavior of Zn-27Al based composites reinforced with silicon carbide and bamboo leaf ash
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Introduction
Zn-Al based alloys (designated as ZA alloys) have been successfully utilized in a
variety of demanding engineering applications [1-3]. The ZA alloys possess attractive
properties such as low melting point, high strength, good cast ability, easy machinability as
well as excellent bearing capability, high wear resistance and corrosion resistance [4-5].
The Zn-27Al alloy is reported to offer a good combination of mechanical and physical
properties in comparison with other members of the ZA cast alloys [6]. It has the highest
strength and the lowest density, offer excellent bearing and wears resistance properties, and
provides the highest design stress capability at elevated temperatures in comparison with all
the commercially available ZA alloys [7]. Zn-27Al alloy has been used for pressure die
castings and gravity castings wherever very high strength is required as well as in bearings
and bushing applications as a replacement for bronze bearings because of its lower cost and
equivalent or superior bearing performances [8]. However, at elevated temperature (> 100°C)
the use of zinc-aluminium alloys are limited which has restricted their use in some
applications [9].
One promising approach to improve the elevated temperature properties as well as the
mechanical, wear and corrosion properties of the Zn-27Al alloy is by reinforcing it with
ceramic dispersoids [10]. The use of silicon carbide (SiC), alumina (Al2O3), graphite (Cg), and
glass in either fibre or particulate shapes as reinforcements in ZA alloys has been well
reported in literature [11-13]. Some of these synthetic reinforcing materials are however noted
to be quite expensive resulting in the increased cost of production of the composites.
Recently, there has been efforts aimed at developing low cost – high performance
MMCs using agro based waste materials as reinforcements [14-16]. This composite materials
design concept was given impetus by the high cost of importation of synthetic reinforcing
materials such as SiC and alumina in most developing countries. Also the potentials of
conserving foreign exchange and improving agro waste management were further incentives.
Ashes derived from controlled burning of agro wastes such as coconut shell, rice husk,
bamboo leaf, bagasse among others have been tested as reinforcements particularly with
Aluminium based composites with very promising results obtained [17-19]. The use of these
agro waste ashes as sole or hybrid reinforcements in Zn-Al based alloys has received very
little attention from researchers.
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ISSN 1583-1078
Issue 25, July-December, 2014
p. 58-71
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In this research work, the mechanical and corrosion behaviour of Zn-27Al alloy based
composites reinforced with bamboo leaf ash and silicon carbide is investigated. This is aimed
at assessing the potentials of producing low cost Zn-27Al based composite grades with
comparable properties with the those reinforced with solely SiC which is a much expensive
reinforcing material.
Material and method
Commercial pure Aluminium and Zinc (with chemical composition presented in Table
1) were selected for the production of the Zn-Al alloy matrix. Chemically pure silicon carbide
(SiC) particles having average particle size of 30 μm and bamboo leaf ash (ash) (<50 µm)
derived from controlled burning and sieving of dry bamboo leaves were selected as
reinforcement for the Zn-27Al based composites to be produced. Graphite particles having
particle size of < 50 μm was also procured for addition in the composite mix to help improve
machinability of the composites [20]. The chemical composition of the bamboo leaf ash
utilized in this research is presented in Table 2.
Table 1. Elemental composition of the zinc and aluminium used for the production of the Zn-27Al based composite matrix
Elements Weight percentageAl 99.92 Fe 0.003 Si 0.033 Mn 0.021 others 0.023
Element Weight percentage Zn 99.96 Fe 0.02 Si 0.006 Pb 0.004 others 0.01
Table 2: Composition of bamboo leaf ash taken into study [19] SiO2 Al2O3 Fe2O3 CaO MgO K2O TiO275.9 4.13 1.22 7.47 1.85 5.62 0.20
Production of the Zn-27 Al based composites
Double stir casting process performed in accordance with Alaneme and Aluko [21]
was adopted for the production of the composites. The amounts of bamboo leaf ash (BLA and
silicon carbide (SiC) required to prepare 7 and 10 wt. % of the BLA-SiC reinforcements (in
the Zn-27Al alloy matrix) was first determined using charge calculations. Four different
BLA-SiC reinforcement weight mix ratios were prepared consisting of 0, 20, 30 and 40%
Mechanical properties and corrosion behavior of Zn-27Al based composites reinforced with silicon carbide and bamboo leaf ash
Kenneth K. ALANEME, Sumaila I. ADAMA, Samuel R. OKE
61
BLA. Graphite (0.25 wt. %) was added to each charge for improved machinability of the
composites after casting. In order to remove moisture, and improve wettability between the
reinforcements and the molten Zn-Al alloy; preheating of the bamboo leaf ash, silicon carbide
and graphite particles were performed separately at a temperature of 250°C. The melting
operation was carried out using a gas fired crucible furnace. The Aluminium billets was
charged into the furnace and heated to a temperature of 670°C until it has melted completely.
(The temperature of the furnace was monitored during melting using a temperature probe
fitted to the furnace). The temperature of the furnace was lowered to 500°C before Zinc was
added in to the crucible and allowed to melt completely. The liquid alloy was then allowed to
cool in the furnace to a semi solid state (temperature of 450°C); after which it was stirred at
200rpm for 5minutes to achieve homogenization. The preheated bamboo leaf ash, SiC and
graphite particles were then charged into the melt and the ensuing slurry stirred for 5-10
minutes. The composite slurry was subsequently superheated to 530°C and second stirring
performed using a mechanical stirrer. The stirring operation was performed at a speed of 400
rpm for 10 minutes before casting into prepared sand moulds. The sample designations for the
different compositions of the Zn-27Al based composites produced are presented in Table 3.
Table 3: Sample designations for the composites produced Sample designation Weight percent BLA:SiC7wt% Reinforcement A0 0: 100 A20 20:80 A30 30:70 A40 40:60 10wt% Reinforcement B0 0: 100 B20 20:80 B30 30:70 B40 40:60
Mechanical testing
Hardness tests (HRC) were performed on the composites produced using Indentec
Hardness Testing Machine. The composite specimen surfaces were well polished following
standard metallographic procedures to ensure a smooth surface is produced to allow for
reliable measurement of the hardness values. Multiple hardness tests were performed on each
sample and the average from values within the range of ± 2% was taken as the hardness of the
specimen.
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ISSN 1583-1078
Issue 25, July-December, 2014
p. 58-71
Tensile tests were also performed on the composites produced following the
specifications of ASTM 8M-91 standards [22]. The samples for the test were machined to
round specimen configuration with 6 mm diameter and 30 mm gauge length. The test was
carried out at room temperature using an Instron universal testing machine operated at a strain
rate of 10-3/s. The tensile properties evaluated from the tension tests are the ultimate tensile
strength and the strain to fracture. Three repeat tests were performed for each grade of the Zn-
27Al based composite produced to ensure repeatability and reliability of the data generated.
Circumferential notch tensile (CNT) specimens were used for the determination of the
fracture toughness of the composites following specimen preparation and test procedures in
accordance with Alaneme [23]. The CNT testing was also performed at room temperature
using an Instron universal testing machine. The samples for the test were machined having
gauge length, specimen diameter (D), and notch diameter (d) of 30, 6, and 4.5 in mm
respectively; and notch angle of 60°. The specimens were subjected to tensile loading to
fracture and the fracture load (Pf) obtained from the load – extension plots were used to
evaluate the fracture toughness using the equation [24]:
K1C = Pf/(D)3/2[1.72(D/d)–1.27] (1)
where, D and d are respectively the specimen diameter and the diameter of the notched
section. Plane strain conditions and by extension, the validity of the fracture toughness values
obtained was determined using the relations in accordance with Nath and Das [25]:
D ≥ (K1C/σy)2 (1)
Three repeat tests were performed for each grade of the Zn-27Al based composite
produced to ensure repeatability and reliability of the data generated.
Microstructural examination
The microstructure of the composites was examined using a Zeiss Metallurgical
Microscope with accessories for image analysis. The specimens for the test were
metallographically polished and etched in dilute aqua regal solution before they were viewed
under the microscope.
Corrosion test
The corrosion behaviour of the Zn-27Al alloy based composites produced was studied
using weight loss method. The mass loss (g/cm2) and corrosion rate (mmy) measurements
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Kenneth K. ALANEME, Sumaila I. ADAMA, Samuel R. OKE
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determined from the weight loss data (in accordance with ASTM G31 standard recommended
practice [26]) were used to access the corrosion behaviour of the composites. The corrosion
test was performed by at room temperature (25°C) by immersion of the test specimens in still
solutions of 0.3M H2SO4 and 3.5% NaCl which were prepared following standard procedures.
The specimens for the test were cut to size 15×15×10 mm and then mechanically polished
with progressively finer grit size emery papers to produce a smooth surface. The samples
were de-greased with acetone, rinsed in distilled water, and then dried in air before immersion
in the solutions. The solution-to-specimen surface area ratio was about 150 ml cm-2, and the
corrosion setups were exposed to atmospheric air for the duration of the immersion test. The
weight loss readings were monitored on two day intervals for a period of 42 days. Three
repeat corrosion tests were carried out for each grade of the Zn-27Al based composites
produced to guarantee reliability of results generated.
Results and discussion
Microstructure
Representative microstructures of the Zn-27Al based composites reinforced with BLA
and SiC are presented in Figure 1. For the two microstructural images, the dendritic
solidification structure of the Zn-27Al alloy which serves as the composite matrix are visible
alongside the dispersed reinforcements.
a. b. Figure 1: Representative microstructures of (a) the Zn-27Al based composite containing 7
wt% BLA-SiC (with 20% BLA: 80% SiC in wt %) and (b) the Zn-27Al based composite containing 10 wt% BLA-SiC (with 30% BLA: 70% SiC in wt. %)
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Issue 25, July-December, 2014
p. 58-71
Mechanical behaviour
The results of the mechanical properties of the Zn-27Al alloy based composites
produced are summarized in Table 3.
Table 3. Mechanical properties of Zn27Al based composites produced Sample designation
BLA (%)
HRC UTS (MPa)
E (%)
KIC
(MPam1/2) 7wt% A0 0 26.2 273.2 6.55 7.3 A20 20 25.6 269.7 6.7 8.8 A30 30 24.7 266 6.9 10.2 A40 40 23.4 258 6.2 9.6 10wt% B0 0 28.3 316.8 6.3 7 B20 20 27.4 310.2 6.4 7.8 B30 30 26.7 292.4 6.5 9.6 B40 40 25.8 283.7 6.1 8.9
It is observed from Table 3 that the hardness and tensile strength of the composites
decreased with increase in the weight percent of BLA. For hardness, reductions of 2.3, 5.7,
and 10.6% was observed for the 7 wt% BLA-SiC reinforced Zn-27Al composite grades
containing 20, 30, and 40% BLA (A20, A30, and A40) respectively. In the case of the 10
wt.% BLA-SiC reinforced Zn-27Al composite grades, 3.2, 5.6 and 8.8% reduction in hardness
was observed for the composites containing 20, 30, and 40% BLA (B20, B30, and B40)
respectively. For tensile strength, reductions of 1.3, 2.6 and 5.6% were obtained for the 7 wt%
BLA-SiC reinforced Zn-27Al composite grades containing 20, 30, and 40% BLA (A20, A30,
and A40) respectively. For the 10 wt% BLA-SiC reinforced Zn-27Al composite grades 2.1,
7.7 and 10.5% were observed for the composites containing 20, 30, and 40% BLA (B20, B30,
and B40) respectively. For both cases of reduction in hardness and tensile strength with
increase in BLA content, the predominance of silica in BLA (Table 2) which is known to be
softer compared to SiC is largely responsible [19]. The percent elongation (%E) is observed
to improve slightly with the addition of a maximum of 30% BLA content for both the 7 and
10 wt% composite grades. Further increase to 40% BLA content is noted to result in decrease
in the % Elongation of the composites. The fracture toughness also increased with increase in
the weight percent of BLA in both the 7 and 10 wt. % composite grades which is in contrast
with the trend observed for the hardness and tensile strength. For the 7 wt.% BLA-SiC
reinforced Zn-27Al composite grades, significant increases of 17.1 , 28.4 and 24.0 % were
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Kenneth K. ALANEME, Sumaila I. ADAMA, Samuel R. OKE
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obtained for the composites containing 20, 30, and 40% BLA (A20, A30, and A40)
respectively. In the case of the 10 wt.% BLA-SiC reinforced Zn-27Al composite grades 10.3,
27.1 and 21.4 % increment in fracture toughness was observed for the composites containing
20, 30, and 40% BLA (B20, B30, and B40) respectively. The improvement in the fracture
toughness with increase in BLA content of the composites is due to the reduced amount of
relatively harder and brittle SiC particles in the Zn-27Al based composites produced. The SiC
particles like most hard and brittle ceramic particles have a higher tendency to undergo rapid
crack propagation [19]. Thus it is noted that the addition of BLA in the Zn-27Al based
composites results in improved resistance to crack propagation and fracture.
Corrosion behaviour
The results of the variation of mass loss and corrosion rate with exposure time for
composites immersed in 3.5wt% NaCl solution are presented in Figures 2 and 3.
(a)
(b) Figure 2. Variation of (a) mass loss, and (b) corrosion rate of Zn-27Al based composites
containing 7 wt% BLA-SiC in 3.5% NaCl solution
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ISSN 1583-1078
Issue 25, July-December, 2014
p. 58-71
(a)
(b)
Figure 3. Variation of (a) mass loss, and (b) corrosion rate of Zn-27Al based composites containing 10 wt % BLA-SiC in 3.5% NaCl solution
For the 7 wt% reinforced Zn-27Al based composite grades (Figure 2), it is observed
from both the plots of mass loss (Figure 2a) and corrosion rate (Figure 2b) that there are
consistent fluctuations in the mass loss and corrosion rate of the composites in NaCl solution
over the exposure period for this study. This trend is linked to repeated film formation and
breakdown on the surface of the composites. It is noted however that the composite grade
containing 20% BLA had the highest resistance to corrosion of all the composites produced in
this series. The fluctuating mass loss notwithstanding, the 20% BLA containing composite
grade is observed to exhibit weight gain for most of the period of immersion. This suggests
fairly steady film formation.
The composite with 40% BLA is observed to be the most susceptible to corrosion
compared to the other composites in this series. This is a clear indication that proper selection
of BLA/SiC mix ratio can result in improved corrosion resistance of the Zn-27 Al based
composites in NaCl environment in comparison to the grades reinforced with only SiC.
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Mechanical properties and corrosion behavior of Zn-27Al based composites reinforced with silicon carbide and bamboo leaf ash
Kenneth K. ALANEME, Sumaila I. ADAMA, Samuel R. OKE
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For the 10 wt% reinforced composite grades (Figure 3), it is observed that the
composites were relatively more stable in NaCl solution compared with the 7 wt % composite
grades (Figure 2). The mass loss of the composites (Figure 3a) reduced significantly with the
addition of 30 to 40% BLA compared with the other composite compositions in this series.
The progressive weight gain observed in the composite grades containing 30 and 40%
BLA, is indicative of the consolidating nature of film deposition on the surface of the
composites with continuous exposure in the NaCl solution.
Thus the oxide films formed are very stable in NaCl solution. Similar trend in
improvement of corrosion resistance with the addition of BLA has been reported by Alaneme
et al [19]. The trends observed from the mass loss results (Figure 3a) are supported by the
corrosion rate plots (Figure 3b).
The variation of mass loss and corrosion rate with exposure time of the composites
produced in 0.3M H2SO4 solution is presented in Figures 4 and 5.
(a)
(b) Figure 4. Variation of (a) mass loss, and (b) corrosion rate of Zn-27Al based composites
containing 7 wt% BLA-SiC in 0.3M H2SO4 solution
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Issue 25, July-December, 2014
p. 58-71
For the 7 wt% reinforced composite grades (Figure 4), it is observed from the mass
loss plots (Figure 4a) that the corrosion resistance of all the hybrid composites was superior to
that of the single reinforced composite grade.
This observation is supported by the corrosion rate plot (Figure 4b) where it is noted
that peak corrosion rate was obtained at the third day of immersion. It is apparent that the
corrosion resistance of the composites roughly improved with increase in the BLA content.
This suggests that the addition of BLA (up to 40%) helps in stabilizing the passive film
formed on the surface of the composites and hence improves its protective capacity.
For the 10 wt% reinforced composite grades (Fig. 5), it is observed from the mass loss
(Fig. 5a) and the corrosion rate plots (Fig. 5b) that with the exception of the composite grade
containing 30% BLA, the corrosion resistance of the hybrid composite grades containing 20
and 40% BLA was better than that of the single SiC reinforced composite grade. This
corrosion trend is quite similar to that of the 7 wt% reinforced composite grades.
(a)
(b) Figure 5. Variation of (a) mass loss, and (b) corrosion rate of Zn-27Al based composites
containing 10 wt% BLA-SiC in 0.3M H2SO4 solution
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Mechanical properties and corrosion behavior of Zn-27Al based composites reinforced with silicon carbide and bamboo leaf ash
Kenneth K. ALANEME, Sumaila I. ADAMA, Samuel R. OKE
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Thus it can be stated the use of hybrid compositions of BLA and SiC in reinforcing
Zn-27Al based composites results in improved corrosion resistance in H2SO4 environments in
comparison with the use of single SiC reinforced Zn-27Al composite grade.
Conclusions
The mechanical and corrosion behavior of Zn27Al alloy based composites reinforced
with 7 and 10 wt % BLA and SiC in varied weight ratios was investigated. The results show
that:
• The hardness and tensile strength of the composites decreased with increase in the weight
percent of BLA although less than 11% for all experimental cases studied.
• The percent elongation (%E) improved slightly with the addition of a maximum of 30%
BLA content for both the 7 and 10 wt% composite grades.
• The fracture toughness increased consistently with increase in the weight percent of BLA
in both the 7 and 10 wt. % composite grades.
• The hybrid composites were very stable in 3.5 % NaCl solution and the corrosion
resistance in 0.3M H2SO4 solution was superior to that of the single SiC reinforced Zn-
27Al composite grade.
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