EXPERIMENTAL EVALUATION OF ALUMINIUM –CU COMPOSITE MATERIAL TO INCREASE THE MECHANICAL PROPERTIES WITH DIFFERENT COMPOSITION PRESENTED BY EDWIN.A EDWIN.A Under the guidance of Mr.G.SURENDHAR M.E (Assistant professor) DEPARTMENT OF MECHANICAL ENGINEERING E.G.S.PILLAY ENGINEERING COLLEGE NAGAPATTINAN

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 gm Density of copper=8.9gm/cc Weight of copper 162*8.9= gm =1.441kg Density of aluminum=2.7gm/cc Weight of Aluminum =18x2.7= 48.6 gm 30 % for excess (Runner&riser,slag) Total weight of mixture Copper= gm +410 gm= gm Aluminum= =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 gm Density of copper=8.9 gm/cc Weight of copper 144*8.9= gm/cc=1.281kg Density of aluminum=2.7gm/cc Weight of Aluminum =36x2.7=97.2 gm 30 % for excess (Runner&riser, slag) Total weight of mixture Copper=1281.6Kg+360 g= gm Aluminum= =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 gm Density of copper=8.9gm/cc Weight of copper 126*8.9= gm =1.121kg Density of aluminum=2.7gm/cc Weight of Aluminum =54x2.7=145.8 gm 30 % for excess (runner &riser, slag) Total weight of mixture Copper=1121.4g+300 g= gm=1.421kg Aluminum= =190.8gm MATERIAL REQUIREMENT CALCULATION SAMPLE : 3

CASTNG 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.metal castingsandmold Importance of Powder Metallurgy Advantages of Powder Metallurgy Basic process There are six steps in this process: Place a pattern in sand to create a mold.pattern 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 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 Furnace Electric Pit Furnace Fuel-Fired Pit Furnace Electric Retort Pit Furnace Gas-Fired Retort Pit Furnace Nitriding Pit Furnace Tempering 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 Hardness Major Load Applied : 100Kgf Types of Indenter used : 1/16”(Ball) Verification of Raw Materials S.N o Materia l Trial 1 Trial 2 Trial 3 Trial 4 Trial 5 Mean 1 Pure Alumini um (LM4) Pure Copper

APPLICATION OF THE Cu-Al 2 O 3 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 Society for Metals, Metals Park, OH, 1991, pp – [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 density and ultrafine W/Cu composite material, US Patent no (1998).

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