Characterisation of Aluminium
Characterisation of Aluminium
Characterisation of Aluminium
I. INTRODUCTION
Engine Piston is most complex part compared to
other components in an automobile sector. Still lot of
research works have been conducting on piston
regarding material composition, geometry and
manufacturing technique. The function of the internal
combustion engine piston is to receive the energy
from expanding gases after during combustion and
transmit it to the crankshaft by means of connecting
rod. Piston expands appreciably when it gets heated
during the operation so actual clearances need to be
given otherwise it will lead to engine seize. And
hence to avoid this case pistons are made up of cast
aluminium alloy matrix with the combination of
reinforcements in different weight percentage. For
better results here I am replacing conventional piston
material LM13-TF with new composite [Al6061
+Al2O3 + FLY ASH]. The addition of Fly ash and
Alumina reinforcement particles to the Aluminium
matrix improves the tensile strength, compressive
strength and hardness behaviour. The reinforcement
SiO2
Al2O3
CaO
Fe2O3
TiO2
MgO
LOI
Weight%
65.56
19.9
7.56
3.79
1.2
1.24
0.7
C. Alumina(Al2O3)
Alumina is also one of the most cost effective and
widely used ceramic materials and is readily
available.
A. A16061 Alloy
Matrix phase supports the reinforcements by keeping
them in their position and it also takes the load from
the reinforcements to balance the load acting on the
component. Low coefficient of thermal expansion,
high elastic modulus, good thermal conductivity and
improved resistance are the important properties.
AhO3
Weight%
96
SiO2
3.85
MgO
Na2O
0.03
0.15
Fe2O3
0.02
CaO
0.03
TiO2
B2O3
<0.01
<0.02
Values
Al
Mg
Fe
Cu
Si
Cr
Mn
Ti
rest
Wt %
95.8
98.6
0.8 1.2
Max
0.7
0.15
- 0.4
0.4
0.8
0.04
0.35
Max
0.15
Max
0.15
Max
0.05
Unit
Values
Density
gm/cc
2.7
Elastic Modulus
GPa
68.9
Yield strength
MPa
White
Poisson's ratio
GPa
0.21
Flexural strength
MPa
330
Hardness
Kg/mm2
1175
Compressive strength
MPa
2100
Elastic Modulus
GPa
300
Fracture Toughness
MPa-m1/2
3.5
276
Shear modulus Density
Ultimate Tensile
Strength
MPa
310
Fatigue Strength
MPa
96.5
B. Fly Ash
Fly ash is the waste by-product disposed during the
combustion of coal, the shape of the fly ash particles
GPa gm/cc
124 3.69
Take less than 5% weight of solid dry hexachloroethane tablets to degas the molten metal at a
temperature of 780C..
A. SEM Results
The cleaned and polished specimen was used for
SEM and EDX testing. The SEM micrographs were
taken at different magnifications and shown in the
figure 7 to 12.
Nomenclature
Ultimat
e Load
(KN)
Al6061 + 0% reinforcement
Al6061 + 4% Al2O3 +
5%FLY ASH
Al6061 + 4% Al2O3 +
8%FLY ASH
Al6061 + 4% Al2O3 +
12%FLY ASH
3
4
16.08
Ultimat
e
Tensile
Stress
(Mpa)
319.9
%
Elongati
on
16
18.15
370.1
11.6
19.5
386.2
10.25
21.1
398.15
10.1
Nomenclature
LOAD
(N)
BHN
Al6061 + 0% reinforcement
250
50
250
75
250
80
250
83
E. Impact Strength
In recent years the development of advanced high
performance fibre composite materials was mainly
concerned with achieving high modulus and strength
materials. However, high strength and stiffness by
themselves may not be adequate for many structural
applications as this combination of properties usually
produces a brittle material. And have very low energy
absorption capability.
It is necessary to test the specimens to check its
energy absorption capability to avoid the failure of
composite under working conditions. The test is
carried out in charpy impact tester because it is cheap
and faster. The Specimen is prepared as per ASTM
standard E23, The Specimen is cut into 10*10*55
mm dimensions.The below table show the results for
Impact test
Z-scale
Wt %
AL
0.876
83.4
AL2O3
0.074
2.3
Fly ash
0.073
13.6
0.0511
0.7
Nomenclature
Impact
Strength
(J/mm2)
Al6061 + 0% reinforcement
0.6
0.61
0.63
0.64
F. Edx Testing
The below Figures 13 & 14 and below Tables (Table
8.7.1 and 8.7.2.) of Energy dispersive x-ray
spectroscopy report of prepared composites indicate
the physical composition of specimens and it is clear
that the prepared composite specimens are having
mixture of different compounds.
Z-scale
Wt %
AL
0.876
78.8
AL2O3
0.074
8.2
Fly ash
0.073
12.3
0.0511
0.7
F. Fatigue testing
Fatigue testing is in progress
V. DESIGN CALCULATIONS OF PISTON
Kirloskar Rex Engine Specifications:
[6]
Perth Auerkari "Mechanical And Physical
Properties Of Engineering Alumina Ceramics"
Technical Research Centre Of Finland Espoo 1996
Isbn 951-38-4987-2 Issn 1235-0605 Valtion
Teknillinen Tutkimuskeskus (Vtt) 1996.
7] Bharath V, Mahadev Nagaral And V. Auradi
"Preparation, Characterization And Mechanical
Properties Of Al2o3 Reinforced 6061al Particulate
Mmc's" R & D Centre, Department Of Mechanical
Engineering, Siddaganga Institute Of Technology,
Tumkur-572102, Karnataka, India. International
Journal Of Engineering Research & Technology
(Ijert) Vol. 1 Issue 6, August - 2012 Issn: 2278-0181.
REFERENCES
[1]
[8]
Shang-Nan Choua, Jow-Lay Huanga, DingFwu Lii B, Horng-Hwa Lu "The Mechanical
Properties Of Al2o3/Aluminum Alloy A356
Composite Manufactured By Squeeze Casting" A
Department Of Material Science And Engineering,
National Cheng-Kung University, Tainan 701,
Taiwan, Roc B Department Of Electrical
Engineering, Cheng Shiu Institute Of Technology,
Kaohsiung County, Taiwan 833, Taiwan, Roc
Department Of Mechanical Engineering, National
Chin-Yi Institute Of Technology, Taiping, Taichung
411, Taiwan, Roc 2005.
[9]
Vivekananthanl M. And Senthamarai2 K
"Experimental Evaluation Of Aluminium-Fly Ash
Composite Material To Increase The Mechanical
&Wear Behaviour By Stir Casting Method" 2007.
[10]
Peter Andersson "Piston Ring Tribology A
Literature Survey" Vtt Industrial Systems Jaana
Tamminen & Carl-Erik Sandstrom Helsinki
University Of Technology, Internal Combustion
Engine Laboratory.
[11]
F.S. Silva "Fatigue On Engine Pistons - A
Compendium Of Case Studies" Department Of
Mechanical Engineering, University Of Minho,
Azure'M, 4800-058 Guimara~ Es, Portugal 2005
[12]
Prashant S N1, Madeva Nagaral2 & V
Auradi3 "Preparation And Evaluation Of Mechanical
And Wear Properties Of 6061al Reinforced With
Graphite Particulate Metal Matrix Composite" 2009.
[13]
Mahendra Boopathi, M., K.P. Arulshri And
N. Iyandurai "Evaluation Of Mechanical Properties
Of Aluminium Alloy 2024 Reinforced With Silicon
Carbide And Fly Ash Hybrid Metal Matrix
Composites" 2012
[14]
Barbara Sieminska And Antoni Jankowski
"Composite Alloy With Very Low Dimensional
Hysteresis During Heating And Cooling For
Combustion Engine Piston" Institute Of Aeronautics,
Al. Krakowska 110/114, 02-256 Warszawa, Poland
[15]
Varuzan Kevorkija Zrvk. Maribor, Slovenija
"Development Of Aluminum Mmc Composites For
Automotive Industry," Yugoslav Association For
Mechanical
Engineers
Yame.
Udc669.715/419.7:629.11.
[16]
P. Carvalheira1, And P. Gongalves "Fea Of
Two Engine Pistons Made Of Aluminium Cast Alloy
A390 And Ductile Iron 65-45-12 Under Service
Conditions," Ref: A0319.0006,24-26 July 2006.
[17]
Hongyuan
Zhang,
Xingguo
Ma,
Shuangliang Ge "Modeling And Transient Dynamics
Analysis To a new Type Of Engine Piston" 2013.
[18]
Ch.Venkata
Rajam,
P.V.K.Murthy,
M.V.S.Murali Krishna, G.M.Prasada Rao "Design
Analysis And Optimization Of Piston Using Catia
And Ansys" International Journal Of Innovative
Research In Engineering & Science Issn 23195665(January 2013, Issue 2 Volume1).
[19]
Piotr
Szurgott,
Tadeusz
Niezgoda
"Thermomechanical Fe Analysisof The Engine Piston
Made Of Composite Material With Low Histeresis"
Journal Of Kones Powertrain And Transport, Vol. 18,
No. 1 2011.International Journal of Innovative
Research in Science, Engineering and Technology
(An ISO 3297: 2007 Certified Organization)
Vol. 2, Issue 12, December 2013
[20]
M. R. Ayatollahi*, F. Mohammadi And H.
R. Chamani "Thermo -Mechanical Fatigue Life
Assessment Of A Diesel Engine Piston" Faculty Of
Mechanical Engineering, Iran University Of Science
And Technology. Tehran, Iran.
[21]
Shuoguo Zhao, "Design The Piston Of
Internal Combustion Engine By Pro\Engeer"
Mechatronics Department, Handan Polytechnic
College,Handan Hebei 056005, China. 2nd
International Conference On Electronic &
Mechanical
Engineering
And
Information
Technology (Emeit-2012).
[22]
Wilfried Wunderlich , Morihito Hayashi
"Thermal Cyclic Fatigue Analysis Of Three
Aluminum Piston Alloys" Tokai University, Faculty
Of Engineering, Department Of Mechanical
Engineering, 259-1292 Hiratsuka, Kanagawa, Japan.
2012.
[23]
Soniya
Kaushik,
Rayapuri
Ashok,Mohammed Zubair Nizami, Dr.Mohd.
Mohinoddin "Parametric And Material Optimization
Of Two Wheeler Piston Using Aluminum Alloy
7475-761 And Aluminum Alloy 6061" International
Journal Of Advanced Trends In Computer Science
And Engineering, Vol.2 , No.1, Pages : 596 - 601
(2013)
[24]
S N Kurbet, Vinay V Kuppast And
Vijaykumar N Chalwa "Finite Element And Mbd
Analysis Of Piston To Predict The Engine Noise"
Issn 2278 - 0149 ,Vol. 2, No. 1, January 2013.
[25]
Ghodake A. P. Patil K.N. "Piston Design
And Analysis By Cae Tools" Department Of
Mechanical Engineering, Snd Coe & Rc Yeola,
Nashik, India Iosr Journal Of Engineering (Iosrjen)
Issn: 2250-3021 Isbn: 2878-8719 Pp 33-36 National
Symposium On Engineering And Research.
[26]
Andrzej Niewczas, Cezary Sarnowski
"Analysis Of Deformation In Composite Pistons Of
A Diesel Engine" Journal Of Kones Internal
Combustion Engines 2003, Vol. 10, 3-4 Department
Of Internal Combustion Engines, Lublin University
Of Technology Poland, Nadbystrzycka 36 Str., 20618 Lublin.