INVESTIGATION OF INTER MATERIAL SHEAR
PROPERTIES OF IRON AND STANNUM
ROZIAH BINTI ABIDIN
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
INVESTIGATION OF INTER MATERIAL SHEAR
PROPERTIES OF IRON AND STANNUM
Thesis submitted in accordance with the partial requirements of the Universiti Teknikal Malaysia Melaka for the Bachelor
Of Manufacturing Engineering (Engineering Materials) with Honours
By
Roziah Binti Abidin
UTeM Library (Pind.1/2007)
SULIT
TERHAD
TIDAK TERHAD
(Mengandungi maklumat yang berdarj ah keselamat an at au kepent ingan Malaysia yang t ermakt ub di dalam AKTA RAHSIA RASMI 1972)
(Mengandungi maklumat TERHAD yang t elah dit ent ukan oleh organisasi/ badan di mana penyelidikan dij alankan)
(TANDATANGAN PENULIS)
Alamat Tet ap:
A9-00-07 APARTMENT DAMIANA, PROTON CITY
35900 TANJUNG MALIM, PERAK.
Tarikh: _______________________
JUDUL: INVESTIGATION OF INTER MATERIAL SHEAR PROPERTIES OF IRON AND STANNUM
SESI PENGAJIAN: 2004-2008
Saya
mengaku membenarkan t esis (PSM/ Sarj ana/ Dokt or Falsaf ah) ini disimpan di Perpust akaan Universit i Teknikal Malaysia Melaka (UTeM) dengan syarat -syarat kegunaan sepert i berikut :
1. Tesis adalah hak milik Universit i Teknikal Malaysia Melaka.
2. Perpust akaan Universit i Teknikal Malaysia Melaka dibenarkan membuat salinan unt uk t uj uan pengaj ian sahaj a.
3. Perpust akaan dibenarkan membuat salinan t esis ini sebagai bahan pert ukaran ant ara inst it usi pengaj ian t inggi.
ROZIAH BINTI ABIDIN
/
DECLARATION
I hereby, declared this thesis entitled “INVESTIGATION OF INTER MATERIAL
SHEAR PROPERTIES OF IRON AND STANNUM” is the results of my own
research except as cited in references
Signature : ………
Author’s Name :
Date :
ROZIAH BINTI ABIDIN
APPROVAL
This thesis submitted to the senate of UTeM and has been accepted as partial fulfillment of the requirements for the degree of Bachelor of Manufacturing Engineering (Manufacturing Process). The members of the supervisory committee are as follow:
……… (MR. MOHAMAD HAIDIR BIN MASLAN)
ABSTRACT
ABSTRAK
DEDICATION
ACKNOWLEDGEMENT
Thanks to Allah S.W.T because with the blessing has made me complete my Final Year Project (PSM) successfully without having any problem at all during the period. Thanks to Universiti Teknikal Malaysia Melaka (UTeM) and Faculty of Manufacturing Engineering (Engineering Materials) because give me an opportunity to gain this valuable experience.
Endless appreciation and gratitude to my supervisor, Mr. Mohamad Haidir bin Maslan and to my second examiner Mr Mohammad Kamil b. Sued for their encouragement and support and for spending quite some time with myself, providing a lot of guidance and ideas for my project research. Their knowledge and experience really inspired and spurred myself. I truly relished the opportunity given in working with them.
Many thanks to the technicians of Faculty Manufacturing Engineering (FKP) and Faculty Mechanical Engineering (FKM) because of the acquires and co-operation.
TABLE OF CONTENT
2 LITERATURE REVIEW
2.1 INTRODUCTION 7
2.2.1 Introduction 8
2.2.2 Matrix 8
2.2.2.1 Metal Matrix Composite 8
2.2.2.2 Polymer Matrix Composite 9 2.2.2.3 Ceramics Matrix Composite 9
2.2.3 Reinforcement 10
2.1.3.1 Types of Reinforcement 10
2.3 METAL MATRIX COMPOSITE
2.3.1 Introduction 12
2.3.2 Properties of Copper Matrix 12
2.3.3 Properties of Iron (Ferrum) Reinforcement 13
2.3.4 Properties of MMC 13
(a) Physical Properties 13
(b) Mechanical Properties 14
2.3.5 Advantages and Disadvantages of MMC 14
2.3.6 Processing Method of MMC 15
2.3.6.1 Liquid- Phase Processing 15
2.3.6.2 Solid-Phase Processing 15
2.3.6.3 Two-Phase Processing 16
2.4 INTERFACE 17
2.4.1 Introduction 17
2.4.2 Function 18
2.4.3.1 Mechanical Bonding 19
2.4.3.2 Electrostatic Bonding 19
2.4.3.3 Chemical Bonding 20
2.4.3.4 Reaction Bonding 20
2.5 MECHANICAL TESTING FOR
MEASURING BONDING STRENGTH 22
2.5.1 Introduction 22
2.5.2 Single Fiber Tests 23
2.5.3 Bulk Specimen Tests 24
2.5.4 Micro-Indentation Test 26
2.5.5 Iosipescu Shear Test 27
2.5.6 Arcan Shear Test 28
2.5.7 Wyoming Version of Shear Test 29
2.5.8 Idaho Version of Shear Test 29
2.5.9 FPL Version of Shear Test 30
2.6 SPECIMEN 32
2.7 MICROSTRUCTURE OBSERVATION 34
2.7.1 Optical Microscope 34
2.7.2 Scanning Electron Machine (SEM) 35
2.7.2.1 Basic Operating 36
3 METHODOLOGY
3.1 RESEACH DESIGN 37
3.3 MOULD PREPARATION 39
3.3.1 Mould Designing 39
3.3.2 Mould Specification 39
3.4 PROCESS SEQUENCE OF SAMPLE
PREPARERATION 40
3.5 EXPERIMENTAL METHOD 41
3.5.1 Shear Test 42
3.5.2 Microstructure 43
3.5.2.1 Microstructure Analysis 44
4 RESULT AND DISCUSSION 45
4.1 INTRODUCTION 45
4.2 SHEAR TEST 46
4.3 MICROSTRUDTURE OBSERVATION 52
4.3.1 Optical Microscope 52
4.3.2 Scanning Electron Microscope 55
5 CONCLUSION AND SUGGESTION 58
LIST OF TABLES
Table 2.1 Different metal particles shapes and manufacturing methods. 11 Table 3.1 Typical chemical composition for copper alloy- C106. 41 Table 3.2 Typical chemical composition for aluminum 2024. 42
Table 4.1 The Data of Al-SS (smooth surface). 47
Table 4.2 The Data of Al-SS (v-shape surface). 47
Table 4.3 The Data of Sn-SS (smooth surface). 49
LIST OF FIGURES
Figure 2.1 Formation of a composite material using reinforcement
and matrix. 8
Figure 2.2 Continuouse fiber composites and short fiber composites. 10
Figure 2.3 The interface function. 18
Figure 2.4 Interlock of mechanical bonding. 19
Figure 2.5 Electrostatic bonding. 20
Figure 2.6 Chemical bonding. 20
Figure 2.7 Reaction that involving polymer. 21
Figure 2.8 Interfacial that formed by interdiffusion. 21
Figure 2.9 Single fiber test. 24
Figure 2.10 Illustration of specimen geometry. 25
Figure 2.11 Cross-sectional diagram of loaded indentor. 26
Figure 2.12 Iosipescu shear test fixture. 27
Figure 2.13 Test fixture and specimen by Arcan et al. 1978. 28 Figure 2.14 Modified Wyoming shear test fixture. 29
Figure 2.15 Idaho shear test fixture. 30
Figure 2.17 Specimen dimension of Single Fiber Pull-Out Test. 32
Figure 2.18 Single Fiber Test 33
Figure 2.19 Optical Microscope 34
Figure 2.20 SEM component. 35
Figure 2.20 SEM operating. 36
Figure 3.1 Material involve and parameter consideration. 38
Figure 3.2 Mould specification. 39
Figure 3.3 The process sequence of sample composites preparation. 40
Figure 3.4 Single Fiber Test 43
Figure 3.5 Pull-Out Shear Test Diagram 43
Figure 4.1 Sample 46
Figure 4.2 The position of The Sample at UTM 46
Figure 4.3 Shear Test of Al-SS Composites 48
Figure 4.4 Shear Test of Sn-SS Composites 50
Figure 4.5 The Shear Test for Smooth Surface 51
Figure 4.6 The Shear Test For V-Shape Surface 51
Figure 4.7 Microstructure on Boundary Surface with 500X, Al-SS 52 Figure 4.8 Microstructure on Boundary Surface with 500X, Sn-SS 53
NOMENCLATURE
SEM Scanning Electron Microscopy. TEM Transmission Electron Microscope.
ASTM America Society for Testing and Materials. MMC Metal Matrix Composite.
PMC Polymer Matrix Composite. CMC Ceramics Matrix Composite. EDM Electrical Discharge Machining.
Al Aluminum.
SS Stainless Steel.
CHAPTER 1
INTRODUCTION
1.1BACKGROUND
Metal matrix composites (MMC) consist of an intricate structure of metals and an inorganic reinforcing material. The frontier zone between these two phases (interface or interphase) is one essential part of MMC. Bonding that developed from physical or chemical interactions, interfacial frictional stress and thermal stresses due to mismatch between coefficient of thermal expansion of reinforcement and matrices. The understanding and control of the underlying interfacial phenomena governing the transmission of thermal, electrical, and mechanical properties across the whole composite might become paramount importance when designing MMC for a particular task.
problems have been reported for composites testing such e.g. nonhomogenous stress fields, problems with evaluating the experimental data, non-linear material behavior, gripping, and undesired loading states. But for this report, the test is modifying form pull out for single fiber test.
1.2 OBJECTIVE
The main objectives of this investigation are to:
Study shear stress and characteristic shear responses between two different metals.
Determine the shear toughness relationship between two different materials with Stannum (Sn) and Stainless Steel (SS).
1.3SCOPE
1.4POTENTIAL OF BENEFIT
From this project, the shear properties between two different materials will be known. This project is important to:
o Get the best method on producing the composite with high bonding between two different materials.
o Detect what parameter that will involve in shear properties.
o Analyze the shear stress and characteristic of shear responses between two different materials.
1.5STUDY OUTLINE
Investigation of inter material shear properties of iron and stannum
CHAPTER 2
LITERATURE REVIEW
2.1 INTRODUCTION
Composite is a mixture of two or more distinct constituents or phases. So, composite are produced by combining two or more homogenous materials such as that the physical and chemical different phase that are formed will make possible the high performance required. Once the matrix has wet the reinforcement, and is therefore in intimate contact with the reinforcement bonding will occur. In achieving this high performance, the interaction between component materials in the interface and the properties of each constituent are of utmost important.
The load acting on the matrix has to be transferred to the reinforcement via interface. Thus reinforcements must be strongly bonded to the matrix if their high strength and stiffness are to be imparted to the composite. The fracture behavior is also dependent on the strength of the interface. The interface is important whether the reinforcement is in the form of continuous fiber, short fibers, or whisker or particles although the exact role of the interface may differ with the type of the reinforcement.
