INVESTIGATION OF ABRASIVE WEAR BEHAVIOR OF SILICON CARBIDE REINFORCED COPPER-BASED METAL MATRIX COMPOSITE
Parth Patel, Dr. T. K. Mishra
Gyan Ganga Institute of Technology and Sciences, Jabalpur
Abstract- Engineering materials known as Metal Matrix Composites (MMC) mix two or more different materials to produce enhanced qualities. In this work, Silicon Carbide (SiC) is mixed in Copper (Cu)in varying percentages as 5,10, and 15 wt. % as the matrix and reinforcement phases, respectively. The microstructural study is carried out using a scanning electron microscope (SEM) and X-ray diffraction (XRD) to evaluate the distribution of reinforcement particles in the copper matrix phase and phase identification. Vickers hardness test and abrasive wear test were performed by using a Vickers hardness tester and a pin-on-disc tribometer. Abrasive media was used to conduct an abrasive wear test.
The result shows that the optimum addition of 10 wt. % of SiC makes the microstructure dense and increases the hardness and wear resistance.
Keyword: Abrasive wear, composite, Copper, Silicon carbide, SEM, XRD.
1 INTRODUCTION
Due to its extensive array of uses in a variety of disciplines, copper is regarded as one of the essential elements in the modern world. It is mostly utilized in transmission wires, cables, generators, vehicles for transportation, musical instruments, building construction, roofing, etc. Due to copper's exceptional qualities, it may be used for such a diverse range of purposes.
1.1 Important Copper Properties [1]
Excellent thermal and electrical conductivity; corrosion resistance;
ductility and ease of joining; non- magnetic nature and ease of alloying;
antibacterial and recyclable.
Atomic No of copper: 29
Melting temperature: 1356 K
Atomic wt. : 63.546
Boiling temperature: 2868 K
Copper Density: 8940 kg/ cubic meter.
Copper Structure: FCC
Copper's relative weakness is one of its main disadvantages. It is frequently alloyed or reinforced with suitable materials to create a composite in order to enhance its strength-related qualities. In general, strengthening the copper matrix with SiC particles gives it exceptional strength and greatly enhances its wear qualities. We are all aware of how well pure copper conducts electricity. Copper's electrical conductivity may often be decreased by creating an alloy or composite to increase its strength.
Therefore, a compromise between
increasing pure copper's strength and decreasing its electrical conductivity is required, or we risk losing some of the applications for pure copper. It has been noted that [3] the copper's ductility and strength decrease with an increase in temperature.
1.2 Composite
Although natural materials, including wood, can occasionally be used in composites, they are mostly man-made [5]. They are mostly created by combining two materials that are separated by a clear interface. In comparison to the combined properties of its parts, a composite's properties are improved. The reinforcing phase and matrix phase are the two components that make up a composite. The matrix phase is embedded in the reinforcing phase, which primarily gives the matrix strength. The matrix materials used in composites might take the shape of polymers, ceramics, or metals, while the reinforcing phases are typically found as particles, fibers, or sheets.
Composites' high strength [6] and stiffness, combined with their light weight, are the most significant benefits.
Due to their excellent strength-to-weight ratio, composite materials can now be used more frequently in space applications where being both light and strong is of utmost importance.
Additionally, the presence of fibers in composites distributes the applied load and prevents cracks from spreading as quickly as they do in metals. The
versatility associated with composites' way of design is another benefit. It's because they can be molded into a variety of shapes, no matter how simple or intricate. Corrosive and high-temperature conditions can be withstood by composites with the right composition and production techniques. With all these benefits, it is understandable to wonder why composites have not completely replaced metals. Composite has a high cost due to the higher cost of raw materials.
1.3 Composites Classification
Depend on particle reinforcement- Large particle composites and dispersion- enhanced composites are the two subgroups of particle-reinforced composites once again [7]. Particle sizes in large particle composites are larger than those in dispersion-enhanced composites. The matrix mobility can be limited if the connection is strong. Large particle composites include materials like concrete and reinforced concrete. Particle sizes in dispersion strengthened range from 10 to 100 nm. The tiny particles are spread throughout the matrix and stop dislocations from moving, therefore preventing plastic deformation. A dispersion-enhanced composite is one made of sintered aluminum powder (SAP).
Depend on fiber reinforcement- The high strength and stiffness ratio to the weight of the composite is due to the fibers [8]. There are two other categories within this one: continuous and discontinuous fibres. Discontinuous fibres have lengths that are less than 15 times the critical length (l >15 lc), whereas continuous fibers typically have lengths more than this. The direction of the discontinuous fibers might either be aligned or random. It should go without saying that continuous fibers will improve load transmission and composite strength. Examples of some fibers include carbon, boron, E-glass, SiC, and others.
to stop the sandwich panel from buckling.
The sheets facing the outside should be constructed of a sturdy and rigid material, such as steel, titanium, or aluminum.
Polymer bases matrix composite-They have fibers like carbon, aramid, or E-glass as the reinforcing phase and polymer as the matrix phase [8]. Glass Fiber
Reinforced Polymer (GFRP), Carbon Fiber Reinforced Polymer (CFRP), and Aramid Fiber Reinforced Polymer Composites are the three main types of Polymer-Matrix Composites (PMC) that are most frequently utilized. Vinyl esters and polyesters are the two polymers that are most frequently utilized as matrices.
Because of its characteristics and simplicity of production, PMCs are frequently employed.
Ceramic-based matrix composite-In this group of composites, the matrix phase is made of ceramic materials. The primary goal of CMC development is to increase the ceramic materials' fracture toughness [8]. This enables the use of CMCs in high- temperature, high-stress situations. In order to stop cracks from spreading, the dispersion phase is crucial.
Metal baed matric composite- The matrix phase of an MMC is frequently a ductile metal. Strong strength to weight ratio, high resistance to abrasion and corrosion, resistance to creep, good dimensional stability, and high temperature operability are all goals while making MMCs [8]. Usability at high temperatures and resilience to corrosion by organic fluids are MMCs' key benefits over CMCs. MMCs are employed in sectors including aerospace and automotive. The main metals utilised as the matrix are copper and aluminium.
Using MMC at high temperatures could cause composite deterioration. To prevent this, the matrix alloy's composition must not be altered or a protective surface coating applied to the reinforcement.
Hybrid- composite - Typically, two or more fibres that differ from one another are present in one matrix phase of a hybrid composite [8]. The hybrid composite that uses both glass and carbon fibres for reinforcement and polymeric resin as the matrix is the most widely used hybrid composite. Most hybrid composites have anisotropic characteristics. In comparison to composites using just one fibre as reinforcement, hybrid composites have better overall characteristics. It is now clear that the matrix phase of metal matrix composites is a metal or an alloy.
Al-SiC or Cu-SiC composites are two MMCs that we come across more frequently. Typically, fibres, particles, or
whiskers are used as reinforcement stages.
1.4 Metal-Matrix Composite Manufacturing Procedure-
A metal-matrix composite can be produced in a variety of ways:
a. Solid-phase manufacturing techniques [12]
b. Diffusion-bonding procedure c. Technique of Powder Metallurgy 2) Liquid-phase manufacturing techniques
(a) Liquid-metal encroachment
(b) Spray co-deposition, squeeze casting, and compocasting
3) Vapor state technique
(a) PVD, or physical vapour deposition 1.5 Powder Metallurgy Route of MMC One of the most popular methods for creating metal-matrix composites is this one. Typically, particles or whiskers are used as reinforcements in this procedure [12]. This procedure involves blending and mixing produced powders from the matrix and reinforcement stages. The desired
amount of pressure is used to compact the powder after placing this mixture in the mould. It's called cold pressing. The compressed form of the powder is then heated to a high enough temperature in an inert environment to create the correct solid state diffusion bonding between the matrix and reinforcement. Sintering takes place in this manner. The powder combination that has been combined can alternatively be directly pressed using hot pressing.
1.6 Wear-
The life of machine parts or components is reduced by wear, which is a serious issue. Additionally, it raises the cost of replacement, which ultimately raises operating costs. Wear is the detachment of metals from their components as a result of metal-to-metal contact, metal-to- metal contact with abrasive particles, metal-to-metal contact with erosive particles, or environmental factors. The quality of the metal's surface decreases with wear.
1.7 Types of wear
Table 1 1List of Wear
2. LITERATURE REVIEW
T.E.Abioye et al. (2022) investigated the effect of SiC on Sn-Sb-Cu alloy. SEM, XRD, and hardness tet was counducted to know microstrucutre. Phase identification and hardness. With an increase in SiC composition, the Sn-Sb-Cu alloy's characteristics such as hardness, compressive strength, and wear resistance improved. The improvement in hardness, compressive strength, and wear resistance over the Sn-Sb-Cu alloy was found to be greatest with the addition of 9 weight percent SiC.
Mohammadmehdi Shabaniet al.
(2020) investigated the wear behavioir of Cu-SiC composite prepared by sintering and sinter-forging process. The author reported that Cu+ 60 vol.% SiC shows minimum wear. The addition of SiC increases the density and wear resistance.
Dry sliding wear tests represented that the sinter-forged Cu composite compacts with exhibit the lowest wear loss compared to other compacts. Moreover, the results indicated that applying compressive force during sintering process of Cu and Cu/SiCp compacts has
a significant effect on reducing and eliminating porosities and achieving to higher bulk density. Therefore, wear loss of the Cu and Cu/SiCp compacts produced through sinter-forging process was improved significantly compared to conventionally sintered Cu and Cu/SiCp composite compacts
Curle et al research .'s [20], wear rates on SiC abrasive mediums for F (ascast) and T6 (six hours of solution treatment at 5400 C followed by quenching in room-temperature water and then artificial ageing for ten hours at 1700 C) conditions were found to decrease with the increase in volume fraction of SiC particles in Al alloy 359 and plates of SiC particles as einforcement produced by rheo- processing However, in the same F and T6 circumstances, it was discovered that the wear rates on diamond abrasive media increased with an increase in the volume fraction of SiC particles.
Wang et al. [19] investigated the wear behaviours of hybrid metal matrix composites with cast aluminium alloy, A356 Al-Si as the matrix and alumina fibres and silicon carbide particles as the reinforcing components. Their research suggests that the orientation of the fibres and the inclusion of SiC particles affected the wear resistance in cases of dry sliding and lubricated sliding wears.
Candel et al. [18], the microhardness increased along with the decrease in wear rate on increasing the volume fraction of TiC when Ti6Al4V hot rolled alloy substrate was coated with Ti6Al4V atomized powders and TiCp to produce a metal matrix composite coating on Ti6Al4V substrate by laser cladding process.
Sahin et al. [17], when continuous boron fiber was added to the aluminum alloy (2014) matrix, its wear resistance significantly increased when compared to that of the unreinforced aluminum alloy under all conditions. This improvement was based not only on the fiber content but also on the orientation of the fibers as well as other factors like the applied load and rubbing speed.
2.1 Need of Work
Copper is videly used in industries due to its versitle properties. copper's ductility and strength decrease with an increase in
temperature. It also deform in application of higher load and wear out during sliding and abrasive action. Current literature shows that a different alloy which add in copper improve its microstrucutre, mechanica, and wear properties. There are less literature available the effet of SiC in copper metal metrix. There is stil need to investigate the effect of SiCin microstrucutre, mechanica, and wear properties.
2.2 Objective of Work
1. To investigate effect of SiC on microstrucutre properties of Cu based metaal matrix composite.
2. To investigate effect of SiC on mechanical properties of Cu based metaal matrix composite.
3. To investigate effect of SiC on wear properties of Cu based metaal matrix composite.
4. To compare the result and present in graphical manner.
3. METHODOLOGY/EXPERIMENTAL TECHNIQUES
In this section procedure of experiments is described in detail. The selection of powder, mixing, compaction method, sintering, and characterization of composite and mechanical properties are discussed in brief.
Figure 3.1 Flow chart of Experiment procedure
3.1 Selection of material
For this experiment, two different powderscopper (Cu) and silicon carbide (SiC) were selected and procured from Parashwamani Metals, Mumbai. In order
to maintain lubricant during compaction graphite powder was also mixed at 2 wt % in the matrix. Specification of powder mentioned in Tables 1, 2 and 3
Table 3.1 Specification -Copper powder
Element CU≥ Si Fe Pb Al Mg Zn Other Wt.% 99.00 0.37 0.31 0.14 0.02 0.04 0.050 0.070
Table 3.2 Specification - Silicon carbide powder Element Assay min. Carbon
Wt.% 99.95 0.05
Table 3.3 Specification -Graphite carbide powder Element C Fe H20 Other
wt.% 98.0 0.044 0.51 1.455 3.2 Fabrication of Die & Punch
Die and punch are required to compact the metal powder, therefore, Die and punch are fabricated using die steel in the Gyan Ganga workshop. The dimension of the die and punch are mentionedin Figure 3.2.
Figure 3.2 Design of die and punch and mage of die and punch
3.3 The blending of copper and silicon powder
Silicon carbide powder is reinforced in copper powder with the variation of 0, 5, 10, and 15 Graphite powder is missed for lubrication during compaction. A mechanical ball mill was used to mix the above powder for 1h1 hourackword and
for forward direction to ensure uniform mixing. An electronic weighing machine was used to weigh the powder.
Figure 3.3 Electronic Weighing Machine showing weight measurment 3.4 Compaction of powder
A universal testing machine was used to compact the above powder at a very slow strain rate to ensure an aspect ratio of 1 ꓽ 1. 60 Kn load is applied during the compaction process for 40 minutes. The green sample after compaction immediately shifts carefully in a muffle furnace for sintering. Figure 3.4shows the compaction process.
Figure 3.4 Showing compection process by UTM
3.5 Sintering of green specimens
Sintering is used to defuse and interlock the powder particles. Green sample after the connection is put inside the muffle furnace in a controlled atmosphere. The sintering
.
Figure 3.5 Showing sintering sample (a) and muffle furnace(b)
3.6 Characterization
Using a scanning electron microscope and energy dispersive spectroscopy (EDS), powder and coatings were examined for microstructure and elemental composition using a JSM-6390LV, Jeol, Japan.
The phase development of sintered composite was examined using X-ray diffraction (XRD), a Rigaku Smart Lab 9 KW XRD diffractometer, and Cu-K radiation with a wavelength of 1.5406 Figure 9. (3.3). The X-ray Diffraction (XRD) test was conducted at VNIT, Nagpur.
Figure 3.6 SEM and XRD machine 3.7 Hardness
Vickers hardness of sintered composites was measured using 3 kg applied load a on the cross-section of the surface. An average of five readings on the surface consider for calculation. Figure 3.7 shows the hardness tester.
Figure 3.7 Hardness Tester 3.8 Wear Test
Megnun Engineering, Bangalore (India) provided the Pin on Disc Wear Tester (TR- 20), which was used to quantify wear and coefficient of friction under dry sliding conditions as ashon in Figure 3.8. These tests were conducted in an environment with an ambient temperature between 25°C and 32°C and a humidity level between 60% and 65%.
A coated pin specimen of 12 mm in diameter and 25 mm in length was placed against a counter surface made of silicon carbide (100 µm size paper). These tests were conducted with a 1200 meter sliding distance and a 40 N load at 300
rpm. The abrasive paper was applied to a rounded disc with a 165 mm diameter and a 6 mm thickness. A LVDT installed on a pin and disc wear tester measures wear in terms of height loss. Throughout the individual sliding test, the coefficient of friction and the frictional force was also continually monitored and recorded independently.
Figure 3.8 Pin on disc wear tester 4 RESULT AND ANALYSIS
The aim of this chapter is to explain the results obtained by the different tests and experiments. These results describe in brief and along with the correlation between other factors.
4.1 Microstructure of Powder
The Sem images of Cu and Cu+SiC powder are shown in figure 4.1. Powder possesses a spherical shape. Cu powder is agglomerated with SiC powder which helps to increase the bonding of particles during compaction and sintering.
Figure 4.1 Microstructure of (a) Cu and (b) Cu + SiC powder
4.2 Microstucter of sintered composites
Figure 4.2 (a-d) depicts the microstructure of 0, 5, 10, and 15 addition of Sic in Cu metal powder composite (a-d). The bright and bright grey area reveals the existence of dark and copper. Shaded grey area with a sharp corner denotes the presence of SiC.
Microstructure clearly shows that dense structure grows and pore cavity reduces as SiC levels increase. On the matrix, SiC particles are loosely spread around the Cu particles. As Sicc contents increase the pores structure reduces and the microstructure becomes homogeneous and dense up to 10 Wt % addition of SiC after that separation of particles increases and the pores structure formed due to extra SIC. Figure 4.3 shows the EDS of 10 wt. % Sic in Cu metal composite which confirms the presence of Cu and Sic.
Figure 4.2 Microstructure of Sic addition (a) 0 (b) 5, (c) 10, and, (d) 15
wt. % in Cu metal composite
Figure 4.3 Eds of 10 wt. % in Cu metal composite
4.3 X-ray Diffraction
The XRD pattern of sintered specimens of 0, 5, 10, and 15 addition of SiC in Cu metal powder composite is shown in Figure 4.4 (a-d). The Cu-SiC matrix clearly shows Cu as the predominant phase, according to the XRD results. Cu was represented by strong peaks, and SiC by minor peaks. The peak height of SiC particles increases with increasing SiC contents in the composite form Cu-5SiC to Cu-15SiC, and no additional phase was found. There was also a very slight graphite peek. These findings support the solubility of SiC particles in the Cu
Campsite as well as their direct impact on microstructure and mechanical characteristics.
Figure 4.4 XRD of Sic addition (a) 0 (b) 5, (c) 10, and, (d) 15 wt. % in Cu metal
composite 4.3 Hardness
The hardness of the Cu-SiC sintered composite is shown in Figure 4.5. Cu- 10Sic sintered composite shows a higher hardness that is 55 HV0.3. Cu-0SiC shows minimum hardness. The result indicates that the addition of silicon carbide increases the hardness up to the optimum addition of 10wt. % Sic after that hardline shows a reducing trend. The reduction in hardness after optimum addition is due to the extra addition of SiC which segregates the particles and makes structure pores.
Figure 4.5 Hardness of SiC addition (a) 0 (b) 5, (c) 10, and, (d) 15 wt. % in Cu
metal composite 4.4 Wear
The abrasive wear behaviour of 0, 5, 10, and 15 addition of SiC in Cu metal powder composite is shown in Figure 4.6.
Weigh loss method was adopted to find out the wear and the specimen was cleaned before ad after each experiment with acetone to remove foreign particles.
The result indicates that the addition of SiC increases the wear resistance up to the optimum addition of 10 wt. % in Cu metal matrix. Addition of 0, 5, and 15 shows 92.3, 61.5, and 46.1% higher wear (weight loss) as compared to 10 wt.%
addition of SiC. The higher wear resistance of 10 wt.% addition is attributed to dense and uniform microstructure and higher hardness.
The coefficient of friction of 0, 5, 10, and 15 addition of SiC in Cu metal powder composite is shown in Figure 4.7.
The average value of the coefficient of friction of 10, 15, 5, and 0 addition of SiC in Cu metal powder composite are 0,20, 0.12, 0.11, and 0.02 respectively. The result shows that 10 wt. % SiC shows a higher coefficient of friction due to the minimum wear rate whereas 0 wt. % Sic shows a minimum coefficient of friction due to higher wear.
Figure 4.6 Abrasive wear of SiC addition (a) 0 (b) 5, (c) 10, and, (d) 15
wt. % in Cu metal composite
Figure 4.7 Cofficient of SiC addition (a) 0 (b) 5, (c) 10, and, (d) 15 wt. % in Cu
metal composite 5 CONCLUSION
In this work addition of SiC on abrasive wear behaviouron Cu metal mxxxxx, compote was prepared by powder metallurgy route. On the basis of
experiments and characterization following conclusion was made.
1. Addition of Sic in Cu metal powder compositemakes the microstructure dense and uniform. The addition of SiC also decreases the pores.EDS results confirm the presence of Cu and SiC in the composite.
2. XRD pattern shows the Cu and SiC present as a major and minor peak respectively. Presents.
3. The hardness of composite increases the hardness up to the optimum addition of 10wt. % SiC which is 55 HV0.3 after that hardline shows a reducing trend. The reduction in hardness after optimum addition is due to the extra addition of SiC which segregates the particles and makes structure pores.
4. Addition of 0, 5, and 15 shows 92.3, 61.5, and 46.1% higher wear (weight loss) as compared to 10 wt.% addition of SiC. The higher wear resistance of 10 wt. % addition is attributed to dense and uniform microstructure and higher hardness.
5. The average value of the coefficient of friction of 10, 15, 5, and 0 addition of SiC in Cu metal powder composite are 0,20, 0.12, 0.11, and 0.02 respectively. The result shows that 10 wt. % SiC shows a higher coefficient of friction due to the minimum wear rate whereas 0 wt. % Sic shows a minimum coefficient of friction due to higher wear.
REFERENCES
1. http://www.eurocopper.org/copper/copper- education.html 2)
2. http://www.copper.org/resources/properties /atomic/homepage.html 3)
3. http://www.copper.org/resources/properties /144_8/144_8.html 4)
4. https://www.ifm.liu.se/semicond/new_page/
research/sic/Chapter2.html 5)
5. http://www.engr.sjsu.edu/WofMatE/Compos ites.htm 6)
6. http://www.science.org.au/nova/059/059ke y.htm 7)
7. http://www.virginia.edu/bohr/mse209/chap ter17.htm
8. W. D. Callister, Jr., “Materials Science and Engineering”, (2008), John Wiley & Sons, page 400-736.
9. T. W. Clyne, P. J. Withers, An Introduction to Metal Matrix Composites, Cambridge University Press, Cambridge (1993).
10. Karl Ulrich Kainer, “Basics of Metal Matrix Composites”, (2006), WILEY-VCH Verlag GmbH & Co. KGa A, Weinheim.
11. K.U.Kainer, Keramische Partikel, Fasern und Kurzfasern für eine Verstärkung von metallischen Werkstoffen. Metallische Verbundwerkstoffe, K.U. Kainer (Ed.), DGM Information sges ells chaft, Oberursel (1994), pp. 43–64.
12. D. Huda, M.A. El Baradie and M.S.J.
Hashmi, Journal of Materials Processing Technology, 37 (1993), 513-528.
13. D.L. Erich, Met. Powder Rep., 43 (June, 1988) 418.
14. D. G. Teer and R. D. Arnell, Wear, Principles of Tribology, J. Halling, Ed., Macmilan.
(1975).
15. W. Batchelor, L. N. Lam and M.
Chandrasekaran, Materials degradation and its control by surface engineering, Imperial college press (1999).
16. ASM Handbook, „Friction, Lubrication, and Wear Technology, U.S.A. 18 (1992) 713. ~37~
17. Y. Sahin, and S. Murphy, “The effect of sliding speed and microstructure on the dry wear properties of metal matrix composites”, Wear 214 (1998), 98-106.
18. J.J. Candel, V. Amigó, J.A. Ramos, D.
Busquets, “Sliding wear resistance of TiCp reinforced titanium composite coating produced by laser cladding”, Surface &
Coatings Technology 204 (2010) 3161–3166.
19. Y.Q. Wang, A.M. Afsar, J.H. Jang, K.S. Han, J.I. Song, “Room temperature dry and lubricant wear behaviors of Al2O3f/SiCp/Al hybrid metal matrix composites”, Wear 268 (2010) 863–870.
20. U. A. CURLE, L. IVANCHEV, “Wear of semi- solid rheocastSiCp/Al metal matrix composites”, Trans. Nonferrous Met. Soc., China 20(2010), s852-s856. Huda, M.A. E1 21. T. E. Abioye, Zuhailawati M, A.I.Azlan, A.S.
Anasyida “ Effects of SiC additions on the microstructure, compressive strength and wear resistance of Sn-Sb-Cu bearing alloy formed via powder metallurgy ” J. Mater. Res., 9 (6), (2022) 13196-13205
