Synthesis and formability of Al/(Fe-Mn) particulate compositeusing stir casting

Abstract

Demand for lightweight and fuel economy by automotive and aircraft industries focuses to explore different materials. Alloys and composites developed with same objective to obtain superior desired mechanical properties compatible for such intended applications. However, alloy consider as solid solutions with metallic properties and cannot mix with primary major element in random proportions. This forced researcher community to develop composites, which are heterogeneous solid solutions or multi-phase materials comprising matrix and reinforcement.Aluminium being lighter, cheaper and abundant material compared to others, present investigation aimed at using this as matrix material. In addition to it, stir casting processing technique (less expensive) used for introducing ferromanganese (5% & 10%) into aluminium matrix. Optical microscopic analysis of processed composites reveals non-agglomeration and uniform distribution of Fe-Mn in the aluminium matrix. Mechanical testing performed on composites to find strength, toughness and hardness. Outcomes of these tests shows enhancement of both strength and hardness compared to parent aluminium matrix while as toughness reduced. Open die forging carried out in between temperature 400⁰C and 550⁰C to establish suitable forming temperature for composites. Composite1 (5% Fe Mn) forged for higher extent of deformation compared to Composite 2(10% Fe Mn) at same forging temperatures. Similarly, for same forging temperature load carrying capacity found to be higher for Composite 1 compared to Composite 2. This accounted due to the availability of higher extent of softer matrix phase near reinforced particles. Increasing forging temperature of compositesexhibit brittleness and initiates crack at earlier stage of forming.Thus, it is suitable to do forging at lower temperature especially for both composites to take the advantage of attaining higher deformations.