Manufacture of Aluminum-Magnesium Reinforced Metal Matrix

Composite Silicon Carbide with Powder Metallurgy Method

T. Endramawan

, A. Sifa

, D. Suwandi

and E. Riyanto

Design Manufacturing, Politeknik Negeri Indramayu, Jl. Lohbener Lama no.08, Indramayu, Indonesia

Department of Mechanical Engineering, Politeknik Negeri Indramayu, Jl. Lohbener Lama no.08, Indramayu, Indonesia

Keywords: Metal Matrix Composites, Powder Metallurgy, Al-Mg-SiC, Mechanical Properties.

Abstract: Metal matrix composites (Metal Matrix Composites) are a combination of two or more materials with

aluminium metal as the matrix and developed to improve metal properties, strength, high heat stability, and

hardness. Powder metallurgy technique is one of the metal matrix composite manufacturing processes in solid

condition which is still being developed because it is more economical, does not require complicated

equipment. In this study, the manufacture of metal composites with aluminium-magnesium as the matrix and

SiC as reinforcement was carried out using the powder metallurgy method of composition variation (75% Al

: 15% SiC : 10% Mg, 80% Al : 15% SiC : 5% Mg). Then the results of the mixing are compacted at a pressure

of 14 ton-force with a holding time of 4 minutes. After compaction in the form of a specimen, then sintered

at various temperatures (500 °C and 550 °C) for 2 hours. After sintering with a furnance machine, the

specimen is ready to be tested for mechanical properties and microstructure photos. The results of the bending

and hardness test are obtained by increasing the composition of magnesium resulting in the bending strength

and hardness also increasing successively. In mixing Al:SiC:Mg (80%: 15%: 5%) with a temperature of

550°C, the highest bending strength is 50.31 MPa and the highest hardness is 76.21 HV.

1 INTRODUCTION

The results of technology with good quality of course

require processing of technical materials with the

perfect combination so as to create new materials that

have a high level of quality(Pasaribu, 2017). Material

technology composite is one of the smart technology

engineering to get a new material that is much better

than the raw materials used(Ginting, 2009). There are

several composite materials according to the type of

matrix, including metal matrix composites (MMC),

ceramic matrix composites (CMC), and polymer

matrix composites (PMC).

Metal matrix composites have various advantages

over other types of composites. Such as high strength,

high modulus, high toughness and impact property,

low sensitivity to temperature changes or thermal

shock, high surface resistance and low sensitivity to

surface flaws, high electrical conductivity.(Chandra,

2014).

Metal composites that are often used today are

aluminium-based metal matrix composites because

they are one of the most abundant and inexpensive

mineral materials in the world. Al metal as

monolithic, when viewed from the mechanical

properties, such as hardness value (hardness) is very

low. Therefore, Al metal as a monolithic material has

many weaknesses, especially its mechanical strength,

stiffness and coefficient of expansion(Sakti et al.,

2009).

To increase the mechanical value of the metal, it

is necessary to add other elements, one of which is

magnesium. Magnesium has properties such as low

density and light and strong when combined. The

addition of magnesium in certain concentrations can

increase the hardness and bending strength of

aluminum alloys(Shomad & Jordanianshah,

2020).the addition of Mg in aluminum alloys

increases the strength and hardness of aluminum,

increases corrosion resistance and increases

wettability(Supriyatma et al., 2016).

To increase the hardness value of metal

composites, it is necessary to strengthen the metal, by

adding hard materials, such as ceramics. Common

types of ceramic materials used include: Al2O3, SiC,

TiC, and ZrO2. Among these types of ceramics, the

hardest is SiC(Idris et al., 2003).

Endramawan, T., Sifa, A., Suwandi, D. and Riyanto, E.

Manufacture of Aluminum-Magnesium Reinforced Metal Matrix Composite Silicon Carbide with Powder Metallurgy Method.

DOI: 10.5220/0011711400003575

In Proceedings of the 5th International Conference on Applied Science and Technology on Engineering Science (iCAST-ES 2022), pages 50-55

ISBN: 978-989-758-619-4; ISSN: 2975-8246

In addition to the matrix and reinforcement,

another important thing is the fabrication technique

used today. Powder metallurgy (powder metallurgy)

has several advantages compared to liquid

metallurgy. The temperature used in powder

metallurgy processes can be lower, that is, below the

melting point of the material. Meanwhile, in liquid

metallurgical engineering, high temperatures are

required to reach the melting point of the component

materials (Ramadhonal, 2010).

(Risky, 2019)examined the effect of the addition

of SiC on the properties of hardness and bending

strength as well as the microstructure of aluminium

composites. The studies varied between SiC (0%, 3%,

5%, 9%). The research proves that there is an increase

in the results of the hardness test and bending test

results for each addition of SiC. This proves that SiC

can increase the strength of metal composites.

(Supriyatma et al 2016) examined the Effect of

Magnesium Addition on Hardness, Impact Strength

and Microstructure of Aluminium Alloy (Al-Si)

Using Lost Foam Casting Method. In this study, there

was an increase in the addition of Mg to Al-Si alloys

based on used car alloy wheels using the lost foam

casting method. The hardness number after the

addition of Mg was 109.70 HRL, and before the

addition of Mg was 99.8 HRL. It was concluded that

the increase was 9.9%.

(Triadi, 2022)examined the effect of sintering

temperature and material composition on the

mechanical characteristics of composites made from

waste aluminium and glass using powder metallurgy

methods. This study found that the specimen with the

highest compressive strength value was found at a

sintering temperature of 590 C and a composition of

90:10, which was 235.59 MPa. While the lowest

strength value is 45.11 MPa at a sintering temperature

of 390 C and a composition of 70 :30. The results of

the hardness test showed that the highest hardness

value was obtained in specimens with a composition

of 90: 10 and a sintering temperature of 590 C,

namely 60 HRF, followed by temperatures of 490 C

and 390 C. The same applies to the composition of

other materials, namely the greatest hardness value is

found at the highest sintering temperature.

1.1 Metal Matrix Composite (MMC)

Metal matrix composite (MMC) comes from a

combination of metal-based materials with ceramics.

MMC can also be called a material consisting of a

matrix in the form of metal and its alloys which is

reinforced by reinforcing materials in the form of

continuous fiber, whiskers, or particulate. The

manufacture of metal matrix composites can be done

by several methods, including powder metallurgy,

diffusion bonding, liquid phase sintering, squeeze

infiltration and stir casting.(Risky, 2019).

The reasons why MMC has been attracting attention

for nearly 30 years:

1. The MMC approach in metallurgical processes is

the only way to produce a wide variety of these

composites. So that the resulting product is very

wide (varied). It is only in this way that we can

combine aluminium, copper, magnesium with the

carbide, oxide or nitride phase. Because the above

material has a solubility to carbon, the nitrogen in

the molten metal is too low.

2. MMC also provides significant changes to the

properties of the material, such as resistance to

high temperatures, does not react to chemicals,

good hardness, and wear resistance.

Metal matrix composites can be made by the

casting method or by the powder metallurgy method.

However, the casting method has a problem, namely

it is difficult to make homogeneous composites,

because the reinforcing particles usually settle or float

due to differences in specific gravity.

1.2 Powder Metallurgy

Powder Metallurgy (Powder Metallurgy) is the

process of forming commercial workpieces from

metal where the metal is in the form of a powder, then

the powder is pressed in a mold and heated below the

melting temperature of the powder to form a

workpiece. So that the metal particles coalesce due to

the mass transport mechanism due to atomic diffusion

between the particle surfaces. Powder metallurgy

methods provide precise control over the composition

and use of mixtures that cannot be fabricated by other

processes. As the size is determined by the mold and

finishing touch.

Basic steps in powder metallurgy

(Demasya, 2018):

1. Powder maker.

2. Mixing.

3. Compaction.

4. Sintering.

Figure 1: Compaction Process(Risky, 2019).

Manufacture of Aluminum-Magnesium Reinforced Metal Matrix Composite Silicon Carbide with Powder Metallurgy Method

1.3 Hardness Test

Hardness is the ability of a material to withstand

compressive loads. The hard test mechanism is to

press the indenter to the surface of the test object so

that the geometry of the indentation is obtained. The

type of hard test based on the shape of the indenter is

spherical (for Brinell test), pyramidal (Vickers and

Knoop test), or conical (Rockwell test).

VHN =

,

²

(1)

VHN = Vickers hardness value (HV)

P = amount of load (kgf)

D = average diagonal (mm)

1.4 Bending Test

Bending test is one of the mechanical properties

testing of materials that is carried out on specimens of

materials, both materials to be used as construction or

components that will receive loading. With this load

it will even experience deformation with two

opposing forces acting at the same time(Mahadi ST

& Novri, 2017).

=

..

..²

(2)

Where:

= Bending Stress (MPa)

F = Load (N)

L = Length of span /Support span(mm)

b = Width (mm)

h = Thickness (mm)

2 RESEARCH METHODS

2.1 Research Flowchart

In conducting research, the stages are carried out

referring to the flow chart shown in Figure 2

Figure 2: Research Flow Chart.

2.2 Tool

Details of the equipment used in this study are:

1. Universal Testing Machine

Universal Testing Machinefor the process of

making composites with cold compaction in 14

Tons of compaction that has been dies previously

Figure 3: Universal Testing Machine.

iCAST-ES 2022 - International Conference on Applied Science and Technology on Engineering Science

2. Furnance

Furnance used to carry out heat treatment during the

sintering process with temperatures of 500 C and 550

C on Metal Matrix Composite specimens.

Figure 4: Furnance.

2.3 Ingredient

In this study, the main materials used are aluminium

powder with a content of 85% and magnesium as the

matrix of the metal composite, while the reinforcing

material is silicon carbide.

2.4 Research Procedure

Prepare materials for the manufacture of composites

with a composition (80%Al-5%Mg-15%SiC and

75%Al-10%Mg-15%SiC) then compacted with a

loading of 14 tons and then held for holding time 4

minutes, then The specimen is removed from the

mold for further sintering with a sintering temperature

of 500 C and 550 C.

2.5 Vickers Hardness Test

The hardness test carried out in this study refers to

ASTM E384. The hardness of the SiC-reinforced Al-

Mg composite material was tested using a macro

hardness tester, Innova test brand, with an indenter in

the form of a diamond pyramid with a load of 1 kgf

and indentation time of 30 seconds with 5 tests in one

composite variation.

Figure 5: Vickers Hardness Test Tool.

2.6 Bending Test

The bending test carried out in this study refers to the

ASTM D790, where the shape of the specimen used

is in the form of a plate with sizes, P = 125 mm, l =

12.7 mm and t = 3.2 mm. With the test parameter

compressive speed of 20 m/s and stops at 50%

breaking.

Figure 6: Bending Test.

3 RESULTS AND DISCUSSION

3.1 Hardness Testing

In this study, the hardness test used was a hardness

test using the Vikers method. Hardness testing using

the Vickers method aims to determine the hardness of

a material in the form of material resistance to

pyramid-shaped diamonds with a peak angle of 136

degrees which is emphasized on the surface of the test

material.

In this test the indenter load is 1 kgf with a holding

time of 30 seconds for each hardness test specimen.

The following is the Vickers hardness test process.

Manufacture of Aluminum-Magnesium Reinforced Metal Matrix Composite Silicon Carbide with Powder Metallurgy Method

Table 1: Hardness Test Results.

Composition

Variations

Temperature

Variation

Hardness value

(VHN)

Al 75%

SiC 15%

Mg 10%

500

53,824

550

76.218

Al 80%

SiC 15%

Mg 5%

500

43,098

550

65,464

Figure 7: Vickers hardness chart.

The results of the Vickers hardness test show

that with different compositions and sintering

temperatures, we can conclude that the addition of

magnesium and the effect of temperature variations

on the manufacture of Al-Mg metal matrix composite

(MMC) with silicon carbide reinforced with powder

metallurgy method can increase the hardness value

(VHN). This can be seen from the results of the

Vickers Hardness Test on the 5% magnesium

composition in the total mass of the SiC reinforced

Al-Mg specimen at a temperature of 500 C the

average value is 43,098 HV, at the 5% magnesium

composition in the total mass of the Al-Mg reinforced

specimen. SiC at a temperature of 550 C the average

value is 65.464 HV, at a composition of 10%

magnesium in the total mass of SiC-strengthened Al-

Mg specimens at a temperature of 500 C the average

value is 53.824 HV.

The results of this test are similar to the

research(Mahadi ST & Novri, 2017)that the addition

of magnesium can increase the value of hardness and

in research(Triadi, 2022)The higher the sintering

temperature, close to 90% of the melting matrix

temperature, the higher the hardness value.

3.2 Bending Test

In this study, one of the mechanical properties testing

is the bending test carried out to measure how strong

the bending to fracture of a test specimen material is.

In this test, all samples of Metal Matrix Composite

(MMC) standard ASTM D790 with dimensions of

length = 125 mm, width = 12.7 and thickness = 3.2

mm with a compression parameter of 20 m/s and

stops at 50% breaking.

Table 2: Bending Test Results.

Composition

Variations

Temperature

Variation

Bending Value

(Mpa)

Al 75%

SiC 15%

Mg 10%

500

36.07

550

50.45

Al 80%

SiC 15%

Mg 5%

500

32.19

550

42.72

Figure 8: Bending Test Graph.

The results of the bending test show that with

different compositions and sintering temperatures, we

can conclude that the addition of Magnesium and the

effect of temperature variations on the manufacture of

Al-Mg metal matrix composite (MMC) with silicon

carbide reinforced with powder metallurgy method

can increase the value of bending strength. the results

of bending tests on 5% magnesium composition in the

total mass of SiC-reinforced Al-Mg specimens at a

temperature of 500 C the average value is 32.19 Mpa,

at 5% magnesium composition in the total mass of

SiC-reinforced Al-Mg specimens at 550 C the

average value is 42.72 Mpa, at 10% magnesium

composition in the total mass of SiC-strengthened Al-

Mg specimens at 500 C the average value is 36.07

Mpa,at 10% magnesium composition in the total

mass of SiC-strengthened Al-Mg specimens at a

temperature of 550 C the average value is 50.45 Mpa.

The results of the research above are similar to the

research(Triadi, 2022)With the higher the sintering

temperature, the value of the bending compressive

strength increases.

iCAST-ES 2022 - International Conference on Applied Science and Technology on Engineering Science

4 CONCLUSION

The research that has been done can be concluded as

follows:

1. The hardness value of the SiC-reinforced

aluminium-magnesium matrix composite will

increase along with the increase in the addition of

magnesium (Mg) and the increase in the sintering

temperature. The addition of 10% Mg at a

sintering temperature of 550ºC has the highest

hardness of 76.218 HV.

2. The value of the bending strength of the SiC-

reinforced aluminium-magnesium matrix

composite will increase along with the increase in

the addition of magnesium (Mg) and the increase

in the sintering temperature. The addition of 10%

Mg at a sintering temperature of 550ºC has the

highest bending strength of 50.45 Mpa.

ACKNOWLEDGEMENTS

The author would like to thank the Ministry of

Research and Technology, Indramayu State

Polytechnic and the Department of Mechanical

Engineering, Indramayu State Polytechnic.



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