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Study on the Effect of NanoSilica Sand Addition to the Physical and Mechanical Properties of Iron Powder

by

Nurhafeezan Bin Malik

Dissertation submitted in partial fulfilment of the requirements for the

Bachelor of Engineering (Hons) (Mechanical Engineering)

JUNE 2010

Universiti Teknologi PETRONAS Bandar Seri Iskandar

31750 Tronoh

Perak Darul Ridzuan

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CERTIFICATION OF APPROVAL

Study on the Effect of NanoSilica Sand Addition to the Physical and Mechanical Properties of Iron Powder

by

Nurhafeezan Bin Malik

A project dissertation submitted to the Mechanical Engineering Programme

Universiti Teknologi PETRONAS in partial fulfilment of the requirement for the

BACHELOR OF ENGINEERING (Hons) (MECHANICAL ENGINEERING)

Approved by,

____________________________________

(AP Dr. Othman Mamat)

UNIVERSITI TEKNOLOGI PETRONAS TRONOH, PERAK

June 2010

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CERTIFICATION OF ORIGINALITY

This is to certify that I am responsible for the work submitted in this project, that the original work is my own except as specified in the references and acknowledgements, and that the original work contained herein have not been undertaken or done by unspecified sources of persons

__________________________

NURHAFEEZAN BIN MALIK

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ABSTRACT

Iron base alloys materials have mostly been used in lots of industrial application. Pure iron is very soft thus further improvement should be made by introducing the reinforcement into the iron for various applications. This present study aims to develop an iron matrix composite with nanoparticles silica sand. The objective of project is to study the effect of silica sand (SiO2) nanoparticles addition on the physical and mechanical properties of iron powder . The nanoparticles silica sand with average size of 60-80 nm was mix with 10µm (99.5%) of iron using powder metallurgy process. The powder metallurgy process involves mixing, compaction and sintering. Few samples of composite is mixed with 5wt.%, 10wt.%, 15wt.%, and 20wt.% of nanoparticles silica sand and compacted by powder metallurgy. Green sample is then sintered at 3 different temperature ; 900 oC, 1000 oC and 1100 oC. Green density and sintered densities are measured using Archimedes technique and then the results are analyzed. Results show that the sintered density is denser compared to green body density and the optimum sintered density of 7.347 g/cm3 was obtained at temperature of 1100oC. It was observed that with increasing sintered temperature the microstructure and mechanical properties of the composites improved. The addition of silica sand nanoparticles to iron enhanced the hardness from 82.7 HRV to 167.4HRV. Optimum hardness of 167.4HV also obtained at temperature of 1100 oC. FESEM and EDX analysis had showed that silica sand nanoparticles diffuse in the porous sites of composites causing an improvement in mechanical properties as well as improved the microstructure.

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ACKNOWLEDGEMENT

Syukur Alhamdullilah, Many thanks and praise to our Mighty Lord, Allah S.W.T., for the blessings and the kindness that He has given me for this project to be an accomplishment.

My Final Year Project (FYP) has become one of the many achievements I had so far.

Being able to write the acknowledgement column brings warm feelings to my heart. This indicates that all hard work and commitment that I have put into and the many challenges and difficult moments that I have gone through, have finally bring meanings that worth the while.

My humble gratitude goes to my beloved parents, for having so much faith and courage in me and supporting my project endlessly. Not forgetting my respected supervisor, Dr.

Othman Mamat and Mr Taher Ahmad, for the wonderful support and wisdom. The great thoughts and encouragement that you have showed me, right from the beginning made it possible for me to complete the given project with great success. In this one year period, I must say I have learnt so much from your guidance and wisdom.

My special thanks continues to the panel examiners, Dr Patthi Hussain, Dr Faiz Ahmad and Dr Mohd Asri for the constructive comments and critical thoughts that help me a lot in order to improve my project in one way or another. To the lab technicians of Mechanical Engineering Department, especially Mr. Faisal, Mr. Shairul, Mr. Irwan, Mr.

Omar and Mr. Anuar, I could have not accomplished this task if it weren‟t for your assistance and guidance. Thank you so much.

Last but not least, special appreciation to my friends and colleagues, especially to Mohamed Khalil, Amar Rahimi, Mohamad Firdaus and Mohd Nor Azlan for lending a hand when I needed the most and I must say, the teamwork that we put into while completing our tasks makes the journey a lot easier and possible. I hope all the findings of my project will bring meaningful contributions and benefits to Universiti Teknologi PETRONAS and others.

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TABLE OF CONTENTS

CERTIFICATION . . . . . . . . ii

ABSTRACT . . . . . . . . . iv

ACKNOWLEDGEMENT . . . . . . . v

TABLE OF CONTENTS . . . . . . . vi

LIST OF FIGURES . . . . . . . . viii

LIST OF TABLES . . . . . . . . x

CHAPTER 1: INTRODUCTION . . . . . . 1

1.1 Background of Study . . . . . 2

1.2 Problem Statement . . . . . 2

1.3 Significance of Project . . . . . 2

1.4 Objective . . . . . . . 3

1.5 Scope of Study . . . . . . 3

1.6 Relevancy of the Project . . . . 3

1.7 Feasibility of the Project . . . . 3

CHAPTER 2: LITERATURE REVIEW AND THEORY. . . 4

2.1 Iron . . . . . . . 4

2.2 Silica Sand. . . . . . . 5

2.3 Metal Matrix Composite . . . . . 5

2.4 Powder Metallurgy Processing . . . . 7

2.4.1 Blending/Mixing . . . . 7

2.4.2 Cold Pressing . . . . . 8

2.4.3 Sintering . . . . . . 9

2.4.4 Sintering Cycles . . . . . 9

2.4.5 Sintering Atmosphere . . . . 10

2.5 Related Work . . . . . . 10

CHAPTER 3: METHODOLOGY . . . . . . 15

3.1 Project Planning . . . . . . 17

3.2 Materials . . . . . . . 17

3.3 Processing of Composite Materials . . . 17

3.3.1 Mixing . . . . . . 18

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3.3.2 Compaction . . . . . 18

3.3.3 Sintering . . . . . . 18

3.4 Testing and Analysis . . . . . 19

3.4.1 Physical Properties . . . . 19

3.3.2 Mechanical Properties . . . . 20

CHAPTER 4: RESULTS AND DISCUSSION . . . . 21

4.1 Theoretical Density . . . . . 21

4.2 Density of Fe-SiO2 nanoparticles . . . 22

4.3 Optical Microscope Anaysis of FeSiO2 Nanoparticles composites . . . . 25

4.4 FESEM Analysis of Fe-SiO2 Nanoparticles Composites . . . . 28

4.5 EDX Analysis of Fe-SiO2 Nanoparticles Composites . . . . 31

4.5 Hardness Measurement of Fe-SiO2 Nanoparticles Composites . . . . 41

CHAPTER 5: CONCLUSION AND RECOMMENDATION . . 42

5.1 Conclusions . . . . . . 42

5.2 Recommendations . . . . . 43

REFERENCES . . . . . . . . 44

APPENDICES . . . . . . . 45

Appendix I: FYP 1 GANTT CHART . . . 48

Appendix II: FYP 1 GANTT CHART . . . 49

Appendix III: EDX (point) analysis for 1000 oC & 1100 oC 50 Appendix IV: Hardness Test Data . . . . 53

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LIST OF FIGURES PAGE

Figure 2-1 Different types of metal matrix composite . . . 6

Figure 2-2 SEM Picture of nano-composite . . . . . 11

Figure 3-1 FYP 1 and FYP 2 Flow Chart . . . . . 16

Figure 3-2 Iron Powder . . . . . . 17

Figure 3-3 Ball Mill . . . . . . . 18

Figure 3-4 Autopalletiser . . . . . . . 19

Figure 3-5 Sintering Furnace . . . . . . 19

Figure 3-6 Toledo Ax205 . . . . . . 20

Figure 4-1 Green density and sintered density at 900 oC . . . 21

Figure 4-2 Green density and sintered density at 1000 oC . . 22

Figure 4-3 Green density and sintered density at 1100 oC . . 23

Figure 4-4 Optical Microscope image at 100x resolution of Fe-SiO2 nanoparticles composites at 900 oC sintering temperature . . . . 25

Figure 4-5 Optical Microscope image at 100x resolution of Fe-SiO2 nanoparticles composites at 1000 oC sintering temperature . . . . 26

Figure 4-6 Optical Microscope image at 100x resolution of Fe-SiO2 nanoparticles composites at 1100 oC sintering temperature . . . . 27

Figure 4-7 FESEM images (1000x) of Fe-SiO2 nanoparticles composites at 900 oC sintering temperature of . . . . . 28

Figure 4-8 FESEM images (1000x) of Fe-SiO2 nanoparticles composites at 1000 oC sintering temperature . . . . 29

Figure 4-9 FESEM images (1000x) of Fe-SiO2 nanoparticles composites at 1100 oC sintering temperature . . . . 30

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Figure 4-10 FESEM and EDX analysis (whole area) of Fe-SiO2 nanoparticles composites

at 900 oC sintering temperature . . . . 32 Figure 14-11 FESEM and EDX analysis (point)

of Fe-SiO2 nanoparticles composites

at 900 oC sintering temperature . . . . . 34 Figure 14.12 FESEM and EDX analysis (point)

of Fe-SiO2 nanoparticles composites

at 900 oC sintering temperature . . . . 36 Figure 14-13 FESEM and EDX analysis (Whole area)

of Fe-SiO2 nanoparticles composites

at 1000 oC sintering temperature . . . . 37 Figure 14-14 FESEM and EDX analysis (point)

of Fe-SiO2 nanoparticles composites

at 1000 oC sintering temperature . . . . 39 Figure 14-15 FESEM and EDX (whole area) analysis of

Fe-SiO2 nanoparticles composites

at 1100 oC sintering temperature . . . . 40 Figure 14-16 FESEM and EDX (point) analysis of

Fe-SiO2 nanoparticles composites

at 1100 oC sintering temperature . . . . 42 Figure 4-17 Hardness Vs wt% of silicasand nanoparticles . . 43

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LIST OF TABLES PAGE

Table 2-1 Iron Properties . . . . . . . 4

Table 2-2 Silica Sand Properties . . . . . 5

Table 3-3 Type of samples summarized . . . . . 18

Table 4-1 Theoretical Density . . . . . . 21

Table 4-2 Green Density Result . . . . . . 22

Table 4-3 Sintered Density of the MMC samples at different temperatures . . . . . 22

Table 4-4 Hardness test result based on sintering temperature . . 43

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CHAPTER 1 INTRODUCTION

1 INTRODUCTION

This chapter is dedicated to introduction and explanation of the project topic, „„Study on the Effect of NanoSilica Sand Addition to the Physical and Mechanical Properties of Iron Powder‟‟. A background about this FYP project is given followed by statement of the problem addressed and lastly the objectives and scope of the work are pointed out.

1.1 Background of Study

It is known that iron is the most common metals and most common ferromagnetic materials in everyday usage. Pure single crystals or iron are soft which is softer that aluminum [1,5].Therefore to make iron useful for various applications, some improvement should be made. There are various ways of improving metals (iron). The most common ways to improve it properties is by alloying a partial or complete solid solution of one or more elements in a metallic matrix.

In this study, Iron (matrix) will be reinforced with nanoparticles silica sand (ceramics) to produce a new composite (metal matrix composite) that is improved on its properties.

Composite materials are basically materials made from two or more constituent materials with different physical or chemical properties which remain separate and distinct on a macroscopic level within the finished structure[1, 5].

One of the importances of developing metal matrix composites is enhanced stiffness and strength for some application. As examples, we can have an ability to control thermal expansion in applications involving electronic packaging using composite. By adding ceramic reinforcement, we can definitely reduce the coefficient of linear thermal expansion of the composite. Electrical and thermal conductivity characteristics may be important in some applications [6].

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1.2 Problem Statement

Generally, iron (metal) has high electric, thermal conductivity, luster and density, and the ability to be deformed under stress without cleaving[5]. Pure iron is known to be softer than aluminum and lower melting temperature compare to ceramics. Otherwise, Ceramic such as Silica (SiO2) have few characteristic different from metal such as high mechanical strength, low coefficient of thermal expansion, relatively high temperature capabilities, good dielectric properties and good biological compatibility[5]. In a certain application that involves high temperature; pure iron is not suitable to be use. Therefore, in this project, the iron properties will be enhanced by reinforcing the iron (matrix) with nanoparticles silica sand (SiO2) (particulate) by powder metallurgy technique. This type of composite is called metal matrix composite (MMC).

1.3 Significance of the Project

Development of Metal Matrix Composite has grown rapidly with its usefulness in many applications for industries and has showed no sign of slowing down. For the past few decades, development of MMC focus on micro-sized particulate reinforcement but now a day, the development of MMC has evolved into the advance stage after the development of the nanotechnologies. MMC‟s have now reached a certain level on which the reinforced particulate used are in nanoparticles sized. This project will not only provide a portion of studies in nanoparticles sized reinforcement on MMC but most importantly it is also the building blocks in developing capabilities in engineering material research among UTP student.

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1.4 Objective

The objective of this project are to study the effect of silica sand (SiO2) nanoparticles addition on the physical and mechanical of iron powder (Metal Matrix Composite) at different sintering temperature

1.5 Scope of study:

The scope of project is to develop metal matrix composite (MMC) using iron powder as a matrix base metal and reinforced by nanoparticles silica sand (SiO2) particulate. The development of this MMC is carried out using powder metallurgical technique.Then, the sample is analyzed to obtain the physical and mechanical properties of the new MMC.

1.6 Relevancy of the Project

This project is relevant to Mechanical Engineering academic syllabus of Universiti Teknologi PETRONAS (UTP). It incorporates a technical knowledge from Introduction to Material Science and Engineering, Engineering Materials, and Advance Polymer, Ceramics and Composites and Failure analysis & NDE. In addition, it also enhances project management, communication skills and skill of producing a research paper.

1.7 Feasibility of the Project within the Scope and Time Frame

For this project, the first semester will cover research on theoretical analysis and formulation of methodology .The second semester will be concentrated on detail development of Metal Matrix Composite, Mechanical and Physical testing and data analysis. Based on the draft methodology, the project‟s objectives are considered achievable within the given time frame.

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CHAPTER 2

LITERATURE REVIEW

2. LITERATURE REVIEW

Before developing the MMC, it is important to understand the basic concept of composite, the basic information on base matrix metal and the type of reinforcement.

Research papers will be the basis in formulation the concept generation and methodology that applies the theoretical knowledge.

2.1 Iron

Pure iron is a metallic chemical element with the symbol of Fe in the, Pure single crystal of iron is softer than aluminum and the addition of small amount of impurities such as carbon, significantly strengthens its properties. Pure iron is a metal and rarely found in this form on the surface of the earth because it oxidized readily in the presence of oxygen and moisture. Table below show some of iron the properties [1,4].

Table 2.1 Iron Properties [1]

Properties Value

Melting Point 1538 oC

Boiling Point 2862 oC

Density 7.874 g/cm3

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2.2 Silica Sand

Silica sand is mostly consisting of Silicon Dioxide (SiO2). There are three crystalline forms of silica; quartz, tridymite, cristobalite and there are two variations of each of these (high and low). Silica is most commonly found in nature as sand or quartz.

Generally Silica has good abrasion resistance, electrical insulation and high thermal stability. It is insoluble in all acids with the exception of hydrogen fluoride (HF). These properties make it among the important element in industrial application. Table 2.2 show some of the properties of silica [2,3].

Table 2.2 Silica Sand Properties [2]

Properties Value

Melting Point 1830 oC

Boiling Point 2230 oC

Density 2.65 g/cm3

2.3 Metal Matrix Composite (MMC)

Before proceed to basic concept of MMC it is very important to understand few types of composites. In engineering material, the matrix phase of fibrous composite may be a metal, polymer or ceramics. These 3 composites are called Polymers Matrix Composite, Ceramics Matrix Composite and Metal Matrix Composite. The definitions of these three types of composites are:

i. Polymer Matrix Composite (PMC) – Consist of a polymer resin as th matrix, with fibers as the reinforcement medium[5].

ii. Ceramics Matrix Composite (CMC) – CMCs combine reinforcing ceramic phases with ceramic matrix to create material with new and superior properties [5].

iii. Metal Matrix Composites (MMC) – MMC consist of a metallic matrix combined with ceramic (oxides, carbides) or different metal[5].

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This project focus more on developing MMC. MMCs, like all composites, consist of at least two chemically and physically distinct phases, suitably distributed to provide properties no obtainable with either of the individual phase. All MMC have a metal or a metallic ally as the matrix. The reinforcement may consist of metallic or ceramic. In general, there are three kinds of MMCs[6]:

i. Particle reinforced MMCs

ii. Short fiber or whisker reinforced MMCs iii. Continuous fiber or sheet reinforced MMCs

Figure 2.1 shows schematically, the four major types of metal matrix composites that are commonly produced.

Figure 2.1 Different types of metal matrix composite[6].

For some reason, particle or discontinuously reinforced MMCs is commonly used in MMC especially for industrial application because it give lot of benefit such as:

i. Particle reinforced composites are inexpensive compare to continuous fiber reinforced composites.

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ii. Conventional metallurgical processing techniques such as casting or powder metallurgy, followed by conventional secondary processing by rolling, forging, and extrusion can be used

iii. Higher use temperatures than the unreinforced metal

iv. Relatively isotropic properties compared to fiber reinforced composites.

This project will emphasize on the In this project, particle reinforced MMC will be produced by powder metallurgy technique.

2.4 Powder Metallurgy Processing

Powder Metallurgy processing is involved when fabricating particle-reinforced MMCs.

This study particularly focuses on producing a particle-reinforced MMC. Generally, powder metallurgy processing involves three main steps which are blending, mixing and sintering. Initial stage, both powder (particulate and matrix) are mix and blended together to obtain homogeneous powder. Then blending stage is followed by cold pressing at certain pressure to obtain green body which is 80% dense. The last stage will be sintering stage where the green body is sintered at certain temperature to form dense composite which is the final product. In general, there are three important steps in powder metallurgy process are:

i. Blending / Mixing

ii. Cold Pressing / Compaction iii. Sintering

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The Summary of powder metallurgy technique that will be used for this project is shown in Figure 2.2

Figure 2.2: Powder Metallurgy Process Technique[11]

2.4.1 Blending/ Mixing

Mixing is performed after ingredients are weighed, using mixing equipments. There are few method can be apply for mixing part. Powder can be mixed in a glass vessel in a tumble mixer, in a steel container with steel balls in a planetary ball mill or in attritor [13]. On the mixing stage, both powder (matrix and particulate) are mixed together with binder. Binder is very important element for powder compaction. It acts as a temporary vehicle for packing powder into the desired shape and holding the particles in that shape until the step of sintering. Most commonly used binder is wax. Wax is used because it is easy to use, low cost and less of hazard. The crucial part during mixing is to obtain the homogeneous properties of the powder. A properly mixed material consists of homogeneous powder dispersion in the binder, and contains no internal porosity or agglomerates. Inhomogeneities result in nonuniform viscosities, uneven shaping, and the

Powder

 metal

Particulate

 Ceramics

Blending

Cold Pressing

Sintering

MMC Pallet

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powder mix will have some difficulties during sintering [1]. Apart from that, another important factor in mixing are the mixing time and rotation rate. The most desirable is for the mixer to rotate fast enough to lift the particles for cascading over one another.

This is usually performed for about 30 minutes[1,3]. If the powders are mixed for longer time, they become more difficult to compact.

2.4.2 Cold Pressing / Compaction

In compaction when an iron powder is compressed, the particles slide pas one another, deform, bond and harden. The greater the compaction pressure, the harder the particles become, thereby resisting further densification. Compaction initially deforms the particles at their contacting point and results in welding at those contacts, the higher the pressure, the higher the density. Typically, iron powders are compressed at pressures in the 550-700 MPa (30-50psi) range. Prior to compaction, it is suggested that lubricant are required to ease ejection and minimize die wear because there is an existing friction between the die wall and the powder during pressing. This friction has made the ejection of the compact from tool become difficult. After compaction, the output from compaction is called green body that is usually 80% dense. Compaction is influenced by the iron powder size, shape and fabrication process and generally key factors affecting compressibility are the purity, particle size, particle shape and internal porosity.

2.4.3 Sintering

Sintering is the key step in transforming the green compact into a high-strength structure. It involves heating the compact to a temperature where the particles weld to each other. Improved strength occurs by events at atomic level. Weld bonds between particles form and grow through the motion of individual atoms. Generally, after the green body is produced, it is sintered in a certain range of temperature to obtain some degree of liquid phase. The liquid phase flows through the pores in the compact resulting in densification of the composite [1]. Besides particles bonding, sintering contribute to changes in the microstructure. The grain size increases and become much larger than the

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initial particle size. The transition from particle to grain occurs then the particles sinter- bond, forming a structure consisting of many grains. This will make the sintered body much dense compare to green body. Simultaneously, this process hardens the composite itself. During sintering, the microstructure also exhibits changes in porosity, pore size, and pore shape. At the sintering temperature the high rate of atomic motion progressively (diffusion) leads to growth of bonds between the particles (interparticle necks)[1]. Therefore, we can conclude that the atomic flow is highly dependent on temperature, with high temperatures increasing atomic motion.

2.4.4 Sintering cycles

In the furnace, the compact is usually heated to a peak temperature for a few minutes to allow heat uniformly soak the load. The first event during heating is the extraction of binders and lubricants because both of them will be burn out at a temperature of 120 oC.

This is accomplished at temperatures below 550 oC. Subsequently, the compact is heated to a high temperature that induces atomic motion and sintering bonding, typically in the temperature range of 1100 -1350 oC for iron which is around 80% of the melting temperature of iron[12].

2.4.5 Sintering Atmosphere

Providing the right atmosphere for sintering is important. Iron naturally forms an oxides in normal air, as is evident by its tendency to rust. The rate of oxidation increases as temperature increase, hence it is not possible to sinter iron in air without forming an oxide. To overcome this, one of the options is to protect the compact from oxidation by heating in a protective atmosphere. For iron, the suitable atmosphere for sintering can be any of variety of gasses such as nitrogen, hydrogen and even argon [1,12]. The objective is only to avoid iron to form oxide at high temperature in normal air. This oxide will effect the final properties of the sample.

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2.10 Related Works

Research papers are the basis of methodology formulation & concept generation for this project. Following summarizes some of the selected research papers:

C.Y.H Lim, D.K Leo, J.J.S Ang, M. Gupta, 2004 “Wear of Magnesium Composites Reinforced with nano-sized alumina particulates” Department of Mechanical Engineering, National University of Singapore.

This paper is basically cover the development of Magnesium (Mg) based metal matrix composites (MMCs) reinforced with only 1.11 % of nano-sized alumina particulates.

This paper gives important information regarding the effect of nano-sized particulate on the MMCs properties. This information is related to this project which is nano-silica particulate. This paper provide information that the nano-sized alumina particulate exhibit higher mechanical properties or even superior to similar composites containing much higher levels of micron-sized reinforcement. The ductility of the composites exceeded even that of pure Mg. This study has shown that a smaller particulate size reduced wear in MMCs caused by delaminating, a mechanism that has been shown to limit the advantages of the increased hardness and strength of the composites during sliding wear test. The wear resistance of the composites improved with increasing amount of reinforcement. These entire criterions are beneficial because it gives some information on the result for this project[7].

A.Mazahery, H.Abdizadeh, and H.R. Baharvandi, “Hardness and Tensile Strength Study On AL356 Alloy Matrix-Nano Al2O3 Particle Reinforced Composite”, School of Metallurgy and Materials Engineering,University of Tehran, Iran.

This paper is cover the study of effect of nano-alumina on the microstructure and mechanical properties of alloy matrix. It involves the study of hardness and tensile strength of AL356 Alloy as based metal matrix and it is reinforced with nano-alumina (ceramics). The microstructure of the composites was investigated by scanning electron

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microscopy (SEM). The experimental results show a nearly uniform distribution and good dispersion of the nano-particles within the Al matrix. The effect of Al2O3 particle content and casting temperature on the hardness and tensile strength of the composites were investigated. The result shows that both hardness and tensile strength was enhanced by incorporation of nano-alumina into matrix. The enhancement in value of hardness and tensile strength observed in this study is due to small particle size and good distribution of the Al2O3 particles which was shown by SEM image in Figure 2.3 [8].

Figure 2.2: SEM Picture of nano-composite [8]

H.Gul, F. Kilic, S. Aslan, A. Alp, H. Akbulut, “Characteristics of electro-co- deposited Ni-Al2O3 nano-particle reinforced metal matrix composite (MMC) coatings”

Department of Metallurgical & Materials Engineering, Sakarya University

This research paper is different compare to other papers which developing a pallet of metal matrix composite. This paper is basically developing a metal matrix composite coating. Even though is mainly focus on coating but, the development of metal matrix composite coating reinforced with nano-particle Al2O3 caught attention. The paper purpose is to find out the on how to increase the surface hardness and wear resistance of electrodeposited Ni. Thus, Al2O3 nano powders with average size of 80nm were co- deposited with nickel matrix. The characterization of the metal matrix coating is investigated using scanning electron microscopy (SEM) and X-Ray diffraction (XRD) facilities. By end of this research the result showed that the wear resistance of the nano

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composites was approximately 2-3.5 times increased compared with unreinforced Ni deposited material [9]. Thus, from this result, it is understand that the nano-particulate ceramics reinforcement in MMC contribute significant improvement on the mechanical properties of the MMC.

Saidatulakmar Shamsuddin, Shamsul Baharin Jamaludin, Zuhailawati Hussain, Zainal Arifin Ahmad, 2008 “Characterization of Fe-Cr-Al2O3 Composite Fabricated by Powder Metallurgy Method with Varying Weight Percentage of Alumina” Faculty of Applied Science, Universiti Teknologi Mara.

This paper is basically giving some overview of how to develop a composite using powder metallurgy method. This paper study focused on fabricating and characterizing composites of iron-chromium alloy reinforced with 5-25% of alumina particle fabricated using powder metallurgy method. The varying weight percentages of alumina particles have an effect on the final physical properties of the composites namely the density, shringkage, porosity and hardness. By end of this paper, experimental data showed that the higher weight percentage of reinforcements resulted in clustering of the reinforcement in the matrix, which causes higher porosity and lower density of the composites, consequently resulted in increase in hardness [10]. This study is very important in order to help develop a good methodology for this project because the basic fundamental of the paper is almost the same with this project.

R.S.Azis, M. Hashim, N. Yahya, R. Alias, N.M.Saiden, N.A. Aini, A.A. Rejab, 2007,

“Effect Of Sintering Temperature On Grain Growth Orientation In Millscale-Derived Bafe12o19” Department of Physics, Universiti Putra Malaysia.

This paper is basically showing us the influence of impurity elements in the millscale and sintering conditions of barium hexaferrite paled derived from millscale on the crystallite microstructure development. In this paper, the sintering temperature for barium hexaferrite pallet used is varies from 1050 oC- 1300oC. This variation of temperature is essential to be a guideline for this project.

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Saurabh Anand and Neerav Verma, 2006, “ Effect of sintering temperature, heat treatment and tempering on hardness of sintered hardened grade steels ” Department of Materials and Metallurgical Engineering, Indian Institute of Technology

This paper is basically to study the changes in hardness of sintered hardened steel sintered at different temperature. The samples were sintered at 1120 oC, 1180 oC and 1250 oC. Then, the sintered samples were characterized for density and densification parameter. The paper provides sintering temperature and compaction pressure information for this project that is beneficial for the methodology.

G.Staniek, F. Lehnert, M. Peters, W.Bunk and W.A.Kaysser,1993 “Powder Metallurgical Processing of a SiC Particle reinforced Al-6wt% Fe Alloy” Institute of Material Research, German Aerospace Research

This paper is basically the study of the development of MMC using powder metallurgy processing for Al6Fe matrix using various fractions and volume content of SiC particles.

This paper focus on the study of effect of a composite with different fraction of particulate varies from 10-15 % .The paper also provides few type of mixing technique observe the effect of this techniques on the mechanical properties of the composite.There are few mixing techniques used on this research which are tumble mixer, ball mill and attritor. By end of this experiment, yield strength and elastic modulus of the composite by the addition of 10 and 15% of SiC particle. This author also mentioned that there is no powder mixing effect visible in the microstructure of the powder composites that give any indication for possible effects on mechanical properties. . The paper gives some ideas on the proper mixing, compaction and sintering methodology for this project.

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S. Eroglu, T. Baykara ,2000, “ Effects of powder mixing technique and tungsten powder size on the properties of tungsten heavy alloys”, Material Research Department, TUBITAK.

This paper provides us information on the effect of powder mixing technique on the properties of tungsten heavy alloys. There are two techniques used in this research which are attritor mill and turbular mixer. By end of the research, result shows that the alloys prepared from turbular mixed powder generally showed lowest tensile properties and metallographic analyses show that these alloys failed in more brittle phase. In contrast, attritor milled alloys exhibited better tensile properties than those of the turbula-mixed alloy. This paper provides significant information to support the importance of right mixing technique to produce best properties of composite. This paper has given some idea for project methodology on the mixing technique.

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CHAPTER 3

METHODOLOGY AND PROJECT WORK

3. METHODOLOGY AND PROJECT WORK

This chapter explains the project methodology for this Final Year Project (FYP). For ease of execution, this project has been divided into 2 main parts which is Final Year Project 1 (FYP 1) and Final Year Project 2 (FYP 2). Overall project takes 2 semesters for completion and the summarized project flow for this FYP is illustrated in Figure 3.1.

Detail Gantt Chart can be refer at Appendix 1 and Appendix 2

Figure 3.1: FYP 1 and FYP 2 flow chart Project Planning

Literature Review

Methodology

Conclusion Sample Preparation

Result and Discussion Testing & Analysis

Recommendation

FYP 1

FYP 2

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3.1 Project Planning

In this project, the main part is to define the problem and to determine the scope of study. The study only focuses on the development of Metal Matrix Composite reinforced by particulate. The study is carried out by identifying the effect of nano-sized particulate (SiO2) on the physical and mechanical properties of the metal base matrix (iron powder). In order to understand the basic concept and idea of problem, some literature review is conducted on the related project. This is the crucial part where all the data is gathered and as a guidance throughout this project. The methodology is extracted from few literature review related to the study.

3.2 Materials Iron Powder

Commercial iron powder was used as a matrix component for the composites. These iron powder has a size of 10µm and contain 99.5% pure iron. It is show in Figure 3.1

(a) (b)

Figure 3.2: Iron Powder

Silica Sand nano-particulate

Silicasand nano-particulate that was produced from Tronoh silica sand was used as a reinforcement material. The average particle size was 60-80 nm.

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3.3 Processing of MMC

3.3.1 Mixing

Iron Powder was mixed with different wt% of silicasand nanoparticles. Binder (paraffin wax) was introduced as a binding agent for both materials. The fwtollowing composite were developed: pure iron, 5wt% of silica sand nanoparticles, 10% silica sand nano particles, 15wt% silica sand nanoparticles and 20wt% silica sand nanoparticles. Then mixture was then undergoes slow ball milling (Figure 3. ) for 1 hour to achieve homogeneity. Three set of sample contains total 15 pallets were developed for this project are shown in Table 3.1.

Table 3.1: Type of samples summarized

1st Sample 2nd Sample 3rd Sample 900oC (Sintering) 1000oC (Sintering) 1100oC (Sintering)

Pure iron Pure iron Pure iron

Fe + 5wt% SiO2 Fe + 5wt% SiO2 Fe + 5wt% SiO2 Fe + 10wt% SiO2 Fe + 10wt% SiO2 Fe + 10wt% SiO2

Fe + 15wt% SiO2 Fe + 15wt% SiO2 Fe + 15wt% SiO2

Fe + 20wt% SiO2 Fe + 20wt% SiO2 Fe + 20wt% SiO2

Figure 3.3 : Ball Mill

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3.3.2 Compaction

The mixture was then compacted using the autopalletiser at 117 MPa force by using a metallic mould with diameter of 13 mm. The Dwell time taken was 3 minutes and Decomposition time for 1 minute.

3.3.3 Sintering

The green compacts were sintered in the sintering furnace. Three sets of samples were sintered at different temperature. 1st set of sample was sintered at 900 oC , 2nd set of sample was sintered at 1000 oC and 3rd set of sample was sintered at 1100 oC. All samples were sintered in an argon atmosphere for 2 hours. The heating and cooling rates of sintering process were 5 oC/ min and 10 oC /min respectively.

Figure 3.5 : Sintering Furnace Figure 3.4 : Autopalletiser

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3.4 Characterization and Analysis 3.4.1 Physical Properties

Density

Density measurements were taken for both green density and sintered densities. Sintered densities for different silica sand nanoparticles wt% and different sintering temperature were recorded. All samples were measured by using mettle Toledo AX205 density measurement instrument following the Archimedes‟s method.

Microstructure

Microstructure analysis is performed to analyze the type of microstructure produced by the nanocomposites at different wt% and sintering temperature. Samples were mounted before the analysis. The analysis was conducted using normal optical microscope and FESEM to observe the detail microstructure as well EDX analysis for point analysis.

3.4.2 Mechanical Property Hardness

The hardness measurement was conducted by using Rockwell (Scale B) hardness tester by using 100-kg force and steel ball of 1/16 inches diameter.

Figure 3.6 : Toledo AX205

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CHAPTER 4

RESULT AND DISCUSSION

In this section, result, finding and outcomes of the project are presented. Result represented cover from the theoretical and experimental result.

4.1 Theoretical Density

Before getting the actual density, it is important to get the idea of the composite density by calculating the theoretical density of the composite. This theoretical density will give some reference on the experimental result later on. Theoretical density of the nanocomposite is calculated base on the metal matrix composite formula given.

ρ c = 1 / (Wp/ ρp + Wm/ ρm) ……… (Eq.1)

ρ c = total density of composite

Wp = Weight percentage of particulate Wm = Weight percentage of metal ρp = density of particulate

ρm = density of metal

Table 4.1 shows the theoretical density of the composite. It is shown that the density of composite decreases with increasing percentage of silica sand nanoparticles

Table 4.1 : Theoretical Density

Material Theoretical

Density

Fe 7.87

Fe + 5wt% SiO2 7.158 Fe + 10wt% SiO2 6.565 Fe + 15wt% SiO2 6.062 Fe + 20wt% SiO2 5.631

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4.2 Density of Fe-SiO2 nanoparticles

Table 4.2 shows the green density of the composite. It can be seen that the green density is less dense compare to the theoretical value calculated in Table 4.1. The green desity produced after compaction is only 80% dense of the theoretical densities.

Table 4.2 : Green Density Result

Material Green

Density

Fe 6.856

Fe + 5wt% SiO2 Nanoparticles 5.698 Fe + 10wt% SiO2 Nanoparticles 5.059 Fe + 15wt% SiO2 Nanoparticles 4.676 Fe + 20wt% SiO2 Nanoparticles 4.312

In this experiment, three sets of composites were sintered at three different temperatures.

The first set was sintered at 900oC, second set was sintered at 1000 oC and the third set was sintered 1100 oC for 2 hours in Argon atmosphere to observe the sintered density behavior at respective temperature. Result obtained are shown in Table 4.3

Table 4.3: Sintered Density of the MMC samples at different temperatures

Material Green

Density

Sintered @ 900 oC

Sintered @ 1000 oC

Sintered @ 1100 oC

Fe 6.502 7.347 6.782 6.638

Fe + 5wt% SiO2

Nanoparticles 5.125 5.509 5.408 5.427

Fe + 10wt% SiO2

Nanoparticles 4.878 4.768 4.838 5.109

Fe + 15wt% SiO2

Nanoparticles 4.423 4.717 4.509 4.608

Fe + 20wt% SiO2

Nanoparticles 4.264 4.256 4.349 5.109

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Table 4.3, Figure 4.1, Figure 4.2 and Figure 4.3 show both green and sintered density of the three sets the Fe-SiO2 nanoparticles composites. It show the sintered density trend at different sintering temperature of 900 oC, 1000 oC, and 1100 oC. Figure 4.1 and Figure 4.2 show the density is slightly improved at 900 oC as well as 1000 oC. More improved density was observed in Figure 4.3 in case of 1100oC. Sintered density of Fe-SiO2 nanoparticles composite show an increased pattern as the the sintering temperature rise from 900 oC, 1000 oC to 1100 oC. This due to more reduction of porosity and filling pores sites by nanosilica sand particles at higher sintering temperature.

Figure 4.1 : Green density and sintered density at 900 oC

Figure 4.2 : Green density and sintered density at 1000 oC

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Figure 4.3: Green density and sintered density at 1100 oC

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4.3 Optical Microscope Analysis of the Fe-SiO2 nanoparticles composites

Figure 4.4 (a, b, c and d) show the image of Fe-SiO2 nanoparticles composite under the optical microscope. This sample was sintered at 900oC. It is clearly shown how silica sand nanoparticles are distributed in iron and occupied the porosity places after sintering. Increasing wt% trend of silica sand nanoparticles shows more pores are filled.

At 900oC sintering temperature, darker zones (shown with arrow) are observed in the composite in Figure. SiO2 agglomerates at this temperature and it is clearly show in Figure 4(d). This temperature is considered lower than the optimum sintering temperature for diffusion inside Fe to occur. Thus it creates unfavorable environment for Si diffusion to take place.

(a) (b)

(c) (d)

Figure 4.4 : Optical Microscope image at 100x resolution of Fe-SiO2 nanoparticles composites at 900 oC sintering temperature of Fe-SiO2 nanoparticles composites with (a) 5wt% SiO2 (b) 10wt% SiO2 (c) 15wt% SiO2 (d) 20wt% SiO2

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Figure 4.5 (a, b, c and d) show the image of sintered Fe-SiO2 nanoparticles composite at 1000oC sintering temperature. It was observed that the dark zone decrease in size with increasing sintering temperature Figure 4.6 as compare to Figure 4.5. The dark zone is actually represented voids surrounding the decomposed SiO2 particles. Increasing sintering temperature will create favorable state for the SiO2 particles to diffuse faster in the Fe particles. SiO2 diffuse easier at this temperature thus decrease SiO2 agglomerate whichis shown in Figure 5(d) as compared to Figure 4(d)

(a) (b)

(c) (d)

Figure 4.5 : Optical Microscope image at 100x resolution of Fe-SiO2 nanoparticles composites at 1000 oC sintering temperature of of Fe-SiO2 nanoparticles composites with (a) 5wt% SiO2 (b) 10wt% SiO2 (c) 15wt% SiO2 (d) 20wt% SiO2

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Figure 4.6 (a, b, c, and d) show the image of sintered Fe-SiO2 nanoparticles composite at 1100 oC. White arrow in Figure 4.7c and Figure 4.7d show the dark zone is decrease in size and well distributed throughout the Fe particle. When we compare this result with the previous Figure 4.5 and Figure 4.6, it is clearly indicates sintering temperature effect the diffusion of SiO2 into the Fe particles. Decomposition of SiO2 particles was thermally activated at 1000 oC and optimum at 1100 oC. During sintering of Fe-SiO2

compacts, some SiO2 particles decomposed into Si and O2 atoms that could diffuse into Fe particles. The higher sintering temperature, more diffusion occurs. Decomposition of SiO2 particles resulted decrease the SiO2 particles size[15].

(a) (b)

(c) (d)

Figure 4.6 : Optical Microscope image at 100x resolution of Fe-SiO2 nanoparticles composites at 1100 oC sintering temperature of of Fe-SiO2 nanoparticles composites with (a) 5wt% SiO2 (b) 10wt% SiO2 (c) 15wt% SiO2 (d) 20wt% SiO2

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4.4 FESEM Analysis of the Fe-SiO2 nanoparticle composite

Figure 4.7 show image of FESEM analysis of the Fe-SiO2 composite. These image show more detail on how silica sand nanoparticles are distributed in iron and occupied the porosity after sintering at 900 oC,. Based on these FESEM analysis of the materials, there existed there different microstructural features. The light zones represented ferritic iron. The light grey zones represent lamellar structure of pearlite phase while the dark zones represent voids surrounding the decomposed SiO2 particles. Figure 4.7, 4.8 and 4.9 clearly show how the structure changes when the sintering temperature increased.

The well distributed dark zone is observed clearly in the Figure 10 at optimum sintering temperature of 1100 oC.

(a) (b)

(c) (d)

Figure 4.7 : FESEM images (1000x) of Fe-SiO2 nanoparticles composites at 900 oC sintering temperature of of Fe-SiO2 nanoparticles composites with (a) 5wt% SiO2 (b) 10wt% SiO2 (c) 15wt% SiO2 (d) 20wt% SiO2

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(b) (a)

(c) (d)

Figure 4.8 : FESEM images (1000x) of Fe-SiO2 nanoparticles composites at 1000 oC sintering temperature of of Fe-SiO2 nanoparticles composites with (a) 5wt% SiO2 (b) 10wt% SiO2 (c) 15wt% SiO2 (d) 20wt% SiO2

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(a) (b)

(c) (d)

Figure 4.9 : FESEM images (1000x) of Fe-SiO2 nanoparticles composites at 1100 oC sintering temperature of of Fe-SiO2 nanoparticles composites with (a) 5wt% SiO2 (b) 10wt% SiO2 (c) 15wt% SiO2 (d) 20wt% SiO2

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4.5 EDX Analysis of the Fe-SiO2 nanoparticle composite

Figures 4.10, 4.13 and 4.15 show the EDX analysis of whole area of the composite.

These analysis had verifies the presence of silica sand nanoparticles in 5, 10, 15 and 20wt.% iron based composites. The curve of 20wt% silica sand nanoparticles is more pronounced as compared to 5wt% silica sand nanoparticles in iron based composite.

EDX analysis of point area in Figure 4.11,4.12, 4.14 and 4.16 show verify that the dark zone in the composites contain Si. It is also observed that the size of void decreases as the sintering temperature increased. This have prove that, during sintering of Fe-SiO2

compacts, some of SiO2 particles decomposed into Si and O2 atoms could diffuse into the Fe particles. These behaviors was also found by Sainatee Chakthin [16] by SiC particles in Fe based composite. Increase the sintering temperature would allow more diffusion to occur. Thus, the void size decreases and the Si is well diffuse to enhanced the properties of the composite.

(a) (a-1)

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Figure 4.10: FESEM and EDX analysis (whole area) of Fe-SiO2 nanoparticles composites at 900 oC sintering temperature of of Fe-SiO2 nanoparticles composites with (a) 5wt% SiO2 (b) 10wt% SiO2 (c) 15wt% SiO2 (d) 20wt% SiO2

(b) (b-1)

(c) (c-1)

(d) (d-1)

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(a) (a-1)

(b) (b-1)

(c) (c-1)

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(d) (d-1)

Figure 14.11 : FESEM and EDX analysis (point) of Fe-SiO2 nanoparticles composites at 900 oC sintering temperature of of Fe-SiO2 nanoparticles composites with (a) 5wt%

SiO2 (b) 10wt% SiO2 (c) 15wt% SiO2 (d) 20wt% SiO2

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Figure 4.12 show the EDX point analysis on the light zone in the Fe-SiO2 nanocomposite. It shows that the area contain Fe particles. Therefore, we can conclude that the dark zone in the nanocomposites contain SiO2 while the the white zone consist of Fe.

(a) (a-1)

(b) (b-1)

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(c) (c-1)

(d) (d-1)

Figure 14.12 : FESEM and EDX analysis (point) of Fe-SiO2 nanoparticles composites at 900 oC sintering temperature of of Fe-SiO2 nanoparticles composites with (a) 5wt%

SiO2 (b) 10wt% SiO2 (c) 15wt% SiO2 (d) 20wt% SiO2

(a) (a-1)

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(b) (b-1)

(c) (c-1)

(d) (d-1)

Figure 14.13 : FESEM and EDX analysis (whole area) of Fe-SiO2 nanoparticles composites at 1000 oC sintering temperature of of Fe-SiO2 nanoparticles composites with (a) 5wt% SiO2 (b) 10wt% SiO2 (c) 15wt% SiO2 (d) 20wt% Si.

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(a) (a-)

(b) (b-1)

(c) (c-1)

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(d) (d-1)

Figure 14.14 : FESEM and EDX analysis (point) of Fe-SiO2 nanoparticles composites at 1000 oC sintering temperature of of Fe-SiO2 nanoparticles composites with (a) 5wt%

SiO2 (b) 10wt% SiO2 (c) 15wt% SiO2 (d) 20wt% SiO2

(a) (a-1)

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(b) (b-1)

(c) (c-1)

(d) (d-1)

Figure 14.15 : FESEM and EDX analysis (whole area) of Fe-SiO2 nanoparticles composites at 1100 oC sintering temperature of of Fe-SiO2 nanoparticles composites with (a) 5wt% SiO2 (b) 10wt% SiO2 (c) 15wt% SiO2 (d) 20wt% SiO2.

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(a) (a-1)

(b) (b-1)

(c) (c-1)

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Figure 14.16 : FESEM and EDX (point) analysis of Fe-SiO2 nanoparticles composites at 1100 oC sintering temperature of of Fe-SiO2 nanoparticles composites with (a) 5wt%

SiO2 (b) 10wt% SiO2 (c) 15wt% SiO2 (d) 20wt% SiO2

(d) (d-1)

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4.6 Hardness Measurement of Fe-SiO2 nanoparticles composites

An increasing trend of hardness was observed with increasing trend of silica sand nanoparticles in iron as well as increasing the sintered temperature. The maximum hardness 167.4 HV was achieved in the composites with 15% of silica sand nanoparticles and 1100 oC sintering temperature. Improved hardness may be resulted from solid solution strengthening of by Si atoms and the formation of pearlite phase. The microhardness tests also reveal that increasing trend of hardness is due to dispersion hardening of silica into iron matrix. Also good mechanical properties can be obtained due to good binding interface between the components.

Table 4.4 : Hardness test result based on sintering temperature Sintering

temperature/Hardness 900 oC/HV 1000 oC/HV 1100 oC/HV

Pure Iron 90.3 83.7 82.7

5% 42.1 51.7 84.9

10% 64.5 71.2 120

15% 61.3 112.1 167.4

20% 57.6 87.9 137.9

Figure 4.17 : Hardness Vs wt% of silica sand nanoparticles

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CHAPTER 5

CONCLUSION & RECOMMENDATION

5. CONCLUSION & RECOMMENDATION 5.1 Conclusion

As the conclusion, the addition of nanosilica sand as a reinforced particulate into the iron powder, based metal matrix will give some significant impact on its properties. The result shows that the density decreases when the percentage of silica sand nanoparticles increased. Decreased density composites may provide benefit of weight saving or higher strength-to-weight ratio. Meanwhile, an improvement in sintered densities was also observed. The addition of silica sand nanoparticles to iron enhanced the hardness with increasing the sintered temperature. Optimum sintered density was reached at 1100 oC.

The addition of silica sand nanoparticles to iron also enhanced the hardness from 82.7 HRV to 167.4HRV. Optimum hardness also obtained at 1100 oC. These indicate that the iron based silica sand nanoparticles composites have hardness and tensile strength of equivalent to many of commercial iron alloy. Increasing the silica sand nanoparticle can be seen in the microstructure analysis on which the present of black zones increases as the content of silica sand nanoparticles increases. From FESEM and EDX analysis it is observed that silica sand nanoparticles diffuse in the porous sites of composites causing an improvement in mechanical properties as well as improved the microstructure.

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5.2 Recommendation

Based on the findings of this project and challenges faced, following recommendation can be made for further works to be carried out in order to improved the mechanical and physical result of the composite :

Pure iron is easily oxidized in normal atmosphere. Formation of Oxide will give some effect on the composite. It is suggested that the mixing and compaction step is conducted in the vacuum space.

Study the effect of mixing speed on the homogeneities of the mixture.

Compaction is suggested to be conducted at higher pressure close to the findings in journal.

Produce dog bone shape mould to produce specimen for measuring the tensile properties of iron-based silica sand nanoparticle composition for future studies

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REFERENCES

[1] Randall M. German, 1998, Powder Metallurgy of Iron & Steel, USA, Wiley [2] William D. Callister, 2007, Materials Science And Engineering : An

Introduction, USA, Wiley

[3] N. Chawla and K.K Chawla, 2006, Metal Matrix Composites, USA, Springer [4] C.Y.H Lim, D.K Leo, J.J.S Ang, M. Gupta, 2004 “Wear of Magnesium

Composites Reinforced with nano-sized alumina particulates” Department of Mechanical Engineering, National University of Singapore.

[5] A.Mazahery, H.Abdizadeh, and H.R. Baharvandi, “Hardness and Tensile Strength Study On AL356 Alloy Matrix-Nano Al2O3 Particle Reinforced Composite”, School of Metallurgy and Materials Engineering,University of Tehran, Iran.

[6] H.Gul, F. Kilic, S. Aslan, A. Alp, H. Akbulut, “Characteristics of electro-co- deposited Ni-Al2O3 nano-particle reinforced metal matrix composite (MMC) coatings” Department of Metallurgical & Materials Engineering, Sakarya University

[7] Saidatulakmar Shamsuddin, Shamsul Baharin Jamaludin, Zuhailawati Hussain, Zainal Arifin Ahmad, 2008 “Characterization of Fe-Cr-Al2O3 Composite Fabricated by Powder Metallurgy Method with Varying Weight Percentage of Alumina” Faculty of Applied Science, Universiti Teknologi Mara.

[8] M.D. Huda, M.S.J. Hashmi and M.A.El-Baradie, 1995,“MMCs: Materials, Manufacturing and Mechanical Properties”, School of Mechanical and Manufacturing Engineering, Dublin City University.

[9] Z.F.Zhang, L.C. Zhang, Y.W. Mai, 2006, “Wear of Ceramic Particle-Reinforced metal-matrix Composites”, Centre for Advanced Materials Technology, Department of Mechanical and Mechatronic Engineering, University of Sydney, Australia

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College of Engineering Qatar University, Department of Mechanical and Manufacturing Engineering University Putra Malaysia

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Rejab, 2007, “Effect Of Sintering Temperature On Grain Growth Orientation In Millscale-Derived Bafe12o19” Department of Physics, Universiti Putra Malaysia.

[12] Saurabh Anand and Neerav Verma, 2006, “ Effect of sintering temperature, heat treatment and tempering on hardness of sintered hardened grade steels ” Department of Materials and Metallurgical Engineering, Indian Institute of Technology

[13] G.Staniek, F. Lehnert, M. Peters, W.Bunk and W.A.Kaysser,1993

“Powder Metallurgical Processing of a SiC Particle reinforced Al-6wt% Fe Alloy” Institute of Material Research, German Aerospace Research

[14] S. Eroglu, T. Baykara ,2000, “ Effects of powder mixing technique and tungsten powder size on the properties of tungsten heavy alloys”, Material Research Department, TUBITAK.

[15] S. Balaji, P. Vijay and A. Upadhyaya, 2007, “Effect of sintering temperature on the elecrochemical, hardness and tribological properties of aluminide-reinforced austenitic stainless steel. Depertment of Materils and Metallurgical Engineering, Indian Institute of Technology.

[16] Sainatee Chakthin, Monnapas Morakotjinda, 2009, “Influence of Carbides on Properties of Sintered Fe-Base Composite” Division of Materials Technology, Faculty of Energy, Environment and Materials, University of Technology Thonburi,

[17] Wikipedia, 14, October 14, 2009, http://en.wikipedia.org/wiki/iron

[18] Wikipedia, 14 October 2009,

http://en.wikipedia.org/wiki/Silicon_dioxide

[19] Azom 2009, 14 October 2009 , http://www.azom.com

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APPENDICES

APPENDIX I :FYP 1 GANTT CHART

TITLE: STUDY ON EFFECT OF NANOSILICA SAND ADDITION ON PHYSICAL AND MECHANICAL PROPERTIES OF IRON POWDER

Rujukan

DOKUMEN BERKAITAN

The presence of graffiti vandalism on vandalised property, the maintenance level of the property, the quality of the building (construction), the quality of the building (design

The objectives of this project are to determine the mechanical and physical properties of Ti6Al4V-7Y and to identify the effect of different addition contents of wt.% Y element in

The objective of this study is to explore the effect of high filler loadings and coupling agent on the physical and mechanical properties of the wood polymer

The mixing time and the intensity of mixing powder and lubricant is an important factor because it will affect the properties of the mixture such as flow and

This paper reports the effect of alumina (Al 2 O 3 ) particle size on the properties of aluminum metal matrix composite (MMC), fabricated via powder metallurgy route.. Mixture

Therefore, at 1400C with coarser grain size, the composite mechanical properties slightly decreases but the readings were quite high compared to the composites sintered lower

There are 3 objectives of this research such as to study the effect of fibre properties on mechanical and physical properties of hybrid medium density

Effect of Sintering on The Microstructure And Mechanical Properties Of Alloy Titanium-Wollastonite Composite Fabricated By Powder Injection Moulding Process.