CHAPTER 4
EXPERIMENTAL METHODOLOGY
4.1 Reinforcement Technique
4.1.1 Stir Casting Technique
The Silicon Carbide particles are reinforced with A356.1 Aluminium alloy through a stir casting Technique. The silicon carbide material is incorporated as loose particles into the molten aluminium matrix in casting of metal matrix composites, because poor wetting is exhibited in most metal reinforced systems. To combine the phases, the mechanical force produced by stirring is required. The SiC particles are mechanically mixed into a molten metal bath. Electric Resistance furnace is the furnace used for the melting of alloy. The capacity of furnace is 3kg, power rating is 7.5kw. The heating element used in the furnace is Kanthal.
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After 30 Seconds, the specimen is removed and using the microscope, the diameter of the indentation is measured.
using the suitable formula, Brinell Hardness number is calculated:- ……………………….............. (4.1) Where,
D = Ball Indenter Diameter, mm, d = Indentation Diameter, mm,
F = Applied load, kgf.
4.4 Wear Test
Machining operation is done in order to convert the prepared casting in to finished product. Machining process is carried out on lathe to prepare Wear specimens. According to ASTM G99 standards, the specimens with diameter of 8mm and a length of 30mm are prepared which are shown in Fig 4.8. Specimens after reinforcement and machining are as shown in Fig 4.9.
Fig 4.8: Standard Dimension for Wear Specimen in mm
Fig 4.9: Wear specimens prepared after Reinforcement of Different Wt. %ratios of SiC
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(2) Sliding Velocity (V)=(2πRN)/(60000) (m/sec) .........................(4.3)
Where,
R =Track Radius=100mm (const.)
N = Speed, rpm.
(3) Sliding Distance (D)=(V×T)=(2πRNT)/(60000) (m) .......................(4.4)
Where,
T= Time Taken (Sec)
V= Sliding velocity (m/sec)
4.5 Impact Test
Machining operation is done in order to convert the prepared casting in to finished product. Machining process is carried out on lathe to prepare Impact specimens. According to ASTM G99 standards, the specimens with a length of 75mm and width of 10mm are prepared which are shown in Fig 4.11. Specimens after reinforcement and machining are as shown in Fig 4.12.
Fig 4.11: Standard Dimension for Impact Test specimens in mm
Fig 4.12: Impact Test specimens Prepared after Reinforcement of different Wt % ratios of SiC particles
Izod Test apparatus (as shown in Fig 4.13) is used in order to conduct the Impact Test.
Fig 4.13: Impact Testing Apparatus (Izod
This shows that it is eroded at one end more which is a sign of long
For the other material ASTM A216 Gr WCB same pressure of 16 Mpa is applied and the stress developed is approximately as similar to the connecting rod made with material of cast iron. Figure no. 9 indicates the maximum and minimum stress developed in connecting rod at small & big end. The equivalent stress maximum and minimum values are 71.347 MPa and 4.4955e-5 MPa respectively.
Die-forming of sheet metal has been around for thousands of years. Originally the metal was manipulated by hand and hammered into the depression, by utilizing crude grooves carved into wood or stone. This technique was used to make spouts, handles, and other forms. Since then, however; they have undergone a remarkable technological evolution. Mate-female conforming dies to create hollow forms by using hydraulic pressure or drop hammer pressure, changed die-forming forever (Paisin, 2013).
At the initial stage of the investigation all the visible evidence is to be observed from the latent impression perspective. At this stage only the physical evidence is taken into account. The objects can be divided into porous and non-porous surfaces from the imprint ability preservation perspective. It is advisable to send all the available evidence to the laboratory expertise, though the non-porous substances...
The burning of the materials is a complex process. Combustion of any material requires three components: heat, oxygen and combusting material or fuel. When heat is applied to the composites materials, temperature of the materials increases. At particular temperature, pyrolysis temperature, materials start to decompose, and produce
]. Some alloying elements sometimes added to impart special characteristics to brass. Lead, which is insoluble in copper alloys, used to improve machinability of leaded brass. However, Pb and Bi or other elements that are used to improve the machinability often deteriorate the low and high temperature ductility of brass [11]. The content of Pb element is varies between 2.5 and 3.5 %, which make the machining processes at high speed and good surface [12]. The solubility of lead in copper alloys is very low therefore, it is found in microstructure as dispersed globules all over the material. These globules lead act as a lubricant decreasing the friction coefficient between the tools and the materials by creating discontinuities of chip fragmentation. Therefore, it makes reducing in cutting force and then, the tools wear rate is minimized [13]. Different alloying elements help to improving the machinability are usually added to brass. The most common element using in this situation is lead, which improving the machinability with
Aluminum is a lightweight, silvery metal. The atomic weight of aluminum is 26.9815; the element melts at 660° C (1220° F), boils at 2467° C (4473° F), and has a specific gravity of 2.7. Aluminum is a strongly electropositive metal and extremely reactive. In contact with air, aluminum rapidly becomes covered with a tough, transparent layer of aluminum oxide that resists further corrosive action. For this reason, materials made of aluminum do not tarnish or rust. The metal reduces many other metallic compounds to their base metals. For example, when thermite (a mixture of powdered iron oxide and aluminum) is heated, the aluminum rapidly removes the oxygen from the iron; the heat of the reaction is sufficient to melt the iron. This phenomenon is used in the thermite process for welding iron .
-Developed and implemented strip casting overseas to eliminate a step in the steel making process
...ything is on it that it doesn’t wear off and you don’t have it anymore. During this examination you have to tell the size and shape of the bullet. You have to look into the deep things when you doing this because anything can be there just small. (“At The Mortuary”)
The micro hardness of the prepared samples were obtained by using a Vickers Micro hardness Tester (Model : Leco LV 700, USA). 5 readings were taken for each sample to calculate the average hardness. An indentation load of 5gf was used. After calculating the average hardness for each sample, mean variance and standard deviation (S.D.) was calculated to check the consistency of the data.
The inefficiencies and the problems involved in making steels in the traditional form of ingots are alleviated by the continuous-casting process, which produces higher quality steels at reduced costs. Conceived in the 1860s, continuous or strand casting was first developed for casting nonferrous metal strips. The process now is used widely for steel production, with major productivity improvements and cost reductions.
To make the steel stronger and reduce the ductile – brittleness transition temperature composition of the steel should Reduce the amount of sag ( a by-product of smelting) by 2-3%
This will be the surface material the ball is dropped on. To make the test fair the same people will carry out the same task each time the ball is dropped e.g. the same person drops the ball. The results from the two investigations will then be compared. Risk assessment There are not many risks from dropping a ball but safety must be considered. Theball should not be thrown, and the person dropping the ball should not stand on chairs or tables.
This test was performed to determine the aggregate impact value of coarse aggregates. Impact testing machine was used. Cup of the machine was firmly fixed. Sample was placed in it and compacted with the help of tamping rod. 15 blows of hammer were given from 380 mm height. Sample is then sieved from 2.36 IS sieve. Material retained was weighed.
There are some international standards for preparation of goods so every organization must follow those standards in preparation of product. Here in this type of products are tested by the device called DIRECT READING OPTICAL EMISSION SPECTRO METER, by sing this methods alloy castings are tested. If any unethical practice is applied in the process the company sued in the court.