ANALYSIS AND COMPARISON OF ABRASIVE WEAR BEHAVIOR AND MECHANICAL PROPERTIES

OF TUNGSTEN CARBIDE COATED AL-SiC COMPOSITE

Prabakar T ( 11P120 ) Srinivasa Raghavan S ( 11P221 ) Surya R ( 11P223 )

Vignesh Krishna NB ( 11P225 )

08P720 Project Work II - Report

BACHELOR OF ENGINEERING

BRANCH: PRODUCTION ENGINEERING

of Anna University, Chennai.

Under the guidance of

Mr. M.R. PRATHEESH KUMAR

Assistant Professor (Senior Grade)

DEPARTMENT OF PRODUCTION ENGINEERING

PSG COLLEGE OF TECHNOLOGY

(Autonomous Institution affiliated to Anna University, Chennai)

COIMBATORE 641 004

Work completed during phase I :

Period Work completed

Internals 1 1. Validation of the project through literature survey

2. Feasibility study

3. Parameter selection

Internals 2 4. Selection of Die material

5. Validation of Die material selection

Internals 3 6. Die design

7. Material procurement

8. Powder Blending

9. Die material heat treatment

10. Die fabrication through WEDM

Need for the study :

Todays industries are highly driven towards cost reduction and scaling up the

productivity of the processes that are being carried out. Powder metallurgy, when it comes to

mass manufacturing is a cost efficient technique validated in many applications. We have

decided to make a study on a possible composite Al-SiC, manufactured through Powder

Metallurgy techniques, and then analyze its strength properties against carbide cemented

carbide or Tungsten carbide, etc. so that it can be used as a possible alternate for the tool

inserts available in the market without compromising on efficiency and quality.

Objective :

It is planned to investigate the abrasive wear behavior of Tungsten carbide

coated Al-SiC Composite 5%, 10%, 15% by weight SiC particles produced by powder

metallurgy technique. Also the same composite will be coated with tungsten-carbide ( WC )

by thermal spraying process and the wear behaviour of the coated composite will also be

studied. The aim is to study the wear behaviour and mechanical properties of the Tungsten

carbide coated Al-SiC composite and if the results are favorable,it can be considered as an

alternative of the Tungsten Carbide ( WC ) inserts that is being currently used for the tooling

operations .

Methodology :

Feasibility Analysis :

I. For compaction process, there is a hydraulic press setup available in the

college ( PSG Tech., metallurgy department, Krishna Drives )

II. For sintering process, there is a sintering furnace available in the college ( PSG

Tech., metallurgy department )

Powder Blending

Powder Compaction

Specimen Sintering

Specimen Coating

Mechanical and wear properties testing of coated and non-coated

specimens

Comparison of Results

Interpretation and documentation

III. For Specimen coating, there is a coating set up available in Kovai Fine Coat

Pvt. Ltd, Kalapatti, Coimbatore

IV. For conducting the various tests like,

1. Abrasive wear behavior Pin on disc wear testing machine ( PSG Tech.,

production department )

2. Compressive strength Universal tensile testing machine ( NIT, Trichy )

3. Hardness test Brinell / Vicker hardness tester ( PSG Tech, Production

department )

Gantt Chart :

Project Progress report I :

Powder has been blended again Al + SiC + Mg at different ratios ( SiC

varied with 5%,10%,15% and Mg by 0.5% of total weight ).

0 2 4 6 8 10 12 14 16

Powder Blending

Powder Compaction

Specimen Sintering

Specimen Coating

Mechanical and wear properties testing forcoated and non coated specimens

Comparison of Results

Intrepretation and Documentation

Week

Planned S

chedule

Lubricant has been chosen and purchased Stearic acid ( Pure Ethyl Acohol

+ Stearate crystals )

Compaction is under progress.