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STUDY AND EVALUATION OF MECHANICAL

PROPERTIES OF AL7075/CENOSPHERE/E-

GLASS METAL MATRIX COMPOSITES.

Sunil kumar K A1 & D.P. Girish2

1Department of Mechanical Engineering, JSSATE, Bangalore 2Department of Mechanical Engineering, Government engineering college, Ramanagar

Abstract— In this present investigation efforts are made to study the mechanical properties of

Cenosphere and e-galass fibers reinforced Al7075. Among various reinforced materials used,

Cenosphere, is one of the cheapest & low density reinforcement which is available as waste

product after the coal has been burnt in thermal power plants. Hence Al 7075 metal matrix with

cenosphere as reinforcement can easily overcome the cost barrier & can serve as best supplement

having different physical and mechanical properties for serving a wide range of applications

offering wide use in the today’s world . Specimens were prepared by varying E-glass and

cenosphere. The test specimens were made as per requirement of ASTM standard for conducting

tensile test. The Metal matrix composites (MMCs) results in improvised properties like increased

specific strength, specific modulus, damping capacity and good wear resistance in comparisons

to regular alloys. Among the available MMC’s aluminium composites are main in use due to

their high strength to weight ratio.

Key words: E-glass, cenosphere, Short E-glass fibers, Al7075 alloy composite, MMCs

1 INTRODUCTION

Composite materials or composites are engineering materials made from two or more constituents’ materials that

remain separate and distinct on macroscopic level while forming a single component. A composite material is

defined as a structural materials created synthetically or artificially by combining two or more materials having

dissimilar characteristic. One constituent is called matrix phase and other is called reinforcing phase. Reinforcing

phase is embedded in the matrix to give desired characteristic.

Particulate aluminium reinforced composite materials are widely used due to its properties like low density,

isotropic nature and the cost of production is low and the secondary processing such as fabrication and use of these

material is easier than any conventionally used. The present research is to study the effect of reinforcement’s like the

cenosphere and e-glass on mechanical properties of Al-7075. Different compositions of Al-7075 hybrid composites

were made by stir-casting method by varying the weight percentage of cenosphere, e-glass and Al-7075 alloy, then

it is followed by machining of casts to standard test specimen size was done. Later tensile test are performed on the

test specimens.

International Journal of Research

Volume VIII, Issue I, January/2019

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2. OBJECTIVES OF PRESENT WORK

Objective of this work is to fabricate the Al 7075- Cenosphere-E-glass composite by using stir-

casting technique. This approach involves mechanical mixing of the reinforcement particulate

into a molten metal bath and transferring the mixture directly into a shaped mould prior to

complete solidification. In this technique aluminium alloy 7075 ingot pieces are to be heated in

the furnace to its molten state. When the temperature is maintained between 800-850oC, a vortex

will be created using a mechanical stirrer. Cenosphere particles are to be preheated in the

furnace. The temperature of the furnace is maintained between 825-850oC. Preheated cenosphere

particles and e-glass are to be added to the melt when the stirring is in progress. Stirring is

continued for about 15 min after addition of cenosphere particles and E-Glass fibers for uniform

mixing in the melt.

Castings are prepared by pouring the melt into preheated moulds of cylindrical shapes. Then

these specimens are to be tested for mechanical and to be compared with pure Al 7075.

3. EXPERIMENTAL DETAILS

Following steps are carried out in our experimental work:

1. Material selection

2. Composite preparation

3. Testing

3.1 Material selection

The Al 7075 alloy (matrix material), cenosphere (reinforcement) and E-glass short fibers

(reinforcement) were used for fabrication of MMCs. The chemical composition of Al7075 is

given in the Table 1.

Table 1: Chemical Composition of Al 7075

Composition Zn Fe Mg Mn Cu Si Cr Ti

% Composition 5.6 0.5 2.5 0.3 1.6 0.4 0.23 0.2

3.2 Composite preparation

The cenosphere and short E-Glass fibers were used as the reinforcement and the cenosphere

content in the composites was varied from 2 to 6% in steps of 2% by weight and E-glass short

fibers are varied from 1 to 5% in steps of 2% by weight. Liquid metallurgy technique was used

to prepare the composite materials in which the cenosphere particles were introduced into the

molten metal pool through a vortex created in the melt by the use of an alumina-coated stainless

steel stirrer. The coating of alumina on the stirrer is essential to prevent the migration of ferrous

ions from the stirrer material into the molten metal. The stirrer was rotated at 550 rpm and the

depth of immersion of the stirrer was about two-thirds the depth of the molten metal. The pre-



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heated (773 K) cenosphere particles and short E- Glass fibers were added into the vortex of the

liquid melt which was degassed using pure nitrogen for about 3 to 4 min. The resulting mixture

was tilt poured into preheated permanent moulds.

Figure 3.1 Furnace Figure 3.2 Die

Figure 3.3 pouring Figure 3.4 specimen after casting

3.3 Machining

The specimens that are casted are further machined into desired shape with the help of Lathe in

Machine shop because the casted specimen will not have required dimension. For the testing of

the specimen on the machine the centre portion diameter should be according to the standard.



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Figure 3.5 Lathe machine figure 3.6 Hardness specimens

Figure 3.7 tensile specimens

3.4 Hardness test

Brinell hardness is determined by forcing a hard steel or carbide sphere of a specified diameter

under a specified load into the surface of a material and measuring the diameter of the

indentation left after the test. The Brinell hardness number, or simply the Brinell number, is

obtained by dividing the load used, in kilograms, by the actual surface area of the indentation, in

square millimeters. The result is a pressure measurement, but the units are rarely stated.

The BHN is calculated according to the following formula:

Where

BHN = the Brinell hardness number



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F = the imposed load in kg

D = the diameter of the spherical indenter in mm

Di = diameter of the resulting indenter impression in mm

Figure 3.9 computerized brinell hardness testing machine

3.5 Tensile test

Tensile tests were conducted at room temperature using universal testing machine (UTM) in

accordance with ASTM E8-82. The tensile specimens of diameter 8.9 mm and gauge length 76

mm were machined from the cast composites with the gauge length of the specimen parallel to

the longitudinal axis of the castings. Fracture surface was studied using Scanning Electron

Microscope

4. RESULTS AND DISCUSSION

4.1 Hardness test

Hardness of aluminum based metal matrix composites are mainly influenced by type of

reinforcement is largely influenced by type of reinforcement dispersion, size shape. The

influence of E-glass fiber and cenosphere content on hardness of Al7075 matrix alloy is shown

in Fig.4.1 and 4.2 shows variation of hardness of Al7075+E-glass fiber+ cenosphere hybrid

composite with increase in cenosphere at constant percentage of E-glass fiber. It is observed that,



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for a given percentage of E-glass fibers, there is a continuous increase in the hardness of the

hybrid metal matrix composites with increase in cenosphere. In the absence of E-glass fiber a

maximum BHN is noticed for 6wt% cenosphere particles (Al7075+6% cenosphere +0%E-glass

fiber). In the presence of E-glass fiber, the maximum hardness recorded with increase in the

percentage of cenosphere alone from 0 to 6wt%, a maximum improvement of 38 % is observed,

whereas with addition of E-glass fibers from 0% to 5% with corresponding cenosphere content a

maximum hardness was recorded Al7075+4% cenosphere +3%E-glass fiber hybrid composite.

With further increase in cenosphere there is decrease in hardness. This marginal decrease is

observed at higher percentage of reinforcement may be attributed to uneven dispersion and poor

wettability of reinforced phase. Among all the combinations of hybrid composites studied, the

highest hardness was recorded for Al7075+4% cenosphere +3% E-glass fiber hybrid metal

matrix composites. This combination has exhibited a maximum improvement of 84.5 BHN,

which is 33% higher than the unreinforced alloy. The fundamental reason behind the

improvement in the hardness of hybrid composites was the presence of hard reinforcing phase

underneath the indenter during brinel hardness test [48-49]. Presence of hard secondary phase in

soft and ductile aluminum matrix generally contributes to significant improvement in the

hardness of hybrid composites. The remarkable improvements in the hardness of the hybrid

composites with addition of reinforcing phase are generally attributed to following reasons [50].

Figure 4.1variation of hardness with respect to cenosphere and E-glass for as cast

composite specimens

80

82

84

86

88

90

92

94

96

98

100

1% 3% 5%

Hard

ness(B

HN

)

E GLASS

2% cenosphere

4% cenosphere

6% cenosohere



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Figure 4.2 variation of hardness with respect to E-glass and cenosphere for as cast

composite specimens

4.2 Tensile test

4.2.1 Effect of e glass, cenosphere and heat treatment duration on ultimate

tensile strength of al 7075 alloy

Figure 4.3 shows variation of ultimate tensile strength with respect to cenosphere and E glass

for as cast specimens

80

82

84

86

88

90

92

94

96

98

100

2% 4% 6%

Hard

ness(B

HN

)

Cenosphere

1% E-Glass

3% E-Glass

5% E-Glass

0

50

100

150

200

250

300

350

1% 3% 5%

UT

S,

Mp

a

E GLASS

2% cenosphere

4% cenosphere

6% cenosphere



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Figure 4.4 shows variation of ultimate tensile strength with respect to E glass and cenosphere for

as cast specimens

The ultimate tensile strength values for AA7075 alloy and its hybrid composites with varying

cenosphere and glass fibre content are shown in Fig. 4.3. It can be observed that with the

increase in cenosphere and Glass fibre content the ultimate tensile strength is increased

Compared to AA7075 alloy, the composite with highest cenosphere and Glass fibre content has

highest tensile strength which is almost 55% increment. The reinforcements, cenosphere and

Glass fibre are contributing to ultimate tensile strength of AA7075 matrix. The strengthening of

AA7075 is mainly due to the even dispersion and good bonding of reinforcements with the

matrix material. The uniform dispersion of reinforcements as seen in Fig. 5.4 is reflected in the

increment in ultimate strength values. It is important to be mentioned here that with increase in

the percentage of cenosphere particles there is a tremendous enhancement in the tensile strength

continuously for a given percentage of glass fibre.

4.3 YIELD STRENTH

In the present work, it can be seen from Fig. 4.5 and fig 4.6 that, with the increase in Cenoshere

and Glass fibre content, the yield strength is increasing. The AA7075 alloy had yield strength of

162 MPa while that of hybrid composite with Al7075+6% cenosphere +5% E-glass fiber had

about ~220 MPa. The maximum increment in yield strength of about 58% was displayed by

Al7075+6% cenosphere +5% E-glass fiber hybrid composite when compared with that of

AA7075 alloy. As mentioned, the yield strength of composites mainly depends on the

reinforcements and work hardening. In present the two reinforcements helped in improving the

yield strength of the composites. Further the yield strength doesn’t simply increase with the

0

50

100

150

200

250

300

350

2% 4% 6%

UT

S,

Mp

a

Cenosphere

1% E Glass

3% E Glass

5% E Glass



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addition of reinforcement but their dispersion and bonding with the AA7075 matrix grains do

play very important role. As shown in micrographs in the earlier sections, the uniformly

dispersed reinforcement with good interfacial bonding contributes to yield strength. As reported

by a researcher that with the addition of SiC and rice husk ash, the yield strength of aluminium

hybrid composites was improved [51]. Further, with the increase in reinforcement content from 2

to 8 wt%, the yield strength had an increasing trend.

Figure 4.5 Shows variation of Yield strength with respect to Cenoshere and E-glass for as cast

specimens

0

50

100

150

200

250

1% 3% 5%

YIE

LD

ST

RE

NG

H

E GLASS

2% cenosphere

4% cenosphere

6% cenosphere



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Figure 4.6 Shows variation of Yield strength with respect to E-glass and cenoshere for as cast

specimens

4.4 PERCENTAGE ELONGATION

Fig. 4.7 and fig 4.8 shows the ductility of AA7075 alloy and its composites with varying Glass

fibre and cenoshere content. It can be observed that the ductility is decreasing ith the increase in

the Cenosphere and Glass fibre content. The highest ductility was observed in case of AA7075

alloy while least was observed in case of Al7075+6% cenoshere +5% E-glass fiber hybrid

composite. The maximum drop in ductility of about ~62% was observed in case of Al7075+6%

cenoshere +5% E-glass fiber hybrid composite when compared to other hybrid omposites with

varied cenoshere and E glass fibre content. The drop in the ductility was mainly attributed to

presence of irregularly shaped reinforcement especially cenoshere and glass fibre whose sharp

edges acts as nucleation sites for crack. The presence of hard ceramics leads to embrittlement

due to local stress concentration at the interface of matrix and reinforcement. Further, particle

cracking could be the other reason which can contribute to low ductility values. These results are

well supported by many other works on composites where the researchers have found that the

introduction of hard ceramic phase in the soft ductile matrix can reduce the ductility of base

metal or alloy [53, 54].

0

50

100

150

200

250

2% 4% 6%

YIE

LD

ST

RE

NG

H

Cenoshere

1% E-Glass

3% E-Glass

5% E-Glass



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Figure 4.7 shows variation of percentage elongation with respect to cenoshere and E glass for as

cast specimens

Figure 4.8 shows variation of percentage elongation with respect to E glass and cenoshere for as

cast specimens

0

2

4

6

8

10

12

14

16

1% 3% 5%

perc

en

tag

e e

lon

gati

on

E GLASS

2% cenosphere

4% cenosphere

6% cenosphere

0

2

4

6

8

10

12

14

16

2% 4% 6%

perc

en

tag

e e

lon

gati

on

Cenosphere

1% E galass 3% E galass

5% E galass



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Conclusion

1. Aluminum 7075 based hybrid metal matrix Composites reinforced with E-glass fibre and

cenoshere with various weight fraction were successfully synthesized by stir casting technique.

2. A remarkable improvement in microhardness is noticed with increase in glass fibre and

cenoshere twofold increase in hardness of Al7075-GF- cenoshere composite when compared

with unreinforced alloy.

3. Ductility of the composites diminishes with addition of secondary particles in the aluminum

alloy. However, Al7075 alloy have higher ductility when evaluated with the hybrid composites

under all the compositions studied.

4. Ultimate Tensile strength of Al7075 alloy and Al7075-GF- cenoshere composites increases

with increase in percentage of dual reinforcement.

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