Synthesis of Microstructure and Tribological Properties of AMMCs Fabricated by Two Different Powder Metallurgy Routes

Abstract

In this investigation tribological properties of Aluminium-Alumina metal matrix composites (AMMCs) are developed through developing microstructure and improving physical properties by controlling process parameters of two different powder metallurgy routes. In one route; 5, 10 and 15 weight percent Alumina (Al2O3) powder was manually blended with pure Aluminium (Al) and compacted at 10 ton/inch2 uniform pressure followed by sintering at 400°C, 500°C and 600°C for 30 minutes. Alternately, commercially pure Al powder was oxidized at 500°C, 600°C, 700°C and 800°C for 15, 30 and 45 minutes individually followed by same powder metallurgy process as applied in the first route of AMMCs fabrication like blending, compacting and sintering. Optical micrographs of fabricated AMMCs were taken and corelated with the apparent porosity of fabricated AMMCs as well as with different process parameters and variables like sintering and oxidation temperatures, oxidation duration, and wt. % of Alumina. Tribological properties of all AMMCs were also measured and corelated with the process parameters and variables as well as with the observed microstructure and measured apparent porosity. It is observed that finer grain structures are developed by increasing sintering and oxidation temperatures, and oxidation duration. It is also observed that wear resistance of AMMCs is enhanced by increasing sintering and oxidation temperatures, oxidation duration, and wt. % of Alumina individually; whereas, more enhancement is observed in case of second route of AMMCs fabrication. Therefore, the uniqueness of this investigation is to improve the wear resistance of pure Aluminium by fabricating AMMCs through simply heating pure Al powder at different temperatures followed by powder metallurgy process instead of adding reinforcement material (Alumina powder).

Full text

Mahato et al. 2022. Int. J. Vehicle Structures & Systems, 14(2), 158-164
International Journal of
Vehicle Structures & Systems
Available online at www.maftree.org/eja
ISSN: 0975-3060 (Print), 0975-3540 (Online)
doi: 10.4273/ijvss.14.2.05
© 2022. MechAero Foundation for Technical Research & Education Excellence
158
Synthesis of Microstructure and Tribological Properties of AMMCs Fabricated
by Two Different Powder Metallurgy Routes
Jayanta K. Mahatoa,b, Sameera, Jitender K.S. Jadona, Rajkishor Singha, Raman Gahlauta and
Akshay K. Pramanickc
aMech. Engg. Dept., Shobhit Institute of Engg. & Tech. (Deemed to-be University), Meerut, Uttar Pradesh, India
bCorresponding Author, Email: jayant.mahato@shobhituniversity.ac.in
cMetallurgical and Materials Engg. Dept., Jadavpur University, Jadavpur, Kolkata, West Bengal, India
ABSTRACT:
In this investigation tribological properties of Aluminium-Alumina metal matrix composites (AMMCs) are developed
through developing microstructure and improving physical properties by controlling process parameters of two
different powder metallurgy routes. In one route; 5, 10 and 15 weight percent Alumina (Al2O3) powder was manually
blended with pure Aluminium (Al) and compacted at 10 ton/inch2 uniform pressure followed by sintering at 400°C,
500°C and 600°C for 30 minutes. Alternately, commercially pure Al powder was oxidized at 500°C, 600°C, 700°C and
800°C for 15, 30 and 45 minutes individually followed by same powder metallurgy process as applied in the first route
of AMMCs fabrication like blending, compacting and sintering. Optical micrographs of fabricated AMMCs were taken
and corelated with the apparent porosity of fabricated AMMCs as well as with different process parameters and
variables like sintering and oxidation temperatures, oxidation duration, and wt. % of Alumina. Tribological properties
of all AMMCs were also measured and corelated with the process parameters and variables as well as with the
observed microstructure and measured apparent porosity. It is observed that finer grain structures are developed by
increasing sintering and oxidation temperatures, and oxidation duration. It is also observed that wear resistance of
AMMCs is enhanced by increasing sintering and oxidation temperatures, oxidation duration, and wt. % of Alumina
individually; whereas, more enhancement is observed in case of second route of AMMCs fabrication. Therefore, the
uniqueness of this investigation is to improve the wear resistance of pure Aluminium by fabricating AMMCs through
simply heating pure Al powder at different temperatures followed by powder metallurgy process instead of adding
reinforcement material (Alumina powder).
KEYWORDS:
Aluminium-Alumina metal matrix composites; Powder metallurgy; Wear resistance
CITATION:
J.K. Mahato, Sameer, J.K.S. Jadon, R. Singh, R. Gahlaut and A.K. Pramanick. 2022. Synthesis of Microstructure and
Tribological Properties of AMMCs Fabricated by Two Different Powder Metallurgy Routes, Int. J. Vehicle Structures
& Systems, 14(2), 158-164. doi:10.4273/ijvss.14.2.05.
1. Introduction
The development of metal matrix composites (MMCs) is
evolved exponentially due to their enhanced properties
in last few decades as substitute to conventional
materials used in engineering applications. Among these
MMCs, Aluminium-Alumina metal matrix composites
(AMMCs) have proved their need in engineering
applications like aircraft industries, structural
applications, defence, electronic applications etc. due to
their improved properties. These AMMCs can be
fabricated through various processes like powder
metallurgy and stir casting process by adding different
reinforcement materials as listed in fishbone diagram
Fig. 1 [1-8]. Among the different reinforcement
materials, Alumina (Al2O3) is mostly considered as it
improves properties like strength, wear resistance [9-10]
and corrosion resistance [11] of AMMCs. Among the
different fabrication processes, the powder metallurgy
process is generally used to fabricate MMCs through
steps which directly improve their physical and
mechanical properties i.e., through blending, compacting
and sintering [1,12-18].
Several investigators [19-21] have stated that
Aluminium Oxide (Al2O3 or Alumina) shells are formed
around the Aluminium (Al) powder particles during
heating of macron to nano size Al powder materials at
different temperatures. Rai et al [19] have observed that
by heating from 500°C to 800°C, the density of Al
increases from 2.72 gm/cc to 3.85 gm/cc which
corresponds to the nearest density of Al2O3 in bulk. So, it
can be said that as the oxidation temperature increases to
800°C, Al2O3 concentration in Al powder increases. But
further increasing the temperature to 1000ºC the powder
particles become hollow and consequently the density of
Al powder decreases [19]. So, formation of Al2O3 by
heating Al powder in free oxygen environment and its
concentration depend on the oxidation temperature;
beyond 800°C the oxide shell gets thinning out and
concentration of Alumina in Al decreases. Therefore,
AMMCs can be fabricated by simply heating pure Al
powder at different temperatures followed by powder

Mahato et al. 2022. Int. J. Vehicle Structures & Systems, 14(1), 158-164
159
metallurgy process instead of adding reinforcement
material (Alumina powder) with matrix material (Al
powder). Such kind of investigation is unavailable in
open literature domain. In this context, the present
investigation is aimed towards development of AMMCs
by heating pure Aluminium at several temperatures
between 500°C and 800°C for different durations
followed by powder metallurgy processes.
In open literature domain, researchers have stated
that the thermal, mechanical and corrosion properties of
Metal Matrix Composites fabricated by powder
metallurgy processes strongly depend on several factors
like size of particle [22,23], distribution of reinforcement
[23,24], wt. % of reinforcement [23, 25-27], sintering
temperature, sintering duration [27] and nano-size
reinforcement particles [28-30]. It is well known that
mechanical properties are inversely related to the
porosity of MMCs. The porosity of MMCs also strongly
depends on the process parameters of powder metallurgy
processes like sintering and oxidation temperatures,
oxidation duration, and wt. % of Alumina [27-31]. Durai
et al [27] have observed that with increase in sintering
temperature the porosity of AMMCs decreases and
hence its density increases. This results in increasing the
hardness and improving wear resistance of AMMCs. In
this context, the present investigation is also intended
towards comparative study of wear resistance of
fabricated AMMCs with respect to both process routes
and process parameters (sintering and oxidation
temperatures, oxidation duration) and correlate with the
observed microstructure and apparent porosity.
The present study aims to enhance the mechanical
properties of AMMCs through developing
microstructure and physical properties by controlling
process parameters of two different fabrication
processes; in one process by adding reinforcement
material and in another process without adding
reinforcement material.
Fig. 1: Fishbone diagram showing different processes are available for fabricating different types of MMCs with different matrix materials,
reinforcement materials, additives, wetting agents and process parameters to achieve desire properties of MMCs for different areas of
application. The highlighted ones are only considered in the present research work.
2. Experimental procedure
In the present work, AMMCs have been fabricated by
two distinct procedures of powder metallurgy (PM)
processes. In one PM process; 5% wt. , 10% wt. , and
15% wt. of Al2O3 powder were manually blended with
pure Al powder over a period of 2 hours with the help of
pestle and mortar. The blended powder (3 gm) was
poured into a 14 mm diameter die-cavity and 10
ton/inch2 uniform pressure was applied by a hydraulic
press as shown in Fig. 2(a). The samples were extracted
from die-cavity and sintered in an open tube furnace at
400ºC, 500ºC and 600ºC for 30 minutes after extraction
from die-cavity. In another PM process, commercially
pure Al powder was heated at 500ºC, 600ºC, 700ºC and
800ºC for 15 minutes, 30 minutes and 45 minutes
individually to form Al2O3 on Al powder particles.
AMMCs were prepared from oxidized Al powder
following the same processes as discussed in the first
case followed by sintering at 500ºC for 30 minutes. The
AMMCs fabricated by first and second procedure of PM
process are termed as ‘Category-A’ and ‘Category-B’
MMCs respectively. A total of 48 samples were
fabricated out of which 24 samples were fabricated in
every category. Fig. 2(b) shows the fabricated samples
of AMMCs. Scanning electron micrographs (SEM) of
pure Al, Al2O3, and mixture of Al-Al2O3 powder
materials were taken by a SEM JEOL, JSM-6360. SEM
images of oxidized and blended Al powder were also
taken by the same SEM.
Fig. 2: (a) Die position in hydraulic press, (b) fabricated samples of
AMMCs, (c) porosity measurement setup (d) wear testing machine
Apparent porosity of AMMCs was measured before
sintering and after sintering the samples in an open tube
furnace. The weight of samples in dry condition, weight
of samples in suspended water and weight of samples
after removing from water were taken to calculate the
apparent porosity of AMMCs. The apparent porosity
measurement setup is shown in Fig. 2(c). All Category-
A and Category-B MMC samples and pure Al specimens
fabricated by same powder metallurgy process were

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polished using successively finer grades abrasive papers
(120, 180, 1/0, 2/0) and finally polished by cloth
polisher. Keller’s reagent was used for etching the
polished samples. The micrographs of all samples were
observed under an inverted optical microscope at 50X
magnification and micrographs were taken by digital
camera, Leica DC 300. Wear resistance of Category-A
and Category-B MMCs were measured by pin-on-disc
type wear testing machine (DUCOM; TR-20LE-M2),
shown in Fig. 2(d). Every sample was attached at 30 mm
sliding distance on a 320 RPM rotating disc and 1 kg
load was applied by dead weight with pulley-string
arrangement. Special care was taken to control the
percentage of contact surface area between the samples
and the rotating disc. Around 80% contact surface area
was maintained between samples and rotating disc
throughout the complete test for all cases.
3. Results and discussion
The SEM images of pure Al, pure Al2O3, 5% wt. Al2O3-
Al and 15% wt. Al2O3-Al blended powder materials are
shown in Fig. 3(a-d) respectively. Similarly, SEM
images of Al powder oxidized at 500ºC, 600ºC, 700ºC
and 800ºC are shown in Fig. 4(a-d) respectively. Fig.
3(a-b) represents the real sound structure of Al and
Al2O3 powder respectively. It is found that the
morphology of pure Al2O3 powder is different from that
of pure Al powder. It is also apparently observed that
particle size of Al2O3 powder is more compared to
particle size of Al powder and Al2O3 reinforcement
powder material is homogeneously distributed in Al
matrix powder material. Fig. 4(a-d) apparently shows
that oxide shells on Al powders are formed by heating
Al powder at high temperature and concentration of
Al2O3 increases with increase of oxidation temperature.
Fig. 3: SEM images of (a) pure Al, (b) pure Al2O3, (c) 5% Al2O3 –
Al & (d) 15% Al2O3 – Al powder material
Fig. 4: SEM images of Aluminium powder oxidized at (a) 500ºC,
(b) 600ºC, (c) 700ºC and (d) 800ºC
Fig. 5(a-c) shows optical micrographs of pure Al
specimens fabricated by powder metallurgy (PM)
process and sintered at 400ºC, 500ºC and 600ºC
respectively in an open tube furnace. It is apparently
found that the grain structure of pure Al specimens
becomes finer with increase in sintering temperature.
This is attributed to the formation of denser structure by
agglomerating small particles at higher temperature
because of higher diffusion rate at higher sintering
temperature.
Fig. 5: Optical microstructures of pure Aluminium specimens
sintered at (a) 400ºC, (b) 500ºC and (c) 600ºC
Optical microstructures of Category-A AMMCs
fabricated by blending 5, 10 and 15% wt. Al2O3 powder
materials with Al powder materials followed by sintering
under same heating environment at 400ºC, 500ºC and
600ºC are shown in Fig. 6(a-c), Fig. 7(a-c) and Fig. 8(a-
c) respectively. It is apparently observed that with
increase in sintering temperature the grain structure of
Category-A AMMCs becomes finer irrespective of
different wt.% addition of Al2O3 in Aluminium. This can
be attributed to increase the degree of agglomeration
with increase of sintering temperature. Higher the
sintering temperature the degree of agglomeration
increases resulting in formation of smaller and more
regular agglomerates with finer grains and stronger
structure [31]. On the other hand, it is apparently
observed that the grain structure of Category-A MMCs
becomes coarser with increase of wt. % reinforcement
material (Al2O3 powder) regardless of sintering
temperature. This can be attributed to the lower packing
efficiency of pure Alumina because of its corundum
structure as compared to pure Aluminium because of its
FCC structure.
Fig. 6: Optical microstructures of 5% wt. Al2O3 - Al Category-A
MMCs sintered at (a) 400ºC, (b) 500ºC and (c) 600ºC
Fig. 7: Optical microstructures of 10% wt. Al2O3– Al Category-A
MMCs sintered at (a) 400ºC, (b) 500ºC and (c) 600ºC
Fig. 8: Optical microstructures of 15% wt. Al2O3 - Al Category-A
MMCs sintered at (a) 400ºC, (b) 500ºC and (c) 600ºC

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Optical micrographs of Category-B MMCs
fabricated by oxidizing pure Aluminium powder at
500ºC, 600ºC, 700ºC and 800ºC for 10, 15 and 45
minutes individually followed by powder metallurgy
processes are shown in Fig. 9(a-c), Fig. 10(a-c), Fig.
11(a-c) and Fig. 12(a-c) respectively. It is apparently
observed that the grain structure of Category-B MMCs
does not significantly affect with increase of either
oxidation temperature or duration as the sintering
temperature of all Category-B MMCs was fixed at 500ºC
for 30 minutes. But, it is apparently observed from Fig. 6
to Fig. 12 that the grain structures of Category-B MMCs
are more refined as compared to grain structure of
Category-A MMCs. This can be attributed to the effect
of heating on degree of agglomeration and densification
of Aluminium powder materials due to higher diffusion
rate at higher temperature. Higher temperature favours
the formation of smaller and more regular agglomerates
with finer and stronger grain structure [31].
Fig. 9: Optical microstructures of Category-B MMCs oxidised at
500ºC for (a) 10 min, (b) 15 min and (c) 45 minutes
Fig. 10: Optical microstructures of Category-B MMCs oxidised at
600ºC for (a) 10 min, (b) 15 min and (c) 45 minutes
Fig. 11: Optical microstructures of Category-B MMCs oxidised at
700ºC for (a) 10 min, (b) 15 min and (c) 45 minutes
Fig. 12: Optical microstructures of Category-B MMCs oxidised at
800ºC for (a) 10 min, (b) 15 min and (c) 45 minutes
The apparent porosity of all Category-A and
Category-B composites as well as pure Aluminium
samples were calculated by measuring weight of the
samples in dry condition (Wd), weight of the samples in
suspended water (Ws) and weight of the samples after
removing from water (Ww). The apparent porosity of all
samples was calculated by using the following equation:

 (1)
The variation of apparent porosity with respect to
sintering temperature for both pure Aluminium samples
and Category-A MMCs of different wt. % Al2O3 is
shown in Fig. 13(a). Here, apparent porosity
corresponding to 0ºC sintering temperature represents
the apparent porosity of samples before sintering
condition. Fig. 13(b) shows the comparison study of
apparent porosity between Category-A MMCs with
respect to both sintering temperature and wt.% of Al2O3.
It is evidently noticed that the apparent porosity of pure
Al samples is less and it increases with increase in wt.%
of Al2O3 irrespective of sintering conditions. This is
attributed to the increase of internal voids caused by
decreasing degree of agglomeration with increase of wt.
% Al2O3. In addition, the packing efficiency of pure Al
is more due to its FCC structure as compared to the
packing efficiency of pure Al2O3 because of its
corundum structure. On the other hand, Fig 13(a-b)
clearly shows that the apparent porosity of both pure
Aluminium samples and Category-A MMCs is more at
non-sintered condition and it decreases with increase in
sintering temperature irrespective of amount of
reinforcement material added to the matrix material.
This observation is attributed to the increase of degree of
agglomeration by strongly bonded particles with each
other; with increase of sintering temperature resulting in
formation of smaller and more regular agglomerates with
dense structure which is consistent with the observed
microstructures, Fig. 5 to Fig. 8. It is interestingly
observed that almost 50% apparent porosity can be
reduced by sintering the Category-A MMCs at 600ºC.
Fig. 13: (a) Apparent porosity variation of Category-A MMCs with
sintering temperature, (b) corresponding comparison bar diagram
Fig. 14(a) shows the variation of apparent porosity
of Category-B MMCs with respect to oxidation
temperature for different oxidation duration. Fig 14(b)
shows the corresponding comparison graph of apparent

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porosity between Category-B MMCs with respect to
both oxidation temperature and duration. The apparent
porosity of Category-B MMCs decreases almost linearly
with increase of oxidation temperature irrespective of
oxidation time. It is also clearly noticed that the apparent
porosity of Category-B MMCs decreases with increase
in oxidation time irrespective of oxidation temperature.
These observations are also attributed to the formation of
smaller and more regular agglomerates with dense
structure which is also consistent with the observed
microstructures, Fig. 9 to Fig. 12. In addition, the density
of Aluminium powder increases with increase in both
oxidation temperature and duration, resulting in decrease
of apparent porosity [19,20].
Fig. 14: (a) Apparent porosity variation of Category-B MMCs with
oxidation temperature, (b) corresponding comparison bar diagram
Wear tests of Category-A and Category-B MMCs
were carried out by pin-on-disc type wear testing
machine against 320 RPM rotating disc and 1 kgf
applied load. The experimental curves of wear test for
both Category-A and Category-B MMCs are shown in
Fig. 15(a and b) respectively. It is found that initially the
wear rate of Category-A MMCs is more followed by
gradual decrease of wear rate with test time and finally
reaches a constant wear rate. In case of Category-B
MMCs, initially the wear rate is very high followed by
almost constant wear rate. The cumulative wear and
wear rate of pure Al samples, Category-A and Category-
B MMCs were calculated from the wear tests raw data,
Fig. 15(a-b). The comparison studies of wear rate with
respect to weight percent addition of Al2O3 and sintering
temperature for Category-A MMCs and with respect to
oxidation temperature and duration for Category-B
MMCs are represented by comparison bar graphs as
shown in Fig. 16(a and b) respectively. It is clearly
shown in Fig 16(a) that the wear rate decreases with
increase of wt. % Al2O3 and it can be reduced almost
50% with respect to pure Al samples by adding 15% wt.
Al2O3 powder with pure Al powder. Similar observation
has been reported in open literature domain [32,33].
Such observation is attributed to the general fact of
increase of concentration of more wear resisting
reinforcement material with increase of wt. % Al2O3 in
Al matrix material. Also Fig. 16(a) shows that the
increment in sintering temperature decreases the wear
rate of Category-A MMCs. This observation is attributed
and correlated to the formation of dense grain structure
and reduction of apparent porosity at higher sintering
temperature as shown in Fig. 5 to Fig. 8. and Fig. 13
respectively.
Fig. 15: Experimental curve of wear variation with respect to test
time for (a) Category-A, (b) Category-B MMCs
Fig. 16. Comparison bar diagram of wear rate variation with
respect to (a) wt. % addition of Alumina and sintering temp. for
Category-A AMMCs, (b) oxidation temperature and time for
Category-B MMCs
Fig. 16(b) shows that the increase in oxidation
temperature the wear rate decreases irrespective of
oxidation time. This is ascribed to the increase of density
of pure Al approximately to 4 gram per cubic centimetre
with increase in oxidation temperature which
corresponds to the density of pure Al2O3 [19]. Thus, the
concentration of more wear resisting reinforcement
material increases with increase in oxidation
temperature, resulting in decrease of wear rate. Also, it is

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clearly noticed that the increase in oxidation duration the
wear rate of Category-B MMCs decreases. This is also
attributed to the increase of concentration of
reinforcement material (Al2O3) for longer period of
oxidation. In addition to increase of Al2O3 concentration,
both higher oxidation temperature and longer oxidation
period favour the formation of smaller and more regular
agglomerates with finer grains and stronger structure
[31]. Interestingly, the wear rate is found more in case of
Category-A MMCs than Category-B MMCs. Therefore,
wear resistance of pure Aluminium can be enhanced to
more than double by fabricating AMMCs through both
routes of powder metallurgy process; whereas, more
enhancement of wear resistance of pure Aluminium is
also possible by simply heating pure Al powder at
different temperatures followed by powder metallurgy
process instead of adding Al2O3 reinforcement.
4. Conclusions
This investigation is carried to develop the tribological
properties of AMMCs by controlling process parameters
of two different routes of powder metallurgy (PM)
processes; in one by adding Al2O3 followed by
conventional PM process and another by simply heating
Al powder at different temperatures followed by PM
process instead of adding reinforcement material. From
the present investigation it has been concluded that the
wear resistance of pure Aluminium can be enhanced to
more than double by fabricating AMMCs through both
routes of powder metallurgy process and controlling the
process parameters like sintering temperature, oxidation
temperature and oxidation duration; whereas, more
enhancement of wear resistance of pure Aluminium is
also possible by following second route of fabrication
process i.e. simply heating pure Al powder at different
temperatures followed by powder metallurgy process
instead of adding reinforcement material.
ACKNOWLEDGEMENTS:
The authors would like to acknowledge Metallurgical &
Materials Engg. Dept., Jadavpur University, Kolkata,
West Bengal for providing facilities to carry out the
present research work.
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