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Journal of Polymer & Composites Original Research

Deep Cryogenic Treatment of Copper Chill Plates in Stir Casting of Al6061-Silicon Carbide Composites

  1. Alok Kumar Department of Mechanical Engineering, Nalanda College of Engineering, Chandi (Nalanda), Bihar Engineering University, Patna
  2. Shiv Kumar Ray Department of Mechanical Engineering, Bihar Engineering University, Patna
  3. Rashique Arif Department of Mechanical Engineering, Government Engineering College, Jehanabad, Bihar Engineering University, Patna
  4. Sunny Chandra Department of Mechanical Engineering, Bihar Engineering University, Patna
  5. Ashish Kumar Aman Department of Mechanical Engineering, Government Engineering College, Baxar, Bihar Engineering University, Patna
  6. Rajesh Kumar Department of Mechanical Engineering, Sandip University, Sijoul, Madhubani

Abstract

Aluminum-Silicon Carbide Metal Matrix Composites (Al/SiC MMCs) represent advanced materials created through the integration of aluminum matrices with silicon carbide particle reinforcement. These composites demonstrate superior characteristics compared to conventional aluminum alloys, establishing their relevance across diverse engineering applications. This experimental investigation focuses on developing composites using aluminum as the base matrix while incorporating SiC particles (40-50μm particle size) as reinforcing agents. The reinforcement content was systematically varied from 3 to 12 weight percent in incremental steps of 3 weight percent. Composite fabrication utilized sand mold casting techniques incorporating specialized chill blocks, including Deep Cryogenic Treatment (DCT) processed copper and standard copper alternatives, with subsequent evaluation of resulting material characteristics. Experimental findings revealed that Al/SiC composites achieved maximum tensile strength when produced using DCT copper chill blocks, whereas specimens manufactured with conventional copper chills exhibited reduced strength values. Enhanced thermal conductivity properties of the chill plates directly correlate with improved strength characteristics. Additionally, increased composite hardness contributes to superior tensile strength through the development of refined grain structures during rapid solidification processes. Microstructural analysis conclusively demonstrated that specimens produced using DCT-copper chill plates exhibited significantly refined grain structures, while those manufactured with conventional copper chills displayed notably coarser grain formations. Comparative microstructural examination confirmed that DCT-copper chills produce substantially finer grain sizes compared to conventional copper chills, which generate coarser grain structures.

Keywords

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