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P.H. Nayak et alii, Frattura ed Integrità Strutturale, 48 (2019) 370-376; DOI: 10.3221/IGF-ESIS.48.35
370
Characterization and tensile fractography of nano ZrO2
reinforced Copper-Zinc alloy composites
Prasad H. Nayak
VTU RRC, Belgaum, Dept. of Mechanical Engineering, Oxford College of Engineering, Bangalore, Karnataka, India
Prasadnayak990@gmail.com
H. K. Srinivas
Dept. of Mechanical Engineering, SJBIT, Bangalore, Karnataka, India
Madeva Nagaral
Aircraft Research and Design Centre, Hindustan Aeronautics Limited, Bangalore, Karnataka, India
madev.nagaral@gmail.com, http://orcid.org/0000-0002-8248-7603
V. Auradi
Dept. of Mechanical Engineering, SIT, Tumkur, Karnataka, India
vsauradi@gmail.com
ABSTRACT. Nano particulates fortified metal lattice composites are finding
extensive variety of utilizations in car and sports hardware fabricating
businesses. In the present investigation, an endeavor has been made to create
copper-zinc-nano ZrO2 particulates strengthened composites by utilizing fluid
liquefy technique. 4, 8 and 12 wt. % of nano ZrO2 particulates were added to
the Cu-Zn base grid. Microstructural studies were finished by utilizing SEM
and EDS examination. Mechanical behavior of Cu-Zn-4, 8, 12 wt. % of nano
ZrO2 composites were assessed according to ASTM benchmarks. Checking
electron micrographs uncovered the uniform dispersion of nano ZrO2
particulates in the copper zinc composite network. EDS examination affirmed
the nearness of Zr and O components in nano ZrO2 strengthened
composites. Further, it was noticed that hardness, UTS, yield quality of Cu-
Zn composite expanded with the expansion of 4, 8 and 12 wt. % of nano
ZrO2 particulates. Ductility of nano composites was decreased by adding
zirconium oxide particulates. Fractography of tensile specimens were carried
out by using SEM micrographs to understand the failure mechanisms.
KEYWORDS. Cu-Zn Alloy; Nano ZrO2 Particulates; Liquid Melt Method;
Mechanical Behavior; Fractography.
Citation: Prasad, H., N., Srinivas, H, K.,
Nagaral, M., Auradi, V., Characterization and
tensile fractography of nano ZrO2 reinforced
copper zinc alloy composites, Frattura ed
IntegritàStrutturale, 48 (2019) 370-376.
Received: 17.11.2018
Accepted: 21.01.2019
Published: 01.04.2019
Copyright: © 2019 This is an open access
article under the terms of the CC-BY 4.0,
which permits unrestricted use, distribution,
and reproduction in any medium, provided
the original author and source are credited.
http://www.gruppofrattura.it/VA/48/2261.mp4
P.H. Nayak et alii, Frattura ed Integrità Strutturale, 48 (2019) 370-376; DOI: 10.3221/IGF-ESIS.48.35
371
INTRODUCTION
he common name being composition material or simply a composite is combination of two or many materials
with non-identical physical and chemical behaviors, when intermixed produces entirely different product with
distinct characteristic when compared with the individual material characteristic. The blending of the material is
usually done at a macroscopic level. These materials are intermixed in such a ratio that its certain properties get enhanced.
The ratios of two materials are optimized based on their applications. These composites are used not only for their
improvised mechanical properties, but also for thermal, electrical and environmental applications [1, 2]. These materials
are generally preferred for different applications like concretes, reinforced plastics such as fiber reinforced polymers, metal
composites, ceramic composites. Ceramic matrix composites & metal matrix composites are generally used for bridges
and structure such as boat house, panels of swimming pools, bodies of sports cars, bath tubs, and storage tanks & also
advanced materials in spacecrafts & aircrafts building which are in high demand [3, 4].
The composites usually consist of fiber or particulate phase which is stronger & stiffer when compared with the matrix
phase. The fiber or particulates commonly known as reinforcement phase have good mechanical, thermal & electrical
properties when compared to the matrix phase [5].
Nano Metal Matrix Composites are gradually getting to be distinctly appealing materials for cutting edge aviation
applications and yet their properties can be custom-made by the proper chose of reinforcement. Among three different
composites, particulate strengthened MMCs as of late discovered unique intrigue on account of their quality and firmness
at a normal room and raised temperatures. It is important to note that the properties of the nano metal matrix are
unequivocally affected by secondary parameters of the reinforcement, for example, shape, size, introduction, circulation
and volume [6].
Among any of other commonly used metals, copper is one characterized by the best thermal conductivity and resistance
to corrosion which explains why it is commonly chosen in the first instance for metal material. On the other hand, having
very low mechanical properties, it must be strengthened by ceramic particles, for example, which is one of the most
reliable methods of reinforcement. Copper based metal lattice composites (CMCs) have discovered more prominent
applications in the field of car, air ships and machine apparatus enterprises attributable to their low thickness and
associative high wear opposition, quality, consumption obstruction, firmness and warm conductivity. Copper and its
combination are to a great extent utilized as a material for heading [7, 8].
Since copper-based materials have a relativity high temperature and low wear obstruction, the copper network has been
effectively fortified with nano zirconium oxide and graphite particles, proceeds or irregular strands, called metal matrix
composite (MMCs).
There is a globally developing attention in assembling clay particulate fortified metal grid materials which forms joined
properties of its fortifications and display enhanced physical and tribo-mechanical properties.
In the present investigation, copper-10%Zn amalgam-based composites were manufactured by stir process. Nano ZrO2
particulates were utilized as the support. The 4, 8 and 12 wt. level of earthenware production fortifications were taken to
create the copper-ZrO2 composites. The composites were tried for mechanical properties like hardness, extreme rigidity,
yield quality and rate stretching according to ASTM guidelines.
Elements Content wt. %
Cu 89.20
Zn 9.90
Others 0.90
Table1: The chemical composition of Cu-Zn alloy
EXPERIMENTAL DETAILS
he Copper-Zn-nano ZrO2 composites created in this investigation contains 4, 8 and 12 wt. % of artistic nano
ZrO2 particulates. The density of copper-zinc compound is 8.737 g/cm3 and that of ZrO2 is 5.68 g/cm3. The
density of composites diminishes with expansion of nano ZrO2 particulates. The concoction creation of copper-
zinc combination is appeared in the Tab. 1.
The fabrication of copper-zinc-ZrO2 composites was carried out by liquid metallurgy route via stir casting technique. The
preparation of copper-zinc-nano ZrO2 composites was accomplished by two-stage stir casting technique. Pre-calculated
T
T
P.H. Nayak et alii, Frattura ed Integrità Strutturale, 48 (2019) 370-376; DOI: 10.3221/IGF-ESIS.48.35
372
quantity of Cu-Zn alloy ingots were charged into the heating furnace to liquefy. Though the Cu-Zn alloy melts at 1080˚C,
the melting furnace was superheated to a temperature of 1150˚C. Thermocouples were used to measure temperature. The
melt metal in crucible was then degassed to remove unwanted byproducts using a chemical called hexa-chloro-ethane
(C2Cl6) upto 3 mins. A steel impeller used was coated with a ceramic material known as zirconium which is used to agitate
by rotating the molten metal such that the vortex is created. The process of stirring was carried out at a speed of 300 rpm
& the impeller was immersed for about 60% height of molten metal from the top surface of melt within the crucible.
Simultaneously during the process of stirring the pre-calculated amount of reinforcement was added into the vortex in
two-stages, to ensure good wet-ability stirring was continued for upto 5 mins. The reinforcing materials ZrO2 was
preheated upto 500˚C in oven to remove moisture content before adding it into molten metal vortex. Now, Cu-Zn alloy
along with 4 wt. % ZrO2 particulates were poured into solid cast iron mould to get a composite after solidification.
Similarly, Cu-Zn-8 and 12 wt. % of ZrO2 composites were fabricated for the further studies.
The microstructural analysis completed by utilizing SEM instrument. Tests around 5 mm thickness across taken from the
casting samples and were cleaned appropriately. A reagent named Keller's was utilized to etch the examples. Hardness of
as cast copper-zinc-ZrO2 amalgam composites were coordinated to know the influence of nano scale ZrO2 particles in the
system material ASTM E 10 standard [11]. The cleaned precedents were striven for their hardness, using Brinell hardness
testing machine, which is having a ball indenter and applying a load of 250 kg and tolerate time of 30 seconds, three
courses of action of readings were noted at better places of the sample and an average of all the value was used for
figuring.
The tensile properties of the prepared samples are established as per the ASTM E8 method upon tension test piece of
gauge-diameter 9mm with gauge-length of 45mm. Metal & its alloys are to be designed to provide material properties
tailored to applications. Universal testing machine (UTM) is used to conduct tensile test to find out the effect of nano
ZrO2 particulates on tensile behavior of Cu-Zn alloy composites.
RESULTS AND DISCUSSION
Microstructural Analysis
ig. 1(a) shows microstructure of as cast copper-10% zinc alloy, fig. 1b represents Cu-Zn-12 wt.% of nano ZrO2
composites. The SEM micrographs reveal almost uniform distribution of ZrO2 particulates throughout the matrix
as observed in the fig. 1b. Uniformly distributed particulates increase the overall strength and other properties
reducing the porosity of the MMC.
Fig. 2 is the EDS spectrum of copper-zinc and 12 wt.% of nano ZrO2 reinforced composites. EDS spectrum revealed the
presence of nano ZrO2 particles in the copper-zinc alloy matrix in the form of Zr and O elements along with Cu and Zn
matrix elements.
(a) (b)
Figure 1: SEM micrographs of (a) as cast copper-zinc alloy (b) copper-12 wt. % ZrO2 composite
F
P.H. Nayak et alii, Frattura ed Integrità Strutturale, 48 (2019) 370-376; DOI: 10.3221/IGF-ESIS.48.35
373
Figure 2: EDS spectrum of copper-zinc-12 wt. % ZrO2 composite
HARDNESS MEASUREMENTS
ardness is a property of a material that demonstrates the capacity of the material to oppose nearby plastic
disfigurement. Fig. 3 demonstrates the impact of the nano ZrO2 molecule substance on the hardness of the
copper-zinc compound. The hardness esteems are decidedly related with the weight level of nano particles, since
particles fortified the lattice. Moreover, the outcomes demonstrate that nano particles fortified MMCs harder than copper-
zinc composite because of Hall-Petch and Orowan fortifying components and in addition the great interface between the
fortification and framework. Copper-zinc and 12 wt. % nano ZrO2 composites demonstrate more hardness; the expansion
in hardness of these composites can be ascribed to the scattering fortifying impact [13]. By including 12 wt. % nano ZrO2
particulates into the copper combination, the hardness of copper amalgam expanded to 85.4 BHN from 126.7 BHN.
Figure 3: Showing the hardness of as cast copper-zinc alloy and nano ZrO2 composites
TENSILE BEHAVIOR
ig. 4 and 5 demonstrating the tensile properties of copper-zinc combination and copper-zinc-4, 8 and 12 wt. %
nano ZrO2 composite. Fig. 4 demonstrating the ultimate strength (UTS) of copper-10% zinc compound and ZrO2
composites. Fig. 4 it is apparent that UTS of copper-zinc-ZrO2 composite is much more than the base lattice
H
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P.H. Nayak et alii, Frattura ed Integrità Strutturale, 48 (2019) 370-376; DOI: 10.3221/IGF-ESIS.48.35
374
combination. By including 3, 8 and 12 wt. % of nano ZrO2 nano particulates to the base amalgam UTS has expanded
from 329.7 MPa to 435 MPa. From the fig. 4 it was discovered that yield quality of the copper-zinc base compound is
275.6 MPa and in copper-zinc-12 wt. % nano ZrO2 composite is 356.2 MPa. It demonstrated a change of 29 % in yield
quality.
The expansion in UTS and YS is essentially because of solid holding between fortification particles and copper-zinc grid,
plays an imperative role on the load exchanging from network to support. This is a result of grain refinement and
molecule fortifying [14, 15]. The upgrades of quality are influenced by the higher load bearing and confound fortifying
caused by nano ZrO2 particles. In contrast with the base copper, the immense improvement in the quality saw in the
composites is because of the nearness of the particles as obstructions that confine the movement of separations caught by
ZrO2 particulates. This will prompt increment the strength of the nano composites during tests.
Fig. 5 demonstrates the elongation of as cast copper-zinc amalgam and its composites. The rate prolongation was lessened
in copper-zinc-ZrO2 composite when contrasted with the base combination. It very well may be seen from the diagram
that the flexibility of the composites diminishes fundamentally with the 4, 8 and 12 wt. % nano ZrO2 fortified composites.
This diminishing in rate prolongation in correlation with the base combinations is a most regularly happening burden in
particulate fortified metal lattice composites. The lessened flexibility in copper-zinc-4, 8 and 12 wt. % composites can be
ascribed to the nearness of ZrO2 particulates which may get broke and have sharp corners that make the composites
inclined to confined break commencement and engendering. The embrittlement impact that happens because of the
nearness of the hard-artistic particles causing expanded neighborhood stretch focus destinations may likewise be the
reason [16].
Figure 4: Showing the ultimate tensile and yield strength of as
cast copper alloy and copper-zinc-4, 8 and 12 wt. % nano ZrO2
composite.
Figure 5: Showing the percentage elongation of as cast copper
alloy and copper-zinc-4, 8 and 12 wt. % nano ZrO2 composite.
FRACTOGRAPHY
he study of fractured surface of alloys & its composites becomes necessary to find the cause of failure of the
fabricated materials. There are two important things to be remembered during analysis of fractography, a ductile
material when fails there is a formation of small dimple like structure in the broken areas whereas in case of brittle
fractures there is transgranular (fracture through grains) or inter-granular (fracture through grain boundaries) failures
which can be observed in SEM images taken from a failed material. The fractured surfaces of copper-zinc along with 12
wt. % of nano ZrO2 composite resulted from tension tests, are shown in fig. 6 (a-b). Fig. 6a represents the ductility
fracture in copper-zinc alloy. SEM analysis of the fractured surfaces shows the dimpled fracture surface for the reinforced
& unreinforced material.
T
P.H. Nayak et alii, Frattura ed Integrità Strutturale, 48 (2019) 370-376; DOI: 10.3221/IGF-ESIS.48.35
375
(a) (b)
Figure 6: SEM tensile fractured surfaces of (a) Copper-Zinc alloy (b) Copper-Zinc-12 wt.% of nano ZrO2 composites
CONCLUSIONS
n this research, by using stir casting fabrication technique the nano ZrO2/Copper-Zinc nano composites have been
fabricated by considering 4, 8 and 12 wt. % of reinforcement. The micro-structural analysis, major mechanical
behaviors like hardness, ultimate and yield strength, percentage elongation, and fractography behavior of prepared
samples are studied as per ASTM standards. The matrix is almost free from pores in as cast alloy and uniformly
distributed of nano particles in the prepared composite, which is evident from SEM microphotographs. The EDS analysis
confirms the presence of nano ZrO2 particles in the Cu-Zn alloy matrix. Compared to unreinforced material the
mechanical properties of Cu-Zn-4, 8 and 12 wt. % nano ZrO2 composite are superior and enhanced. Due to strain
localization, the fracture surface of the composite material consists of small voids.
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/NLD (Gebruik deze instellingen om Adobe PDF-documenten te maken die zijn geoptimaliseerd voor prepress-afdrukken van hoge kwaliteit. De gemaakte PDF-documenten kunnen worden geopend met Acrobat en Adobe Reader 5.0 en hoger.)
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/UKR <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>
/ENU (Use these settings to create Adobe PDF documents best suited for high-quality prepress printing. Created PDF documents can be opened with Acrobat and Adobe Reader 5.0 and later.)
>>
/Namespace [
(Adobe)
(Common)
(1.0)
]
/OtherNamespaces [
<<
/AsReaderSpreads false
/CropImagesToFrames true
/ErrorControl /WarnAndContinue
/FlattenerIgnoreSpreadOverrides false
/IncludeGuidesGrids false
/IncludeNonPrinting false
/IncludeSlug false
/Namespace [
(Adobe)
(InDesign)
(4.0)
]
/OmitPlacedBitmaps false
/OmitPlacedEPS false
/OmitPlacedPDF false
/SimulateOverprint /Legacy
>>
<<
/AddBleedMarks false
/AddColorBars false
/AddCropMarks false
/AddPageInfo false
/AddRegMarks false
/ConvertColors /ConvertToCMYK
/DestinationProfileName ()
/DestinationProfileSelector /DocumentCMYK
/Downsample16BitImages true
/FlattenerPreset <<
/PresetSelector /MediumResolution
>>
/FormElements false
/GenerateStructure false
/IncludeBookmarks false
/IncludeHyperlinks false
/IncludeInteractive false
/IncludeLayers false
/IncludeProfiles false
/MultimediaHandling /UseObjectSettings
/Namespace [
(Adobe)
(CreativeSuite)
(2.0)
]
/PDFXOutputIntentProfileSelector /DocumentCMYK
/PreserveEditing true
/UntaggedCMYKHandling /LeaveUntagged
/UntaggedRGBHandling /UseDocumentProfile
/UseDocumentBleed false
>>
]
>> setdistillerparams
<<
/HWResolution [2400 2400]
/PageSize [612.000 792.000]
>> setpagedevice