Indian Journal of Engineering & Materials Sciences

Vol. 29, June 2022, pp. 355-365

Influence of TAC/TI/Si3N4 on mechanical and corrosion performance of

AA7075 alloy matrix composite processed by stir processing route
J Pradeep Kumara, D S Robinson Smart a*, & Kuldeep Kr Saxenab
a
Department of Mechanical Engineering, Karunya Institute of Technology and Sciences, Coimbatore, Tamil Nadu 641 114, India
b
Department of Mechanical Engineering, GLA University, Mathura, Uttar Pradesh 281 406, India

Received: 25 January 2022; Accepted: 16 February 2022

In modernistic years, Metal Matrix Composites (MMCs) are becoming enchanting in fields of aerospace, military,
defence and automobile applications reason being they offer merit such as high strength to weight proportion, good
tribological, good corrosion resistance, excellent fatigue and creep performance and good bending behaviour etc. In the
current research, an attempt was made to synthesize AA7075 blended with distinct wt% of Titanium (Ti), Tantalum Carbide
(TaC) and Silicon Nitride (Si3N4) multi hybrid MMCs were examined. Microstructural, flexural, corrosion and low cycle
fatigue aspects of the developed multi hybrid MMCs were examined as per ASTM standard. The brittleness of Si3N4, TaC
and Ti particulates structured with the interface betwixt matrix culminates in increment in the flexural strength of the
composite. The bending analysis clearly shows that, TaC and Si3N4 are the major contributing materials for flexural aspect
because the presence of hard ceramic particulates restricts the dislocation movement by providing additional strength.
Microstructural analysis reveals the existence of reinforcements. Also, homogeneous dissemination and good interfacial
bonding betwixt the matrix and reinforcement particulates were noticed. AA7075 reinforced with 1 wt% Ti, 6 wt% Si3N4
and 0.5 wt% TaC operated at higher load (1500 N) and higher number of cycles 14103 cycles with a stable strain rate. The
number of cycles to failure was observed to be enhanced for the matured composites on account of an inconsequential
percentage of induced plastic strain.

Keywords: Corrosion, Fatigue, Flexural, Mechanical behaviour, Stirring, Tantalum Carbide

1 Introduction conventional monolithic materials3. The aluminium

In the present contemporary engineering based MMCs shown colossal probable in the multeity
environment, the demand for new age materials with of aircraft, ship, motorcar and diverse transport
ultra-light weight along with significant strength, wagons due to its less weight to potency correlation,
toughness, hardness, stiffness and wear resistance good mechanical workability, desirable corrosion
brought out the evolution of composite materials. The defiance and comparatively smaller price4. Generally
main purpose of using composite material is the composite material consists of base alloy known as
influence of attaining property consolidations that can matrix and ceramic reinforcements to escalate the
result in several service assists1. MMCs are a unique overall attribution of the material. The consolidation
origination of composites that provide the capability of matrix and reinforcement composition exhibits
of assisting the growing insistence for progressed lesser density, high hardness, lesser coefficient of
engineering utilizations such as transportation, expansion, reasonably larger elastic modulus and
structural, thermal, electrical, marine, aerospace, corrosion defiance which prefers to be a potential
automobile, defence and military due to its enhanced candidate for diverse applications like aero-frame
strength to weight ratio, stiffness, good damping structures, space shuttle components, knuckle
capability, good wear and creep resistance over housing, suspension arm, piston rings, landing gear,
monolithic alloy2. Compared to polymer and ceramic connecting rods etc5. The main merits of particulate
matrix composites, MMCs are widely accepted based MMCs include excellent metallic properties.
material and subjected to research and development AA7075 is a light weight material. Because of high
over the past few decades. However, MMCs can strength and high toughness and capability of
operate at elevated temperatures when compared to withstanding elevated temperature AA7075 are
—————— mainly utilized in aerospace, defence, military and
*Corresponding author (E-mail: [email protected]) automobile applications. Addition of hard ceramic
356 INDIAN J ENG MATER SCI, JUNE 2022

reinforcements does not change the overall density of matrix, grain intensity, and strain gradient
the material but improve the specific strength. Several strengthening ramification of composites. It was also
fabrication techniques have been developed for noticed that increase in mass fraction of B4C behaves
production of MMCs. Among all of these, Mechanical as a disincentive to abide the dislocation movement to
Stir Casting (MSC) is more rottenly and exhaustively bring on larger hardness compared to matrix. Abhijit
utilized6. In MSC, reinforcing particles might be Bhowmik et al.10 investigated the wear aspects of
fragmented during stirring. Mechanical stirrer AA7075 blended with SiC hybrid MMCs processed
material gets eroded incessantly during stirring and by mechanical casting technique. Microstructural and
eroded particles are mixed with composite. This leads pin on disc wear analysis were carried. The results
to unpretentious quality of AMCs. According to reveal that wear rate; specific wear rate enhances with
Hashin Shtrikman bound theory, the composites decrease in COF was noticed with increment in
strength can be greatly upgraded by the adjustment of sliding distance. Huge amount of flash temperature
reinforcing particulates and depending upon the was formed in betwixt the disc and the pin surface.
theory, disparate researchers attempted enormous COF was noticed to be declined due to the interfacial
numbers of additives in the matrix for several contact temperature which was found to be increased
applications7. The intention of utilization of ceramic between the two surfaces. Worn surface morphology
reinforcement material is to further enhance showed the formation of mechanically mixed layer
various mechanical, corrosion, thermo-mechanical, that enhances the material removal rate. Salihi et al.11
microstructural and tribological properties of chosen investigated the mechanical and wear behaviour of
matrix material. In order to evaluate the quality of the AA7075 reinforced with 5 wt% Al2O3 particulates
newly developed metal matrix composite materials, processed through stir casting technique. The tensile,
mechanical and corrosion analysis of materials such wear and hardness of the developed composite
as tensile, compression, hardness, creep and fatigue significantly enhanced with the addition of
etc is mandatory. Fayomi et al.8 explored the reinforcement. The hard ceramic particulates impart
microstructural and tribological etiquette of 8011 their strength from matrix to the reinforcing nano
aluminium alloy blended along ZrB2 and Si3N4 nano particles. The improvement in strength was observed
particulates fluctuating up to 20 wt%. The MMCs from matrix strengthening followed by reduction in
were developed using two step stir casting technique grain size.
was utilized with optimal process parameters. The From the detailed literature outline, it was noticed
tribological characterization was experimented at that the effect on addition of reinforcement materials
disparate loads of 20N to 40 N placing alternate such as Si3N4, TaC and Ti in the aluminium matrix
parameters constant like the travel stretch of 5000 m, has not explored much. Also, high and low
sliding pace of 3 mm/s and duration of 60 seconds. As temperature behaviour of aluminium based composite
the wt% increases, the wear rate found to be reduced. materials is not reported widely. Tantalum carbide
This reduction in wear rate was because of the firm (TaC) is one of the primary and expensive ceramic
interfacial adherence and complete wettability betwixt reinforcement material that could serve the purpose of
matrix and reinforcement. Also, the advanced MMCs withstanding high temperature. Therefore, for low
could be associated to the mixed consequence of the economy applications, this particular reinforcement
grain conversion at the time of fabrication, particular cannot be used. In order to enhance the hardness
strengthening characteristics and load-bearing above a particular limit, the material becomes more
capacity of hard ceramic materials. Ramadoss et al.9 brittle. Therefore, the material may not be suitable for
developed Al7075 hybrid composite blended with applications such as heavy cutting tools due to its
B4C and BN manufactured by stir casting route extreme hardness. AA7075 reinforced hybrid MMCs
mainly for marine application. The selected can be utilized for all other engineering applications
reinforcements were consistently dispersed over the related to high and low temperature environmental
base alloy along with the clustering of particulates condition.
inclusion in single spot over the grain boundaries. By In the present research work, the new age multi
increasing the wt% of reinforcements, tensile and hybrid composite dealing with AA7075 as the base
compression strength found to be high because of matrix and Si3N4/TaC and Ti as the reinforcements
good interfacial bonding betwixt the reinforcement & has been processed by utilizing the traditional stir
 KUMAR et al.: INFLUENCE OF TAC/TI/SI3N4 ON MECHANICAL AND CORROSION PERFORMANCE OF AA7075 357

casting method owing to its benefits like simplicity, Table 1 — Empirical Configuration of aluminium 7075 alloy
low cost, and easy portability. The reinforcements Elements Si+Fe+Ti+ Cu Mg
were added in fluctuating proportions by weight and Ni+Zr+Mn
the developed multi hybrid composites exposed to Minimum (wt%) 1.33 1.2 2.1
several mechanical and corrosion analysis. The Maximum (wt%) Fpedal 2.0 2.9
current exploration was focused to interpret the Elements Si+Fe+Ti+ Cu Mg
outcome of microstructural, corrosion, flexural and Ni+Zr+Mn
fatigue behaviour of AA7075/Si3N4/TaC/Ti multi Minimum (wt%) 1.33 1.2 2.1
hybrid MMCs and thereby develop a composite that Table 2 — Formulation of base alloy and reinforcements
could serve turbine, defence, military and automobile Configuration Quantity of Quantity of
applications particularly mechanical components such matrix (wt%) reinforcements (wt%)
as pistons, brake disks, cylinder head, inlet, and AA7075 Ti Si3N4 TaC
exhaust manifold, wind turbine blades and camera B1 100 0 0 0
dome etc. B2 91.25 0.5 8 0.25
B3 92.5 1 6 0.5
B4 93.75 1.5 4 0.75
2 Materials and Methods
B5 95 2 2 1
2.1 Matrix Material
Among various groups of aluminium alloys, 7000 the need for UHTC materials for wing leading edges
series of aluminium alloy known for its immense and nose tips, as well as propulsion system
strength, reduced defiance to stress corrosion cracking components. Group IV and V elements such as
and afford advance combination of strength, fracture borides, carbides and nitrides, as well as mixtures
toughness and corrosion resistance. AA7075 is widely based on these compounds are some of the UHTC
used for its high mechanical strength to weight ratio, materials. UHTCs are the most widely studied
but is still the subject of several studies to further materials due to their good oxidation resistance from
improve its mechanical properties. AA7075 is also room temperature to over 2000°C.
known as aluminum–zinc alloy due to the maximum TaC is one of the Ultra-High Temperature Ceramics
zinc content ranging betwixt 5.1 and 6.1 percentage (UHTC) and an transition metal carbide that is
with minimal fraction of magnesium12. In the current suitable for high temperature applications such as
research work, commercially available AA7075 in the camera dome used in military vehicles, aerospace and
form of ingots were utilised as the matrix alloy. The rocket propulsion systems14. Generally, TaC has
maximal melting point (3985°C) amidst the UHTC
empirical configuration of AA7075 was illustrated in
group of materials. Likewise huge melting point, TaC
Table 1. Due to the presence of zinc as major alloying
is preferred for its high elastic modulus, good wear
element in AA7075, it is demonstrated to be
protection, chemical inertness and balanced thermal
providing higher efficiency correlate to various coefficient of expansion operating in various areas of
materials like steel and has acceptable fatigue rocket nozzles, cutting tools etc15. TaC with average
firmness with mediocre machinability13. particle size 200 – 250 nm was used. Embodiment of
hard ceramic particulates like Si3N4 acts as a solid
2.2 Reinforcement Materials
lubricant on the base alloy that enhances the abrasive
In the present investigation, aluminium based and sliding wear resistance of composites. Si3N4
MMCs containing TaC, Ti and Si3N4 ceramic consists of hard ceramic particles with high
reinforcement particulates with distinct wt% was mechanical strength, capability of withstanding high
preferred based on trial experiments and previous temperature and good tribological characteristics.
research works. Based on several preliminary Si3N4 was selected with average particle size of 40 nm
approaches, the combination of reinforcements in based on previous studies16. Titanium is exceptionally
terms of wt% is illustrated in Table 2. UHTC are a an interesting hard ceramic material because of its
family of compounds that display a unique set of high hardness, low density, high elastic modulus,
properties, including extremely high hardness, high modified thermal characteristics and high specific
melting temperature, and chemical stability and strength with good fatigue properties. However,
strength at elevated temperatures. The increasing standard particle size of 70 µm was utilized
interest in hypersonic vehicles and weapons points to depending on preceding examinations17.
358 INDIAN J ENG MATER SCI, JUNE 2022

2.3 Synthesis of Composite Materials 2.5 Static Immersion type Corrosion Analysis
AA7075 with different weight fraction of As per ASTM G31-72 standard, stationary
TaC/Si3N4/Ti HMMCs were developed using immersion type corrosion experiment was operated on
conventional stir casting technique 18. Stir casting the advanced aluminium HMMCs at ambient
process make high kind aluminium based HMMCs. In atmospheric condition. Generally, Hydrochloric acid
this approach, the AA7075 blocks were originally (HCl) is more acidic when compared to Sodium
held in a graphite crucible at 650°C. Simultaneously Chloride (NaCl) and Sulfuric Acid (H2SO4) solution.
the procured ceramic particulates were foreheated at Hence, HCl acidic solution was used as corrosive
550°C in a foreheater available with the furnace. habitat for the analysis 21. The corrosion testing
Mechanical stirring using a motor was appropriate in samples is shown in Fig. 1. The prepared corrosion
order to accomplish homogeneous dissemination of testing templates were glistened physically utilizing
reinforcement in the matrix material 19. The melt was distinct levels of emery papers to attain smooth
blended at constant rotational speed of 200 rpm surface. Since there are five different composite
utilizing a mechanical stirrer to acquire a passable specimens, five beakers were taken and cleaned
vortex for approximately 5 minutes. The thoroughly using distilled water. The experiment was
reinforcement powders were foreheated and supplied started by filling the beakers with 90 ml of HCl and
to the molten melt at a stable feed rate into the vortex 10 ml of distilled water solution. Before immersing in
of aluminium melt. Thereafter, the liquid alloy was HCl environment, the prepared samples were properly
discharged in the rectangular long-lasting metallic die cleaned with distilled water and drowned in methanol.
of the size of 10 mm in thickness, 100 mm in width Individual sample was scaled before and after each
and 100 mm in length and the mould temperature was experiment. The loss in weight (milligrams) of
confessed to diminish at ambient atmosphere. Later, AA7075/TaC/Si3N4/Ti HMMCs specimens with distinct
the developed HMMCs were shaped by SH300 wt% was obtained by computerized weighing machine.
medium speed wire cut EDM machine (Make: S&T The retrieved weight was reconstructed in the form of
Engineering Pvt. Ltd., Coimbatore, Tamilnadu, India) rate due to corrosion. From the weight loss, the rate due
to develop various testing samples for evaluating the to corrosion was inspected exploiting consecutive
microstructural, flexural, corrosion and fatigue association as displayed in Eq. (1).
behaviour according to ASTM standards. 𝐾×𝑊
𝐶𝑜𝑟𝑟𝑜𝑠𝑖𝑜𝑛 𝑅𝑎𝑡𝑒 = … ( 1)
2.4 Metallographic Examinations 𝐴×𝐷×𝑇
The microstructural analysis of the developed Therefore, K is conversion factor (87.6), T is the
HMMCs was studied by opting computerized optical submerged duration (hours), A is the sample region
microscopy. As per ASTM standard, the samples of (cm2), W is the fall in mass (milligrams) & D is the
proportion 10 x 10 x 10 mm3 were developed by wire composite density (g/cm3).
cut EDM machine and then polished with distinct
grades of emery sheets for determining an articulate 2.6 Flexural Strength Analysis
periphery for microstructural investigation. To In most of the defence and aerospace applications,
analyse the progressive microstructure of the the failure of aircraft wings and other mechanical
composites, chemical etchant called Keller’s reagent components occur due to heavy structural load.
was utilized to polish the circumference of the test Therefore, flexural analysis needs to be conducted to
specimens and was dehydrated in atmospheric air evaluate the flexural properties of the developed
using air gun for 30 seconds 20. Scanning Electron composites. The flexural analysis provides values for
Microscopic (Make: JEOL, Japan – JSM 6390) the modulus of elasticity in bending, flexural stress
investigations were carried out to evaluate the and flexural strain. Three andfour point bending
micrographs of the opted alloy and reinforcements. experiments was executed to reveal the flexural
Later, EDAX was exploited to perceive the
configuration of the matrix and the X-ray Diffraction
(XRD) was treated to affirm that, there’s a
satisfactory amalgamation of reinforcements with
base alloy. Fig. 1 — Corrosion test samples.
 KUMAR et al.: INFLUENCE OF TAC/TI/SI3N4 ON MECHANICAL AND CORROSION PERFORMANCE OF AA7075 359

strength of AA7075 grade with distinct wt% of 𝑁 𝑀×𝑦

𝐹𝑙𝑒𝑥𝑢𝑟𝑎𝑙 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ = … (3)
Si3N4/TaC/Ti particulates. In three and four point 𝑚𝑚 𝐼
flexural strength analysis, the maximum bending load 𝑁 3×𝑃×𝐿
was investigated. This load data was altered into 𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑓𝑙𝑒𝑥𝑢𝑟𝑎𝑙 𝑠𝑡𝑟𝑒𝑠𝑠 = … (4)
𝑚𝑚 2×𝑏×𝑡
flexural strength (MPa). The flexural test samples
were displayed in Fig. 2. The flexural experiments Whereas, D – Maximum deflection at centre (mm),
were executed using the servo operated universal d – Thickness of the specimen (mm), L – Span length
testing machine, to obtain the flexural strength of the (mm), P – Load (N), b – Width of the sample (mm),
multi hybrid MMCs and base alloy. Flexural strength, t – Thickness of the sample (mm), M – Bending
flexural strain and maximum flexural stress were moment (N-mm), Y – Natural axis distance (mm),
determined based on the following Eqs2 – 4 shown I – Moment of Inertia (mm4).
below. Before testing, the specimens were cut 2.7 Low cycle Fatigue Strength Analysis
according to ASTM A370 using wire cut EDM Fatigue analysis is important to determine the
machine and polished metallographically. Four maximal weight that a specimen can endure for a
composite specimens for each composition with a size particular number of cycles. The main logic for
of 140  20  11 mm3 were tested with a loading rate fatigue failure are number of cycles, range of stress
of 0.5 mm/min and a span length of 80 mm (three and local stresses 22. To figure out the fatigue strength
point analysis) and 20 mm (four point analysis). The at ambient atmospheric condition, fatigue experiments
average flexural strength of the composites, and base were regulated on the developed HMMCs confirming
alloy was found. to ASTM E606 regulation as shown in Fig. 3.
Initially, the fatigue samples as shown in Fig. 4 were
6×𝐷×𝑑 developed from the casted specimens utilizing
𝐹𝑙𝑒𝑥𝑢𝑟𝑎𝑙 𝑠𝑡𝑟𝑎𝑖𝑛 = … (2)
𝐿 medium speed wire-cut EDM machine.

Fig. 2 — Flexural test samples as per ASTM standard.

Fig. 3 — Geometry of Fatigue test specimen as per ASTM.

360 INDIAN J ENG MATER SCI, JUNE 2022

For different loading conditions, maximum three reinforced with TaC/Ti/Si3N4 multi hybrid MMCs
samples were prepared for each composition of the were explored. Also, the effect of reinforcements on
aluminium HMMCs. Strain controlled, tensile- the AA7075 matrix material were also acknowledged
compression fatigue experiments were conducted by and discussed in detail.
mounting the fatigue specimens on the computerized
3.1 Microstructural Exploration of AA7075/Si3N4/TaC/ Ti
hydraulic load-controlled fatigue testing machine Hybrid Composites
(Make: AVJ Engineering Pvt. Ltd., Coimbatore, Figure 5 displays the typical optical micrograph of
Tamilnadu, India) equipped with standard load cell. etched unreinforced AA7075 and reinforced AA7075
The fatigue testing machine has an average reinforced with distinct wt% of reinforcements. From
fluctuation ranging from 20 – 40 cycles/min and the microstructural observations, it was confirmed
maximum weight capacity of 1000 kg, corresponding that reinforcement particulates are homogeneously
to 50 – 90 % of yield stress. During experimentation, circulated over the cross sectional area and it was
if the material fails at stress data a minimal stress is established that, the conglomeration of particulates of
incorporated for the next sample and if the sample reinforcement incorporation in particular region and
doesn’t break down the test is continued with a larger along the grain perimeters of alloy material. This
stress data. The total cycles to induce the overall confirms the performance of the liquid metallurgy
calamity or partition of specimen are considered as route used in flourishing the HMMC. It was observed
fatigue life (Nf). A median of three outputs were that the prepared hybrid specimens display the
analysed as fatigue life (Nf) of every specimen. dissemination of the dark coloured particulates in
bright base material 23. Therefore, opaque
3 Results and Discussion reinforcement particulates do not reflect light and
In this section, various significant outcomes such appear dark in reflective base alloy area. Therefore,
as microstructural, corrosion, flexural and low cycle the reinforcement particulates show definite
fatigue characteristics of the developed AA7075 geometrical grains. The morphology also reveals a

Fig. 4 — Fatigue specimens.

Fig. 5 — Optical micrograph of (a) Pure AA7075, (b) AA7075+0.25wt%TaC+8wt%Si3N4+0.5wt%Ti, (c) AA7075+0.5wt%TaC+6wt%
Si3N4+1wt%Ti, (d) AA7075+0.75wt%TaC+4wt% Si3N4+1.5wt%Ti, and (e) AA7075+1wt%TaC+2wt% Si3N4+2wt%Ti.
 KUMAR et al.: INFLUENCE OF TAC/TI/SI3N4 ON MECHANICAL AND CORROSION PERFORMANCE OF AA7075 361

durable interfacial bonding, excellent wettability HMMCs as well as pure AA7075 decreased linearly
betwixt the TaC/Si3N4/Ti and base alloy (AA7075). with increase in exposure duration in HCl medium.
The durable intermetallic adherence, good wettability Generally, it has been found that the aluminium
betwixt the perpetual matrix constituent and the reinforced composites displayed exceptional
disconnected ceramic constituent, and the corrosion resistance when correlated with the pure
homogeneous dissemination can be associated to aluminium alloy. Corrosion rate was found to be
the procedure specifications obtained from stir higher at initial period due to the absorption of
casting 24. chloride content on the surface of the composite and it
was the first stage of localized corrosion attack on the
It has been noticed that the higher concentration of
samples. Enhancing the weight fraction of the TaC
composite particles showed higher quantum of
and Ti particulates increases the corrosion defiance of
reinforced particles in the metal matrix. Some fine the HMMCs. The increase in mass loss with increase
particles of composite are also observed and it forms in time of exposure is an indication that the passive
the grain boundaries of primary aluminum. Fig. 6 film framed on the MMCs was unable to give
displays the SEM micrographs of AA7075 reinforced adequate fortification to the substrates. Increased
with distinct weight fraction of TaC/Si3N4/Ti duration of exposure in HCl solution tend to form a
particulates so that primary plots (matrix) and the passive protective layer composed of hydrogen
secondary plots (reinforcements) were clearly visible. hydroxyl chloride film during the corrosion reaction.
Minor casting deficiencies such as scratches, Moreover, deducing the wt% of Si3N4 particulates
porosity and asperities were noticed in the improved significantly the corrosion defiance of the
unreinforced alloy. However, the deliberately composite material. From the results acquired, it was
combined reinforcement particulates were dispersed clear that, AA7075 blended with 0.75 wt% TaC, 4
compatibly over the base material. These wt% of Si3N4 and 1.5 wt% of Ti shows better
homogeneous disseminations of reinforcement corrosion resistance in the presence of HCl solution.
particulates are required to improve the mechanical Compilation of passive lamina on the circumference
behaviour of HMMCs25. Nonetheless, the appropriate of the specimens and deduction of chlorides gist in the
interface betwixt the hard particulates and matrix acrid medium26. The specific mechanism of corrosion
sector with the desirable adherence of reinforcements inhibition TaC/Ti/Si3N4 to the surface of AA7075 can
be clearly defined by chemisorption process. The
in the base alloy was attained in the on-going research
chemisorption process is denoted by donor acceptor
activity. interaction between the lone pair of the electron from
3.2 Static Immersion type Corrosion Analysis of AA7075/ the orbitals of AA7075 alloy. The inhibition of
Si3N4/TaC/Ti Hybrid Composites corrosion begins by the displacement of molecules in
Figure 7 shows the rate of corrosion of AA7075 HCl medium by inhibitors capacity towards toward
reinforced with different wt% of TaC/Si3N4/Ti specific adsorption of the inhibitor on the metal’s

Fig. 6 — Optical micrograph of (a) Pure AA7075, (b) AA7075+0.25wt%TaC+8wt%Si3N4+0.5wt%Ti, (c) AA7075+0.5wt%TaC+6wt%
Si3N4+1wt%Ti, (d) AA7075+0.75wt%TaC+4wt% Si3N4+1.5wt%Ti, and (e) AA7075+1wt%TaC+2wt% Si3N4+2wt%Ti.
362 INDIAN J ENG MATER SCI, JUNE 2022

Fig. 7 — Variation in rate of corrosion with respect to exposure time.

Fig. 8 — Variation of maximum flexural stress of the developed hybrid composites time.
surface. Minimum research has been reported on the obtained from three point and four point flexural
improvement in corrosion resistance of analysis is displayed in Fig. 8 illustrates that the
AA7075/TaC/Si3N4/Ti HMMCs. This reduction in the flexural strength enhanced with the inclusion of Si3N4,
rate of corrosion may be due to the significant TaC and Ti. It was found that the breaking load and
decrease in pitting potential in the developed
flexural strength was observed to be higher for
composite material. Addition of titanium is one of the
dominant reason for reduction in corrosion rate of the composite material when compared to base material.
developed composite material because it is hard and The structure and properties of the ceramic
does not furnish any chemical revulsion with reinforcements controls the overall mechanical
aluminium to generate any secondary phase27. properties of the composites that are reasoned to
3.3 Flexural Strength Analysis of AA7075/Si3N4/TaC/Ti
strong interfacial bonding that transfers and
Hybrid Composites distributes the load from the matrix to the
The flexural strength of pure AA7075 base reinforcements exhibiting increased elastic modulus
material and the developed composite material and strength of the composite material. The structure
 KUMAR et al.: INFLUENCE OF TAC/TI/SI3N4 ON MECHANICAL AND CORROSION PERFORMANCE OF AA7075 363

and characteristics of the reinforcements controls the modes and the total number of cycles completed by
mechanical behaviour of the MMCs that are reasoned each of the developed composite material at various
to strong interface that transfers and distributes the loading conditions. Also, the table shows the various
load from the matrix to the reinforcements exhibiting stress levels and elongation obtained by the developed
increased elastic modulus and strength. The HMMCs. During experimentation it was noticed that
brittleness of the Si3N4, TaC and Ti particulates well- the established composite material unveiled ductile
ordered with the interface betwixt matrix leads to the nature at 0.5 wt% TaC, 6 wt% Si3N4 and 1 wt% Ti by
increment in the bending strength of the MMCs and it elongating up to 0.36 mm as shown in Fig. 10.
was observed to be larger than that of matrix material. Beyond this composition slight reduction in ductility
The composite material with 0.5 wt% TaC, 6 wt% was observed because of the increment in hardness of
the HMMCs. It was clearly showed that, the proposed
Si3N4 and 1 wt% Tishowed maximum flexural
HMMCs showed higher fatigue life in comparison
strength of 349.175 N/mm2 compared with pure
with unreinforced alloy. The renovation in the fatigue
AA7075 that showed 190.432 N/mm2 for threepoint
firmness of the matured HMMCs was symbolic at
bending analysis. Also, composite material with 1 smaller stress levels compared to higher stress levels.
wt% TaC, 2 wt% Si3N4 and 2 wt% Ti showed It was also observed that AA7075 reinforced with
maximum flexural strength of 88.582 N/mm2 0.5wt% TaC, 6wt% Si3N4 and 1 wt% Ti displays
compared with pure AA7075 that showed 64.505 higher fatigue life by operating at higher tension-
N/mm2 for four point bending analysis. This analysis compression cycles at varying loading condition,
clearly shows that, TaC and Si3N4 are the major when compared to other developed HMMCs. Smaller
contributing material for flexural behaviour of the addition of tantalum carbide and titanium enhances
material because hard ceramic materials restricts the the fatigue life of the developed MMCs to a greater
dislocation movement by providing additional extent. At this composition the composite material
strength to the material. The flexural strength was showed ductile ability of the material. The localized
enhanced by 45% than that of AA7075. sectors of ductile deficiency provoked by the
commonly combined structures of fluctuation slip and
3.4 Low Cycle Fatigue Analysis of AA7075/Si3N4/TaC/Ti fracture tip blunting. The inception of the microscopic
Hybrid Composites cracks initiated from aluminium caused by fatigue due
Figure 9 shows the variation of typical stress versus to periodic weighing very likely associated to the
number of cycles plot deformation for the developed cumulative aggregation of micro-plastic attrition at
hybrid MMCs. This clearly reveals that, the failure the restricted region28. This inferred that cyclic

Fig. 9 — S/N plot for the developed hybrid MMCs.

364 INDIAN J ENG MATER SCI, JUNE 2022

Fig. 10 — Elongation obtained from various samples.

hardening happened during the periodic nature of this experimental investigation are summarised
distortion. This spontaneously demonstrated that below.
original periodic hardening happened with periodic  AA7075 alloy reinforced with different wt% of
behaviour of distortion and then initiated with TaC, Si3N4 and Ti were manufactured by
balanced softening type29. From the analysis, the conventional stir casting technique by using
higher weight fraction of TaC, Si3N4 and Ti particles optimum casting process parameters.
demonstrated remarkable enhancement in fatigue  Microstructural analysis reveals the presence of
firmness of the HMMCs while correlated with the reinforcements and almost homogeneous
base matrix alloy. This phenomenon was associated distribution with good interfacial bonding
with the occurrence of solid TaC, Ti and Si3N4 betwixt the matrix and reinforcements.
particulates. When the weight fraction of the  AA7075 reinforced with 0.75 wt% TaC, 4 wt%
reinforcement particulates enhances the fatigue nature of Si3N4 and 1.5 wt% Ti showed enhanced
of the HMMCs due to the momentous quantity of the corrosion resistance. Reduction in the rate of
weight being relocated to the arthritic particulates and corrosion may be due to the significant decrease
overall strains at a given fatigue stress. in pitting potential of MMCs and the formation
Also, enhancement in fatigue firmness very likely of the passive protective layer composed of
associated to the reduced plastic and elastic strains hydrogen hydroxyl chloride film.
that outcome from the magnitude of work hardening  The HMMCs with 0.5 wt% TaC, 6 wt% Si3N4
and modulus, both of which enhances with enhancing and 1 wt% Ti showed maximum flexural
weight proportion of the particulates 30. Reduction in strength of 349.175 N/mm2. The brittleness of
porosity of the composite material attributes in Si3N4, TaC and Ti and the strong interfacial
improved fatigue life. The larger yield firmness of bonding between the matrix and the
advanced HMMCs is also culpable for admirable reinforcement. TaC and Ti restricts the
fatigue defiance. Adding to that, the excellent bonding dislocation motion by providing additional
betwixt matrix and reinforcement and finer grain size strength to the material.
is also a dominant parameter which persuaded the
enhanced fatigue resistance of developed HMMC. Improvement in fatigue life was noticed from the
When correlated with base matrix and cast HMMCs,
developed hybrid MMCs. Due to the cushioning
hot forged alloy and its MMCs displayed symbolic
enhancement in behaviour due to fatigue.
effect of the reinforcements, the developed
HMMCs with 0.5 wt% TaC, 6 wt% Si3N4 and 1
4 Conclusion wt% Ti operated at higher number of cycles. It was
In this research, attempts have been made to clearly evident, that a smaller wt% of TaC and Ti
fabricate and investigate various mechanical and improved the fatigue life to a larger extent.
corrosion characteristics of AA7075 based multi
hybrid MMCs using Si3N4, TaC and Ti as References
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