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International Journal of Engineering and Physical Sciences 6 2012



          On the Problem of Novel Composite Materials
               Development for Car Brake Rotor
                                                 P. R. K. Fu, A. Gorin, D. Sujan, Z. Oo
   Abstract—This paper presents a study of the potential materials                  This will most likely lead to warping of the disc
that are suitable for the development of the automotive brake disc.              brake.Therefore, higher thermal conductivity and higher
Two new materials are proposed as an alternative material to the                 specific heat capacity are most preferred to promote efficient
conventionally used gray cast iron for the disc brake, which are
                                                                                 thermal energy dissipation and hence avoid the overheating of
namely Metal Matrix Composite (MMC) and Functionally Graded
Material (FGM). MMCs with ceramic particulate reinforcement are                  the disc brake. Subsequently, this leads to the development of
found to have a low density and high thermal conductivity compared               advanced materials for the disc brake.
to the cast irons. Two particulate reinforcements, Al2O3 and SiC were               The main contribution of this paper is two-fold. First, we
being considered for MMC. On the other hand, FGM has                             fabricate the two proposed materials. Second, we perform a
demonstrated high thermal shock resistance, better wear resistance               study on these materials, specifically their hardness property
and low density. Preliminary investigation indicated that MMC
                                                                                 and their characteristic results are analyzed towards the end of
acquired improved hardness property. Meanwhile, the hardness
property of FGM with Al2O3 and Al2TiO5 as layered composites                     this paper.
materials can be further improved.                                                  The rest of this paper is organized as follows. The detailed
                                                                                 description of MMC and FGM are reported in Section II and
  Keywords—Automotive disc brake, functionally graded material,                  III respectively. Section IV listed the procedures required in
metal matrix composite                                                           our experimental work on the fabrication of MMC and FGM
                                                                                 materials and the hardness test. The results derived from our
                         I. INTRODUCTION                                         experiments are analyzed and discussed in Section V.

A     N automotive brake disc is a device that slows or stops
      the motion of a wheel while it runs at a certain speed. The
construction of an adequate brake disc that satisfies the
                                                                                 Concluding remarks are drawn in Section VI.

                                                                                                  II. METAL MATRIX COMPOSITE
increasing demand for low maintenance car has been a popular                        A composite material is a material consisting of two or more
research in the automotive manufacturing area.                                   physically and/or chemically distinct phases. The reinforcing
   In general, an automobile brake system consists of a brake                    component is distributed in the continuous or matrix
disc and brake pads in order to maintain a steady friction                       component. When the matrix is a metal, the composite is
coefficient. Braking system is a vital safety component of the                   termed as Metal Matrix Composite (MMC) [4]. MMCs are
ground-based transportation systems. Thus the structural                         popular substitute materials for automotive, satellite systems,
materials used in developing the brakes have to fulfil a series                  ballistic protection, general industries, sporting goods, aviation
of functions. They ought to be dependable, durable, corrosion                    and are also vastly applied in other engineering fields. This is
resistant, structurally sound, and economically viable [1]. Most                 because MMC possesses excellent mechanical properties and
disc brake rotors in use today are made from gray cast iron,                     wear resistance. Research showed that the wear resistance of
typically containing 2% to 4.5% dissolved carbon within its                      the MMC can be attributed to the strength and hardness of the
matrix and various additives as well [2]. Due to its low cost,                   SiC particles [3]. If the SiC particles remain well bonded to the
relatively ease of manufacture and thermal stability, cast iron                  matrix during the sliding wear process, the aluminium matrix
is a more specialized material for brake applications                            surrounding them will be worn away and all contacts will be
particularly for almost all the automotive brake dics. Gray cast                 between the friction material and SiC particles in the
iron possesses low thermal conductivity (47.3W/m°C) and low                      composite. Therefore, the wear resistance of the composites is
specific heat capacity (0.498J/g.K) [3].          The hydraulic                  related to the hardness property of the SiC particles. In
pressure exerted during typical braking procedures, lies                         addition, Zhang and Wang [5] found that the friction
between 2MPa and 4 MPa. Friction makes rotor reach (within                       performances and wear resistance for brake material sliding
a very small periods of time), temperatures as high as 800°C,                    against drum brake with large-size SiC particles are better than
resulting in a thermal gradient between the surface and the                      those against the drum brakes with small-size SiC particles.
core of the rotors, which may reach up to 500°C.                                 Other than that, Tatar and Ozdemir [6] found that the thermal
                                                                                 conductivity of the Al2O3 particulate reinforced aluminium
   P. R. K. Fu is with Curtin University of Technology Sarawak Campus,
                                                                                 composites (Al/Al2O3-MMC) decreased with the increasing of
CDT 250, 98009 Miri (phone: +6085-443939; e-mail: kimbuali@gmail.com).           Al2O3 volume fraction. They found that Al-MMC 45 vol%
   A. Gorin was with Curtin University of Technology Sarawak Campus. He          Al2O3 showed a lower thermal conductivity as compared to Al-
is now with the Department of Chemical Engineering, Swinburne University
                                                                                 MMC 15 vol% Al2O3. Hence in this paper, the hardness
of Technology Sarawak Campus, Jalan Simpang Tiga, 93350 Kuching (e-
mail: agorin@swinburne.edu.my).                                                  property is investigated by varying the weight fraction (from
   D. Sujan is with the Mechanical Engineering Department, Curtin                5% to 15%) of the reinforcement particles (SiC and Al2O3) in
University of Technology Sarawak Campus, 98009 Miri (e-mail:                     the MMC. Other than that, large-size SiC particles will be used
d.sujan@curtin.edu.my).
   Z. Oo is with Curtin University of Technology Sarawak Campus, CDT             as well.
250, 98009 Miri (email: zeya.oo@curtin.edu.my)




                                                                           333
International Journal of Engineering and Physical Sciences 6 2012




           III. FUNCTIONALLY GRADED MATERIAL                             among the metal matrix more evenly [11]. Stirring was done
   Functionally graded materials (FGM) are defined as those              for 4 intervals, every 30 minutes for a duration time of 2 to 3
materials in which the volume fraction of two or more                    minutes. Stirring must not be done vigorously to avoid air
constituents is varied smoothly and continuously as a function           bubbles and impurities on the surface because that could lead
of position along certain dimension(s) of the structure [7].             to porosity. In order to achieve proper dispersion of particles
Functionally Graded Materials (FGM) has demonstrated to be               among the matrix metal, the temperature was reduced to
advantageous beyond mechanical applications extending to                 550°C. This was done to allow the liquid mixture to turn into a
electronic, optical, nuclear, biomedical, and other fields.              semi solid state so that when force was applied onto the
   Low et al [8] found that layered graded materials (LGM)               particles, there would be abrasive collision between both
formed by a homogeneous Al2O3 layer and a graded                         particles and matrix metal. After the final stirring, the molten
heterogeneous Al2TiO5/Al2O3 layer exhibited a relatively ‘soft’          metal composite was left to cool in the furnace overnight to
surface that encased a hard core. The presence of the ‘soft’             avoid rapid cooling. The final casted Al-MMC product was
surface regions is due to the high concentration of Al2TiO5,             then machined into specific specimen sizes. The above
which displays a low hardness value. Bueno et al [9] suggested           experimental procedures were repeated with Al2O3 as the
that further studies be conducted to establish the effect of             reinforcement particles.
different stacking orders and layer thickness on the mechanical             B. Functionally Graded Material
behaviour of the laminates. The method they have used in
                                                                            Aluminium titanate powder was created by properly
manufacturing the layered composites was slip casting. They
                                                                         synthesizing the rutile and alumina (Al2O3 + TiO2 → Al2TiO5)
discovered that laminated layer Al2O3-Al2TiO5 composite’s                provided and milled using a Rocklab ring mill. The primary
thermal conductivity similar to that of alumina (35.6W/m°C)
                                                                         focus of sample preparation was the creation of thin interface
[10]. The laminated layer Al2O3-Al2TiO5 composite showed
                                                                         of graded Al2O3/Al2TiO5 composite layers sandwiched
low wear rates.
                                                                         between an outer layer of Al2O3 and an inner layer of
   In this paper, the hardness property of FGM formed by                 Al2TiO5. Only three graded layers were included in most of
sandwiching thin interface of graded Al2O3/Al2TiO5 composite
                                                                         the samples comprising of a 75% Al2O3 / 25% Al2TiO5 grade
layers between an outer layer of Al2O3 and an inner layer of
                                                                         located next to the Al2O3 outermost layer followed by a 50%
Al2TiO5 is studied.
                                                                         Al2O3 / 50% Al2TiO5 grade then a 25% Al2O3 / 75% Al2TiO5
                                                                         grade which was located next to the Al2TiO5 innermost layer
               IV. EXPERIMENTAL PROCEDURE
                                                                         (Figure 1). Layering was done by the use of a 15 mm inner
   The materials used for fabricating MMC are aluminium                  diameter cylindrical steel die. 2 mm thickness of Al2TiO5 was
alloy A356 as a matrix material and silicon carbide, SiC                 placed first into the die before a layer of 25% Al2O3 / 75%
(105µm) as reinforcement particles. MMC is being fabricated              Al2TiO5 was placed on top, followed by 50% Al2O3 / 50%
by melting the metal in a furnace then reinforcement particles           Al2TiO5, 75% Al2O3 / 25% Al2TiO5 and finally 1 – 4 mm of
are being added in and stirred slowly. As for FGM,                       Al2O3. The graded layers varied in thickness with either all of
commercial rutile (TiO2) and alumina (Al2O3) were used as                them being 0.1 mm, 0.3 mm, 0.5 mm or 0.7 mm thick. The
materials. Uniaxial press is used to sandwich the graded layers          samples were then uniaxially pressed at 5000 PSI for 20
together.                                                                seconds by a Blackhawk Uniaxial Press. Three batches of
   A. Metal Matrix Composite                                             graded materials were produced, all at varied sintering
                                                                         temperatures and methods of pressing. The first batch
   Aluminium alloy A356 rods were first cut into smaller
                                                                         comprised of non-graded, 0.1 mm graded layers, 0.3 mm
pieces with each 1cm thickness. 500g of 1cm thickness with
                                                                         graded layers, 0.5 mm graded layers, 0.7 mm graded layers
each piece of aluminium alloy and 3 wt% of magnesium
                                                                         and four 50/50 graded layer (0.1 mm, 0.3 mm, 0.5 mm and 0.7
(wetting agent) were melted in the furnace at temperature of
                                                                         mm) samples that were sintered at 1500°C for an hour. The
700°C. Preheated reinforcement particles of silicon carbide
                                                                         second batch comprised of non-graded, 0.1 mm graded layers,
were then added into the molten aluminium alloy. The
                                                                         0.3 mm graded layers and 0.5 mm graded layers samples that
reinforced particles were preheated beforehand at 900°C in the
                                                                         were cold isostatically pressed and sintered at 1550°C for 1 ½
furnace to remove all the moisture on the particles’ surface for
                                                                         hours. The final batch was comprised of non-graded, 0.1 mm
better binding results. The compositions of composite
                                                                         graded layers, 0.3 mm graded layers and 0.5 mm graded layers
materials that were being fabricated were: Al with 0% SiC, Al
                                                                         samples that were sintered at 1515°C for an hour.
with 5% SiC, Al with 10% SiC, Al with 15% SiC all with
different weight percentage. Silicon carbide was added into the
molten metal matrix using the vortex method. Vortex was
created by stirring the molten material manually at a rapid
speed. Silicon carbide was then added at the side of the vortex
and stirring was done continuously for a few minutes. The
vortex method is believed to be able to distribute the particles                           Fig. 1 Graded layers FGM design




                                                                   334
International Journal of Engineering and Physical Sciences 6 2012




   C. Hardness Testing Procedure for MMC                                        B. Hardness Results for FGM
   Hardness test was being carried out by the Rockwell                          In Fig. 4, the highest hardness value in the FGM can be seen
hardness test apparatus. For this hardness test on the MMC                   at the beginning of the alumina layer. The hardness values
samples, the scale HRB was used. Based on the HRB scale, a                   decreased until it reached very low results of 0.4 GPa by the
load 100kgf is to be applied on the MMC sample through a                     end of the first graded layer, 75% Al2O3 / 25% Al2TiO5.
1/16 inch diameter spherical shaped steel indenter. The load                 Hardness in the homogeneous alumina layer should have been
was applied to the sample for a time of 10 seconds and the                   of a higher value as this layer should provide resistance to
hardness values were obtained immediately from the                           deformation by surface indenting or abrasion. This could have
apparatus.                                                                   been done in a number of ways such as using fillers or
   D.Hardness Testing Procedure for FGM                                      reinforcements in the alumina matrix. Another method of
   Vickers microhardness testing was utilized to calculate                   improving the protective properties of the homogeneous
hardness across the cross section of selected samples from the               alumina layer would be to increase the thickness of the layer
first two batches of the functionally graded materials (FGM)                 therefore it will take a higher load in order for cracks to
samples prepared. The selected samples consisting of non-                    propagate towards the first graded layer.
graded, 0.1 mm graded, 0.3 mm graded, 0.5 mm graded and                                                 18


0.7 mm graded samples were mounted in resin and the cross                                               16
section was polished from 20 µm surface roughness to 1 µm
surface roughness. Samples were indented across the cross                                               14



                                                                               Vickers Hardness (GPa)
section of the samples with an average of 6 indents per sample,                                         12

starting from the alumina layer to the aluminium titanate layer.
                                                                                                        10
The resulting indent was then viewed under a microscope and
measured for radial crack length and indent diameter in order                                            8


to calculate hardness (GPa).                                                                             6


                                                                                                         4
                  V. RESULTS AND DISCUSSION
                                                                                                         2

   A. Hardness Results for MMC
                                                                                                         0

   From Fig. 2 and Fig. 3, it can be observed that the hardness                                              0          1          2          3            4           5         6           7           8            9

                                                                                                                                                          Distance (mm)
property for MMC increased with the increased of particle                                                    1500 1hr 0.7mm layers AL~4mm         1500 1hr 0.3mm layers AL~4mm       1500 1hr 0.5mm layers AL~4mm
reinforcements (Al2O3 and SiC).                                                                              1550 1.5hr 0.3mm layers AL~2mm       1500 1hr 0.1mm layers AL~4mm       1550 1.5hr 0.1mm layers AL~2mm

                                                                             Fig. 4 Hardness results for different thickness of graded layers versus
                                                                                               the distance of surface indenting

                                                                                                                                          VI. CONCLUSIONS
                                                                                A disc brake should acquire a combination of properties
                                                                             such as good thermal capacity, acceptable friction coefficient,
                                                                             good compressive strength, wear resistant and economically
                                                                             viable. From the experiments done, MMC showed improved
                                                                             hardness. However further investigation should be done on the
                                                                             hardness property in relation to the wear rate for MMC. As for
                                                                             FGM the hardness property can be improved by increasing the
 Fig. 2 The variation of the hardness values with weight fraction of
                                                                             alumina layer or using reinforcements in the alumina matrix.
       Al2O3 reinforcement particles around room temperature
                                                                             Further investigation on the mechanical behaviour ought to be
                                                                             performed, specifically for different stacking orders and layer
                                                                             thickness of FGM.

                                                                                                                                                  REFERENCES
                                                                             [1]                             P. J. Blau, C. Brian. Jolly, J. Qu, W. H. Peter, C. A. Blue, “Tribological
                                                                                                             investigation of titanium-based materials for brakes,” in Wear, vol.
                                                                                                             263, pp. 1202–1211, March 2007.
                                                                             [2]                             G. Cueva, A. Sinatora, W. L. Guesser, A. P. Tschiptschin, “Wear
                                                                                                             resistance of cast irons used in brake disc rotors,” in Wear, vol. 255,
                                                                                                             2003, pp. 1256-1260.
                                                                             [3]                             A. Daoud, M. T. Abou El-khair, “Wear and friction behavior of sand
                                                                                                             cast brake rotor made of A359-20 vol% SiC particle composites sliding
                                                                                                             against automobile friction material,” in Tribology International, vol.
 Fig. 3 The variation of the hardness values with weight fraction of                                         43, pp. 544-553, October 2009.
        SiC reinforcement particles around room temperature




                                                                       335
International Journal of Engineering and Physical Sciences 6 2012




[4]  J. K. Lees, A. K. Dhihra, R. L. McCullough, “Composite Materials,”
     Wiley, 2005.
[5] S. Y. Zhang, F. P. Wang, “Comparison of friction and wear
     performances of brake material dry sliding against two aluminium
     matrix composites reinforced with different SiC particles,” in Journal of
     Materials Processing Technology, vol. 182, pp. 122-127, July 2006.
[6] C. Tatar, N. Ozdemir, “Investigation of thermal conductivity and
     microstructure of the α-Al2O3 particulate reinforced aluminium
     composites (Al/Al2O3-MMC) by powder metallurgy method,” in
     Physica B: Condensed Matter, vol. 405, pp. 896-899, October 2010.
[7] A. J. Ruys, E. B. Popov, D. Sun, J. J. Russell, C. C. J. Murray,
     “Functionally graded electrical/thermal ceramic systems,” in Journal of
     the European Ceramic Society, vol. 21, pp. 2025-2029, November 2000.
[8] I. Low, “Synthesis and properties of in situ layered and graded
     aluminium titanate/alumina composites,” in Materials Research
     Bulletin, vol. 33, pp. 1475-1482, October 1998.
[9] S. Bueno, R. Moreno, C. Baudin, “Design and processing of Al2O3-
     Al2TiO5 layered structures,” in Journal of the European Ceramic
     Society, vol. 25, pp. 847-856, July 2004.
[10] S. Bueno, L. Micele, C. Melandri, C. Baudin, G. De Portu, “Improved
     wear behavior of alumina-aluminium titanate laminates with low
     residual stresses and large grained interfaces,” in Journal of the
     European Ceramic Society, vol. 31, pp. 475-483, April 2011.
[11] S. N. Aqida, M. I. Ghazali, J. Hashim, “Effects of porosity on
     mechanical properties of metal matrix composite: an overview,” in
     Jurnal Teknologi, vol. 40, pp. 17-32, June 2004.




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V6 62

  • 1. International Journal of Engineering and Physical Sciences 6 2012 On the Problem of Novel Composite Materials Development for Car Brake Rotor P. R. K. Fu, A. Gorin, D. Sujan, Z. Oo Abstract—This paper presents a study of the potential materials This will most likely lead to warping of the disc that are suitable for the development of the automotive brake disc. brake.Therefore, higher thermal conductivity and higher Two new materials are proposed as an alternative material to the specific heat capacity are most preferred to promote efficient conventionally used gray cast iron for the disc brake, which are thermal energy dissipation and hence avoid the overheating of namely Metal Matrix Composite (MMC) and Functionally Graded Material (FGM). MMCs with ceramic particulate reinforcement are the disc brake. Subsequently, this leads to the development of found to have a low density and high thermal conductivity compared advanced materials for the disc brake. to the cast irons. Two particulate reinforcements, Al2O3 and SiC were The main contribution of this paper is two-fold. First, we being considered for MMC. On the other hand, FGM has fabricate the two proposed materials. Second, we perform a demonstrated high thermal shock resistance, better wear resistance study on these materials, specifically their hardness property and low density. Preliminary investigation indicated that MMC and their characteristic results are analyzed towards the end of acquired improved hardness property. Meanwhile, the hardness property of FGM with Al2O3 and Al2TiO5 as layered composites this paper. materials can be further improved. The rest of this paper is organized as follows. The detailed description of MMC and FGM are reported in Section II and Keywords—Automotive disc brake, functionally graded material, III respectively. Section IV listed the procedures required in metal matrix composite our experimental work on the fabrication of MMC and FGM materials and the hardness test. The results derived from our I. INTRODUCTION experiments are analyzed and discussed in Section V. A N automotive brake disc is a device that slows or stops the motion of a wheel while it runs at a certain speed. The construction of an adequate brake disc that satisfies the Concluding remarks are drawn in Section VI. II. METAL MATRIX COMPOSITE increasing demand for low maintenance car has been a popular A composite material is a material consisting of two or more research in the automotive manufacturing area. physically and/or chemically distinct phases. The reinforcing In general, an automobile brake system consists of a brake component is distributed in the continuous or matrix disc and brake pads in order to maintain a steady friction component. When the matrix is a metal, the composite is coefficient. Braking system is a vital safety component of the termed as Metal Matrix Composite (MMC) [4]. MMCs are ground-based transportation systems. Thus the structural popular substitute materials for automotive, satellite systems, materials used in developing the brakes have to fulfil a series ballistic protection, general industries, sporting goods, aviation of functions. They ought to be dependable, durable, corrosion and are also vastly applied in other engineering fields. This is resistant, structurally sound, and economically viable [1]. Most because MMC possesses excellent mechanical properties and disc brake rotors in use today are made from gray cast iron, wear resistance. Research showed that the wear resistance of typically containing 2% to 4.5% dissolved carbon within its the MMC can be attributed to the strength and hardness of the matrix and various additives as well [2]. Due to its low cost, SiC particles [3]. If the SiC particles remain well bonded to the relatively ease of manufacture and thermal stability, cast iron matrix during the sliding wear process, the aluminium matrix is a more specialized material for brake applications surrounding them will be worn away and all contacts will be particularly for almost all the automotive brake dics. Gray cast between the friction material and SiC particles in the iron possesses low thermal conductivity (47.3W/m°C) and low composite. Therefore, the wear resistance of the composites is specific heat capacity (0.498J/g.K) [3]. The hydraulic related to the hardness property of the SiC particles. In pressure exerted during typical braking procedures, lies addition, Zhang and Wang [5] found that the friction between 2MPa and 4 MPa. Friction makes rotor reach (within performances and wear resistance for brake material sliding a very small periods of time), temperatures as high as 800°C, against drum brake with large-size SiC particles are better than resulting in a thermal gradient between the surface and the those against the drum brakes with small-size SiC particles. core of the rotors, which may reach up to 500°C. Other than that, Tatar and Ozdemir [6] found that the thermal conductivity of the Al2O3 particulate reinforced aluminium P. R. K. Fu is with Curtin University of Technology Sarawak Campus, composites (Al/Al2O3-MMC) decreased with the increasing of CDT 250, 98009 Miri (phone: +6085-443939; e-mail: kimbuali@gmail.com). Al2O3 volume fraction. They found that Al-MMC 45 vol% A. Gorin was with Curtin University of Technology Sarawak Campus. He Al2O3 showed a lower thermal conductivity as compared to Al- is now with the Department of Chemical Engineering, Swinburne University MMC 15 vol% Al2O3. Hence in this paper, the hardness of Technology Sarawak Campus, Jalan Simpang Tiga, 93350 Kuching (e- mail: agorin@swinburne.edu.my). property is investigated by varying the weight fraction (from D. Sujan is with the Mechanical Engineering Department, Curtin 5% to 15%) of the reinforcement particles (SiC and Al2O3) in University of Technology Sarawak Campus, 98009 Miri (e-mail: the MMC. Other than that, large-size SiC particles will be used d.sujan@curtin.edu.my). Z. Oo is with Curtin University of Technology Sarawak Campus, CDT as well. 250, 98009 Miri (email: zeya.oo@curtin.edu.my) 333
  • 2. International Journal of Engineering and Physical Sciences 6 2012 III. FUNCTIONALLY GRADED MATERIAL among the metal matrix more evenly [11]. Stirring was done Functionally graded materials (FGM) are defined as those for 4 intervals, every 30 minutes for a duration time of 2 to 3 materials in which the volume fraction of two or more minutes. Stirring must not be done vigorously to avoid air constituents is varied smoothly and continuously as a function bubbles and impurities on the surface because that could lead of position along certain dimension(s) of the structure [7]. to porosity. In order to achieve proper dispersion of particles Functionally Graded Materials (FGM) has demonstrated to be among the matrix metal, the temperature was reduced to advantageous beyond mechanical applications extending to 550°C. This was done to allow the liquid mixture to turn into a electronic, optical, nuclear, biomedical, and other fields. semi solid state so that when force was applied onto the Low et al [8] found that layered graded materials (LGM) particles, there would be abrasive collision between both formed by a homogeneous Al2O3 layer and a graded particles and matrix metal. After the final stirring, the molten heterogeneous Al2TiO5/Al2O3 layer exhibited a relatively ‘soft’ metal composite was left to cool in the furnace overnight to surface that encased a hard core. The presence of the ‘soft’ avoid rapid cooling. The final casted Al-MMC product was surface regions is due to the high concentration of Al2TiO5, then machined into specific specimen sizes. The above which displays a low hardness value. Bueno et al [9] suggested experimental procedures were repeated with Al2O3 as the that further studies be conducted to establish the effect of reinforcement particles. different stacking orders and layer thickness on the mechanical B. Functionally Graded Material behaviour of the laminates. The method they have used in Aluminium titanate powder was created by properly manufacturing the layered composites was slip casting. They synthesizing the rutile and alumina (Al2O3 + TiO2 → Al2TiO5) discovered that laminated layer Al2O3-Al2TiO5 composite’s provided and milled using a Rocklab ring mill. The primary thermal conductivity similar to that of alumina (35.6W/m°C) focus of sample preparation was the creation of thin interface [10]. The laminated layer Al2O3-Al2TiO5 composite showed of graded Al2O3/Al2TiO5 composite layers sandwiched low wear rates. between an outer layer of Al2O3 and an inner layer of In this paper, the hardness property of FGM formed by Al2TiO5. Only three graded layers were included in most of sandwiching thin interface of graded Al2O3/Al2TiO5 composite the samples comprising of a 75% Al2O3 / 25% Al2TiO5 grade layers between an outer layer of Al2O3 and an inner layer of located next to the Al2O3 outermost layer followed by a 50% Al2TiO5 is studied. Al2O3 / 50% Al2TiO5 grade then a 25% Al2O3 / 75% Al2TiO5 grade which was located next to the Al2TiO5 innermost layer IV. EXPERIMENTAL PROCEDURE (Figure 1). Layering was done by the use of a 15 mm inner The materials used for fabricating MMC are aluminium diameter cylindrical steel die. 2 mm thickness of Al2TiO5 was alloy A356 as a matrix material and silicon carbide, SiC placed first into the die before a layer of 25% Al2O3 / 75% (105µm) as reinforcement particles. MMC is being fabricated Al2TiO5 was placed on top, followed by 50% Al2O3 / 50% by melting the metal in a furnace then reinforcement particles Al2TiO5, 75% Al2O3 / 25% Al2TiO5 and finally 1 – 4 mm of are being added in and stirred slowly. As for FGM, Al2O3. The graded layers varied in thickness with either all of commercial rutile (TiO2) and alumina (Al2O3) were used as them being 0.1 mm, 0.3 mm, 0.5 mm or 0.7 mm thick. The materials. Uniaxial press is used to sandwich the graded layers samples were then uniaxially pressed at 5000 PSI for 20 together. seconds by a Blackhawk Uniaxial Press. Three batches of A. Metal Matrix Composite graded materials were produced, all at varied sintering temperatures and methods of pressing. The first batch Aluminium alloy A356 rods were first cut into smaller comprised of non-graded, 0.1 mm graded layers, 0.3 mm pieces with each 1cm thickness. 500g of 1cm thickness with graded layers, 0.5 mm graded layers, 0.7 mm graded layers each piece of aluminium alloy and 3 wt% of magnesium and four 50/50 graded layer (0.1 mm, 0.3 mm, 0.5 mm and 0.7 (wetting agent) were melted in the furnace at temperature of mm) samples that were sintered at 1500°C for an hour. The 700°C. Preheated reinforcement particles of silicon carbide second batch comprised of non-graded, 0.1 mm graded layers, were then added into the molten aluminium alloy. The 0.3 mm graded layers and 0.5 mm graded layers samples that reinforced particles were preheated beforehand at 900°C in the were cold isostatically pressed and sintered at 1550°C for 1 ½ furnace to remove all the moisture on the particles’ surface for hours. The final batch was comprised of non-graded, 0.1 mm better binding results. The compositions of composite graded layers, 0.3 mm graded layers and 0.5 mm graded layers materials that were being fabricated were: Al with 0% SiC, Al samples that were sintered at 1515°C for an hour. with 5% SiC, Al with 10% SiC, Al with 15% SiC all with different weight percentage. Silicon carbide was added into the molten metal matrix using the vortex method. Vortex was created by stirring the molten material manually at a rapid speed. Silicon carbide was then added at the side of the vortex and stirring was done continuously for a few minutes. The vortex method is believed to be able to distribute the particles Fig. 1 Graded layers FGM design 334
  • 3. International Journal of Engineering and Physical Sciences 6 2012 C. Hardness Testing Procedure for MMC B. Hardness Results for FGM Hardness test was being carried out by the Rockwell In Fig. 4, the highest hardness value in the FGM can be seen hardness test apparatus. For this hardness test on the MMC at the beginning of the alumina layer. The hardness values samples, the scale HRB was used. Based on the HRB scale, a decreased until it reached very low results of 0.4 GPa by the load 100kgf is to be applied on the MMC sample through a end of the first graded layer, 75% Al2O3 / 25% Al2TiO5. 1/16 inch diameter spherical shaped steel indenter. The load Hardness in the homogeneous alumina layer should have been was applied to the sample for a time of 10 seconds and the of a higher value as this layer should provide resistance to hardness values were obtained immediately from the deformation by surface indenting or abrasion. This could have apparatus. been done in a number of ways such as using fillers or D.Hardness Testing Procedure for FGM reinforcements in the alumina matrix. Another method of Vickers microhardness testing was utilized to calculate improving the protective properties of the homogeneous hardness across the cross section of selected samples from the alumina layer would be to increase the thickness of the layer first two batches of the functionally graded materials (FGM) therefore it will take a higher load in order for cracks to samples prepared. The selected samples consisting of non- propagate towards the first graded layer. graded, 0.1 mm graded, 0.3 mm graded, 0.5 mm graded and 18 0.7 mm graded samples were mounted in resin and the cross 16 section was polished from 20 µm surface roughness to 1 µm surface roughness. Samples were indented across the cross 14 Vickers Hardness (GPa) section of the samples with an average of 6 indents per sample, 12 starting from the alumina layer to the aluminium titanate layer. 10 The resulting indent was then viewed under a microscope and measured for radial crack length and indent diameter in order 8 to calculate hardness (GPa). 6 4 V. RESULTS AND DISCUSSION 2 A. Hardness Results for MMC 0 From Fig. 2 and Fig. 3, it can be observed that the hardness 0 1 2 3 4 5 6 7 8 9 Distance (mm) property for MMC increased with the increased of particle 1500 1hr 0.7mm layers AL~4mm 1500 1hr 0.3mm layers AL~4mm 1500 1hr 0.5mm layers AL~4mm reinforcements (Al2O3 and SiC). 1550 1.5hr 0.3mm layers AL~2mm 1500 1hr 0.1mm layers AL~4mm 1550 1.5hr 0.1mm layers AL~2mm Fig. 4 Hardness results for different thickness of graded layers versus the distance of surface indenting VI. CONCLUSIONS A disc brake should acquire a combination of properties such as good thermal capacity, acceptable friction coefficient, good compressive strength, wear resistant and economically viable. From the experiments done, MMC showed improved hardness. However further investigation should be done on the hardness property in relation to the wear rate for MMC. As for FGM the hardness property can be improved by increasing the Fig. 2 The variation of the hardness values with weight fraction of alumina layer or using reinforcements in the alumina matrix. Al2O3 reinforcement particles around room temperature Further investigation on the mechanical behaviour ought to be performed, specifically for different stacking orders and layer thickness of FGM. REFERENCES [1] P. J. Blau, C. Brian. Jolly, J. Qu, W. H. Peter, C. A. Blue, “Tribological investigation of titanium-based materials for brakes,” in Wear, vol. 263, pp. 1202–1211, March 2007. [2] G. Cueva, A. Sinatora, W. L. Guesser, A. P. Tschiptschin, “Wear resistance of cast irons used in brake disc rotors,” in Wear, vol. 255, 2003, pp. 1256-1260. [3] A. Daoud, M. T. Abou El-khair, “Wear and friction behavior of sand cast brake rotor made of A359-20 vol% SiC particle composites sliding against automobile friction material,” in Tribology International, vol. Fig. 3 The variation of the hardness values with weight fraction of 43, pp. 544-553, October 2009. SiC reinforcement particles around room temperature 335
  • 4. International Journal of Engineering and Physical Sciences 6 2012 [4] J. K. Lees, A. K. Dhihra, R. L. McCullough, “Composite Materials,” Wiley, 2005. [5] S. Y. Zhang, F. P. Wang, “Comparison of friction and wear performances of brake material dry sliding against two aluminium matrix composites reinforced with different SiC particles,” in Journal of Materials Processing Technology, vol. 182, pp. 122-127, July 2006. [6] C. Tatar, N. Ozdemir, “Investigation of thermal conductivity and microstructure of the α-Al2O3 particulate reinforced aluminium composites (Al/Al2O3-MMC) by powder metallurgy method,” in Physica B: Condensed Matter, vol. 405, pp. 896-899, October 2010. [7] A. J. Ruys, E. B. Popov, D. Sun, J. J. Russell, C. C. J. Murray, “Functionally graded electrical/thermal ceramic systems,” in Journal of the European Ceramic Society, vol. 21, pp. 2025-2029, November 2000. [8] I. Low, “Synthesis and properties of in situ layered and graded aluminium titanate/alumina composites,” in Materials Research Bulletin, vol. 33, pp. 1475-1482, October 1998. [9] S. Bueno, R. Moreno, C. Baudin, “Design and processing of Al2O3- Al2TiO5 layered structures,” in Journal of the European Ceramic Society, vol. 25, pp. 847-856, July 2004. [10] S. Bueno, L. Micele, C. Melandri, C. Baudin, G. De Portu, “Improved wear behavior of alumina-aluminium titanate laminates with low residual stresses and large grained interfaces,” in Journal of the European Ceramic Society, vol. 31, pp. 475-483, April 2011. [11] S. N. Aqida, M. I. Ghazali, J. Hashim, “Effects of porosity on mechanical properties of metal matrix composite: an overview,” in Jurnal Teknologi, vol. 40, pp. 17-32, June 2004. 336