Effect of Fly Ash Addition on the Physical and Mechanical Properties of AA6063 Alloy Reinforcement

Alaa Mohammed Razzaq 1,2, Dayang Laila Majid 1,*, Mohamad R. Ishak 1 and Uday M. Basheer 3,4
1Department of Aerospace Engineering, Faculty of Engineering, Universiti Putra Malaysia, 43400 UPM Serdang, Selangor Darul Ehsan, Malaysia
2Oil Products Distribution Company, Iraq Ministry of Oil, 10022 Al Doura, Baghdad, Iraq
3Faculty of Mechanical Engineering, Universiti Teknologi Malaysia, 81310 Johor Bahru, Johor, Malaysia
4UTM Centre for Low Carbon Transport in Cooperation with Imperial College London, Institute for Vehicle Systems and Engineering, Universiti Teknologi Malaysia, 81310 Skudai, Malaysia
*Correspondence: Tel.: +60-133-818-377; Fax: +60-386-567-125
Received: 12 September 2017 / Accepted: 18 October 2017 / Published: 4 November 2017

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Abstract

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Aluminum-fly ash particulate-reinforced composites (AA6063-FA) have been used in various engineering fields, such as automotive and aerospace industries, due to their low density and good mechanical properties. There are many fabrication techniques available to manufacture these composites according to matrix and reinforcement materials. The compocasting technique for the fabrication of the AA6063 matrix composite reinforced with fly ash particles is the focus of this research. Fly ash content was in the range of 0–12 wt % in increasing increments of 2%. Fly ash particles were added to the molten AA6063 alloy until they were completely blended and cooled down just below the liquidus to keep the slurry in the semi-solid state. After this, the molten AA6063-FA composites were cast into prepared cast iron molds. Bulk density and apparent porosity measurements, Charpy impact testing, Vickers microhardness measurements, Field Emission Scanning Electron Microscope (FESEM), Variable Pressure Scanning Electron Microscope and Energy Dispersive X-ray spectroscope (EDS) elemental mapping were used to evaluate these materials. The results showed that an increase in the fly ash content in the melted leads results in an increase in the microhardness and porosity in the composites. In contrast, the bulk density and Charpy impact energy of the composites decreased with an increase in the fly ash content.
Keywords:

aluminum composites; fly ash; porosity; casting; impact evaluation; microhardness