Investigation Of Inter Material Shear Properties Of Iron And Stannum.
INVESTIGATION OF INTER MATERIAL SHEAR
PROPERTIES OF IRON AND STANNUM
ROZIAH BINTI ABIDIN
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UNIVERSITI TEKNIKAL MALAYSIA MELAKA
INVESTIGATION OF INTER MATERIAL SHEAR
PROPERTIES OF IRON AND STANNUM
Thesis submitted in accordance with the partial requirements of the Universiti Teknikal Malaysia Melaka for the Bachelor
Of Manufacturing Engineering (Engineering Materials) with Honours
By
Roziah Binti Abidin
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UTeM Library (Pind.1/2007)
SULIT
TERHAD
TIDAK TERHAD
(Mengandungi maklumat yang berdarj ah keselamat an at au kepent ingan Malaysia yang t ermakt ub di dalam AKTA RAHSIA RASMI 1972)
(Mengandungi maklumat TERHAD yang t elah dit ent ukan oleh organisasi/ badan di mana penyelidikan dij alankan)
(TANDATANGAN PENULIS) Alamat Tet ap:
A9-00-07 APARTMENT DAMIANA, PROTON CITY
35900 TANJUNG MALIM, PERAK. Tarikh: _______________________
Disahkan oleh:
(TANDATANGAN PENYELIA) Cop Rasmi:
Tarikh: _______________________ BORANG PENGESAHAN STATUS TESIS*
JUDUL: INVESTIGATION OF INTER MATERIAL SHEAR PROPERTIES OF IRON AND STANNUM
SESI PENGAJIAN: 2004-2008 Saya
mengaku membenarkan t esis (PSM/ Sarj ana/ Dokt or Falsaf ah) ini disimpan di Perpust akaan Universit i Teknikal Malaysia Melaka (UTeM) dengan syarat -syarat kegunaan sepert i berikut :
1. Tesis adalah hak milik Universit i Teknikal Malaysia Melaka.
2. Perpust akaan Universit i Teknikal Malaysia Melaka dibenarkan membuat salinan unt uk t uj uan pengaj ian sahaj a.
3. Perpust akaan dibenarkan membuat salinan t esis ini sebagai bahan pert ukaran ant ara inst it usi pengaj ian t inggi.
ROZIAH BINTI ABIDIN
/
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DECLARATION
I hereby, declared this thesis entitled “INVESTIGATION OF INTER MATERIAL
SHEAR PROPERTIES OF IRON AND STANNUM” is the results of my own
research except as cited in references
Signature : ………
Author’s Name :
Date :
ROZIAH BINTI ABIDIN 20 MAY 2008
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APPROVAL
This thesis submitted to the senate of UTeM and has been accepted as partial fulfillment of the requirements for the degree of Bachelor of Manufacturing Engineering (Manufacturing Process). The members of the supervisory committee are as follow:
……… (MR. MOHAMAD HAIDIR BIN MASLAN)
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ABSTRACT
In this paper, an optimized active metal Iron (SS) to Stannum alloy (Sn) joint is examined. Beside that, the purpose of doing this project is to study the shear properties between two different metals. The important of shear properties are primarily used in the design of mechanically fastened components, webs, and torsion members, and other components subject to parallel, opposing loads. Shear properties are dependant on the type of shear test and is a variety of different standard shear tests that can be performed including the single-shear test. The differences of two metal couples at the test surface roughness of on the microstructural developments across the joint region are investigated. Mechanical characterization by means of shear tests as well as fracture toughness measurements at ambient temperature are employed, which show that the obtained values are above those of the reference joint that has been used so far. The phases occurring at the interface region and the fracture surface of the optimized joint are investigated in detail to explain the improved mechanical behavior. The composition and the morphology at the interface region are analyzed by means of Scanning Electron Microscope (SEM). The results shows that inter metallic composite occur at the interface for both aluminium and stanum matrix, however, it is clear for aluminium due to high temperature melting point of aluminium. Rough surface give of the reinforcing material improves the mechanical interlocking at the interface, though the contribution of the resulting interfacial shear strength is secondary compared to chemical bonding. Results also show that different materials will give different ultimate shear strength for the composite.
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ABSTRAK
Dalam kertas ini, satu kajian telah dilaksanakan bagi mengoptimakan sambungan logam aktif Iron (SS) kepada Stannum aloi (Sn) sendi diperiksa. Di samping itu, tujuan melakukan projek ini adalah untuk mengkaji ciri-ciri ricihan antara dua logam yang berlainan. Kekuatan ricihan adalah penting dalam rekaan secara mekanik komponen-komponen, webs, dan perkara komponen-komponen lain untuk muatan-muatan yang selari, atau bertentangan. Ujian pembangunan mikrostruktur pada bahagian sambungan antara dua jenis logam yang berbeza jenis permukaan dikaji. Pencirian mekanikal oleh ujian ricihan serta ukuran keliatan pada suhu ambien telah dikaji, yang mana menunjukkan bahawa memperolehi nilai-nilai daripada sendi rujukan yang telah digunakan setakat ini. Fasa-fasa yang berlaku di rantau antara muka dan permukaan retakan mengoptimakan sendi telah disiasat dengan terperinci untuk menjelaskan tingkah laku mekanikal dan lebih baik. Komposisi dan morfologi di rantau antara muka telah dianalisis oleh cara Scanning Electron Microscope (SEM). Hasil menunjukkan gabungan diantara logam komposit terdapat pada kedua-duanya antara muka aluminium dan stanum matriks, bagaimanapun, ia adalah lebih jelas untuk aluminium disebabkan oleh takat lebur suhu tinggi aluminium. Permukaan kasar memberikan kesan penting yang mana menambah baik ikatan mekanikal di antara muka, walaupun sumbangan mengakibatkan antara muka kekuatan ricih adalah sekunder berbanding dengan pengikatan kimia. Keputusan juga menunjukkan bahawa bahan-bahan lain akan memberikan perbezaan kekuatan ricih muktamad untuk rencam.
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DEDICATION
A million thanks and a lot of love to my husband Mr. Mahizan bin Abdul Rahman and all my family who had support and also sacrifies a lot for me in order to make sure I finished and completely my report of PSM. Also, get the knowladge and experiances and be a useful person in life. For all my friends thanks a lot for helping me up in everything. And once again, thank you to everybody. Only Allah S.W.T can pay all your kindness.
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ACKNOWLEDGEMENT
Thanks to Allah S.W.T because with the blessing has made me complete my Final Year Project (PSM) successfully without having any problem at all during the period. Thanks to Universiti Teknikal Malaysia Melaka (UTeM) and Faculty of Manufacturing Engineering (Engineering Materials) because give me an opportunity to gain this valuable experience.
Endless appreciation and gratitude to my supervisor, Mr. Mohamad Haidir bin Maslan and to my second examiner Mr Mohammad Kamil b. Sued for their encouragement and support and for spending quite some time with myself, providing a lot of guidance and ideas for my project research. Their knowledge and experience really inspired and spurred myself. I truly relished the opportunity given in working with them.
Many thanks to the technicians of Faculty Manufacturing Engineering (FKP) and Faculty Mechanical Engineering (FKM) because of the acquires and co-operation.
Finally yet importantly, thanks also to my entire classmate from materials course and for those who involved directly or indirectly during my complete my PSM, their priceless assistance and patronage throughout the process of data gathering, thank you very much for everybody.
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TABLE OF CONTENT
ITEM NO. TITLE PAGE NO.
DECLARATION i
APPROVAL ii
ABSTRACT iii
ABSTRAK iv
DEDICATION v
ACKNOWLEDGEMENT vi
TABLE OF CONTENT vii
LIST OF TABLE xi
LIST OF FIGURE xii
NOMENCLATURE xiv
1 INTRODUCTION
1.1 BACKGROUND 1
1.2 OBJECTIVE 3
1.3 SCOPE 4
1.4 POTENTIAL OF BENEFIT 5 1.5 STUDY OUTLINE 6
2 LITERATURE REVIEW
2.1 INTRODUCTION 7
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2.2.1 Introduction 8
2.2.2 Matrix 8
2.2.2.1 Metal Matrix Composite 8
2.2.2.2 Polymer Matrix Composite 9 2.2.2.3 Ceramics Matrix Composite 9
2.2.3 Reinforcement 10
2.1.3.1 Types of Reinforcement 10
2.3 METAL MATRIX COMPOSITE
2.3.1 Introduction 12
2.3.2 Properties of Copper Matrix 12
2.3.3 Properties of Iron (Ferrum) Reinforcement 13
2.3.4 Properties of MMC 13
(a) Physical Properties 13
(b) Mechanical Properties 14
2.3.5 Advantages and Disadvantages of MMC 14
2.3.6 Processing Method of MMC 15
2.3.6.1 Liquid- Phase Processing 15
2.3.6.2 Solid-Phase Processing 15
2.3.6.3 Two-Phase Processing 16
2.4 INTERFACE 17
2.4.1 Introduction 17
2.4.2 Function 18
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2.4.3.1 Mechanical Bonding 19
2.4.3.2 Electrostatic Bonding 19
2.4.3.3 Chemical Bonding 20
2.4.3.4 Reaction Bonding 20
2.5 MECHANICAL TESTING FOR
MEASURING BONDING STRENGTH 22
2.5.1 Introduction 22
2.5.2 Single Fiber Tests 23
2.5.3 Bulk Specimen Tests 24
2.5.4 Micro-Indentation Test 26
2.5.5 Iosipescu Shear Test 27
2.5.6 Arcan Shear Test 28
2.5.7 Wyoming Version of Shear Test 29
2.5.8 Idaho Version of Shear Test 29
2.5.9 FPL Version of Shear Test 30
2.6 SPECIMEN 32
2.7 MICROSTRUCTURE OBSERVATION 34
2.7.1 Optical Microscope 34
2.7.2 Scanning Electron Machine (SEM) 35
2.7.2.1 Basic Operating 36
3 METHODOLOGY
3.1 RESEACH DESIGN 37
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3.3 MOULD PREPARATION 39
3.3.1 Mould Designing 39
3.3.2 Mould Specification 39
3.4 PROCESS SEQUENCE OF SAMPLE
PREPARERATION 40
3.5 EXPERIMENTAL METHOD 41
3.5.1 Shear Test 42
3.5.2 Microstructure 43
3.5.2.1 Microstructure Analysis 44
4 RESULT AND DISCUSSION 45
4.1 INTRODUCTION 45
4.2 SHEAR TEST 46
4.3 MICROSTRUDTURE OBSERVATION 52
4.3.1 Optical Microscope 52
4.3.2 Scanning Electron Microscope 55
5 CONCLUSION AND SUGGESTION 58
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LIST OF TABLES
Table 2.1 Different metal particles shapes and manufacturing methods. 11 Table 3.1 Typical chemical composition for copper alloy- C106. 41 Table 3.2 Typical chemical composition for aluminum 2024. 42
Table 4.1 The Data of Al-SS (smooth surface). 47
Table 4.2 The Data of Al-SS (v-shape surface). 47
Table 4.3 The Data of Sn-SS (smooth surface). 49
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LIST OF FIGURES
Figure 2.1 Formation of a composite material using reinforcement
and matrix. 8
Figure 2.2 Continuouse fiber composites and short fiber composites. 10
Figure 2.3 The interface function. 18
Figure 2.4 Interlock of mechanical bonding. 19
Figure 2.5 Electrostatic bonding. 20
Figure 2.6 Chemical bonding. 20
Figure 2.7 Reaction that involving polymer. 21
Figure 2.8 Interfacial that formed by interdiffusion. 21
Figure 2.9 Single fiber test. 24
Figure 2.10 Illustration of specimen geometry. 25
Figure 2.11 Cross-sectional diagram of loaded indentor. 26
Figure 2.12 Iosipescu shear test fixture. 27
Figure 2.13 Test fixture and specimen by Arcan et al. 1978. 28 Figure 2.14 Modified Wyoming shear test fixture. 29
Figure 2.15 Idaho shear test fixture. 30
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Figure 2.17 Specimen dimension of Single Fiber Pull-Out Test. 32
Figure 2.18 Single Fiber Test 33
Figure 2.19 Optical Microscope 34
Figure 2.20 SEM component. 35
Figure 2.20 SEM operating. 36
Figure 3.1 Material involve and parameter consideration. 38
Figure 3.2 Mould specification. 39
Figure 3.3 The process sequence of sample composites preparation. 40
Figure 3.4 Single Fiber Test 43
Figure 3.5 Pull-Out Shear Test Diagram 43
Figure 4.1 Sample 46
Figure 4.2 The position of The Sample at UTM 46
Figure 4.3 Shear Test of Al-SS Composites 48
Figure 4.4 Shear Test of Sn-SS Composites 50
Figure 4.5 The Shear Test for Smooth Surface 51
Figure 4.6 The Shear Test For V-Shape Surface 51
Figure 4.7 Microstructure on Boundary Surface with 500X, Al-SS 52 Figure 4.8 Microstructure on Boundary Surface with 500X, Sn-SS 53
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NOMENCLATURE
SEM Scanning Electron Microscopy. TEM Transmission Electron Microscope.
ASTM America Society for Testing and Materials. MMC Metal Matrix Composite.
PMC Polymer Matrix Composite. CMC Ceramics Matrix Composite. EDM Electrical Discharge Machining.
Al Aluminum.
SS Stainless Steel.
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CHAPTER 1
INTRODUCTION
1.1BACKGROUND
Metal matrix composites (MMC) consist of an intricate structure of metals and an inorganic reinforcing material. The frontier zone between these two phases (interface or interphase) is one essential part of MMC. Bonding that developed from physical or chemical interactions, interfacial frictional stress and thermal stresses due to mismatch between coefficient of thermal expansion of reinforcement and matrices. The understanding and control of the underlying interfacial phenomena governing the transmission of thermal, electrical, and mechanical properties across the whole composite might become paramount importance when designing MMC for a particular task.
One of the main objectives for all shear test methods is to obtain a well-defined and uniform shear stress state in a well-defined test region. A number of test methods for composites are used today which obtaining uniform stress field the standard method used is by using torsion of a thin-walled tube specimen. These methods are too costly and the test specimen is not easy to be prepared. Moreover, not all materials and fiber orientations are possible to produce in tube shapes. Other frequently used methods for shear testing are three points bending of a short beam, double notch compression and inclined double notch compression are tested. Another commonly used test method for plates is the Iosipescu shear test method (ASTM D-5379). It was to test isotropic materials but proven to be well suitable also for composite materials. However, many
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problems have been reported for composites testing such e.g. nonhomogenous stress fields, problems with evaluating the experimental data, non-linear material behavior, gripping, and undesired loading states. But for this report, the test is modifying form pull out for single fiber test.
A lot of effort has been dedicated to solve these problems by improving the fixture to avoid in-plane bending, twisting, and out-of-plane bending of the specimen. Generally, high precision of the specimen preparation is required to avoid such, and other, problems during the testing procedure.
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1.2 OBJECTIVE
The main objectives of this investigation are to:
Study shear stress and characteristic shear responses between two different metals.
Determine the shear toughness relationship between two different materials with Stannum (Sn) and Stainless Steel (SS).
Purpose relation properties with high gain of shear toughness. Study about material degradation mechanisms and failure modes;
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1.3SCOPE
The emphasis of this report is on the establishment of studies inter material shear properties between two different metals. The investigation includes the development of the sample and laboratory shear test. The microstructures are observed using SEM (Scanning Electron Microscope) and Optical Microscope. In this report, it only concentrates at surface roughness parameter of the matrix.
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1.4POTENTIAL OF BENEFIT
From this project, the shear properties between two different materials will be known. This project is important to:
o Get the best method on producing the composite with high bonding between two different materials.
o Detect what parameter that will involve in shear properties.
o Analyze the shear stress and characteristic of shear responses between two different materials.
o Understand the materials degradation mechanism and failure modes at the interface between two materials.
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1.5STUDY OUTLINE
Investigation of inter material shear properties of iron and stannum
Literature Review
Shear Between Metal
o Arcan Test
o Iosipescu Test
o Pull out Test
Parameter Consideration
o Temperature
o Surface roughness
Metal
o Stannum
o Ferrum
o Aluminum
Mould Preparation
Sample Preparation
Shear Test
Result & Discussion
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CHAPTER 2
LITERATURE REVIEW
2.1 INTRODUCTION
Composite is a mixture of two or more distinct constituents or phases. So, composite are produced by combining two or more homogenous materials such as that the physical and chemical different phase that are formed will make possible the high performance required. Once the matrix has wet the reinforcement, and is therefore in intimate contact with the reinforcement bonding will occur. In achieving this high performance, the interaction between component materials in the interface and the properties of each constituent are of utmost important.
The load acting on the matrix has to be transferred to the reinforcement via interface. Thus reinforcements must be strongly bonded to the matrix if their high strength and stiffness are to be imparted to the composite. The fracture behavior is also dependent on the strength of the interface. The interface is important whether the reinforcement is in the form of continuous fiber, short fibers, or whisker or particles although the exact role of the interface may differ with the type of the reinforcement.
In other instance the interface can be viewed as a planar region of only a few atoms in thickness across in which there is a change in properties from those of the matrix to those of the reinforcement. Thus at the interface there is usually a discontinuity in chemical nature, crystal and molecular structure, mechanical properties and other properties.
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2
problems have been reported for composites testing such e.g. nonhomogenous stress fields, problems with evaluating the experimental data, non-linear material behavior, gripping, and undesired loading states. But for this report, the test is modifying form pull out for single fiber test.
A lot of effort has been dedicated to solve these problems by improving the fixture to avoid in-plane bending, twisting, and out-of-plane bending of the specimen. Generally, high precision of the specimen preparation is required to avoid such, and other, problems during the testing procedure.
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1.2 OBJECTIVE
The main objectives of this investigation are to:
Study shear stress and characteristic shear responses between two different metals.
Determine the shear toughness relationship between two different materials with Stannum (Sn) and Stainless Steel (SS).
Purpose relation properties with high gain of shear toughness.
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4 1.3SCOPE
The emphasis of this report is on the establishment of studies inter material shear properties between two different metals. The investigation includes the development of the sample and laboratory shear test. The microstructures are observed using SEM (Scanning Electron Microscope) and Optical Microscope. In this report, it only concentrates at surface roughness parameter of the matrix.
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1.4POTENTIAL OF BENEFIT
From this project, the shear properties between two different materials will be known. This project is important to:
o Get the best method on producing the composite with high bonding between two different materials.
o Detect what parameter that will involve in shear properties.
o Analyze the shear stress and characteristic of shear responses between two different materials.
o Understand the materials degradation mechanism and failure modes at the interface between two materials.
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6 1.5STUDY OUTLINE
Investigation of inter material shear properties of iron and stannum
Literature Review
Shear Between Metal
o Arcan Test o Iosipescu Test o Pull out Test Parameter Consideration
o Temperature o Surface roughness Metal o Stannum o Ferrum o Aluminum Mould Preparation Sample Preparation Shear Test
Result & Discussion
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CHAPTER 2
LITERATURE REVIEW
2.1 INTRODUCTION
Composite is a mixture of two or more distinct constituents or phases. So, composite are produced by combining two or more homogenous materials such as that the physical and chemical different phase that are formed will make possible the high performance required. Once the matrix has wet the reinforcement, and is therefore in intimate contact with the reinforcement bonding will occur. In achieving this high performance, the interaction between component materials in the interface and the properties of each constituent are of utmost important.
The load acting on the matrix has to be transferred to the reinforcement via interface. Thus reinforcements must be strongly bonded to the matrix if their high strength and stiffness are to be imparted to the composite. The fracture behavior is also dependent on the strength of the interface. The interface is important whether the reinforcement is in the form of continuous fiber, short fibers, or whisker or particles although the exact role of the interface may differ with the type of the reinforcement.
In other instance the interface can be viewed as a planar region of only a few atoms in thickness across in which there is a change in properties from those of the matrix to those of the reinforcement. Thus at the interface there is usually a discontinuity in chemical nature, crystal and molecular structure, mechanical properties and other properties.