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Investigation of mechanical, microstructure, and wear behaviors of Al-

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Investigation of mechanical,
microstructure, and wear behaviors of
Al-12%Si/reinforced with melon shell ash
particulates

I. Y. Suleiman, Sani A. Salihu &

T. A. Mohammed

The International Journal of

Advanced Manufacturing Technology

ISSN 0268-3768

Int J Adv Manuf Technol

DOI 10.1007/s00170-018-2157-9

1 23
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 Author's personal copy
The International Journal of Advanced Manufacturing Technology
https://doi.org/10.1007/s00170-018-2157-9

ORIGINAL ARTICLE

Investigation of mechanical, microstructure, and wear behaviors

of Al-12%Si/reinforced with melon shell ash particulates
I. Y. Suleiman 1 & Sani A. Salihu 2 & T. A. Mohammed 3

Received: 13 March 2018 / Accepted: 8 May 2018

# Springer-Verlag London Ltd., part of Springer Nature 2018

Abstract
The use of agricultural wastes which is cost-effective and environmental-friendly materials as reinforcers in metal matrix
composites is growing fast in various engineering fields. With this, the research investigates the mechanical, microstructure,
and wear behaviors of Al-12%Si alloy reinforced with melon shell ash (MSA) for developing a new material. Melon shell ash of
particle size of 50 μm was prepared for the studies. Different weight percentages of 5, 10, 15, and 20 MSA were used to develop
metal matrix composites for the investigations. The melon shell ash was characterized by X-ray fluorescent (XRF). The mor-
phology of the alloy and composites were studied using scanning electron microscope for the distribution of melon shell ash
(MSA) particles. The XRF revealed some oxides with silica (SiO2) being the highest followed by potassium oxide (K2O),
alumina (Al2O3). The results of the mechanical properties indicate that the tensile strength increased from 122.5 MPa in the
alloy to 204.5 MPa in composites, the hardness values increased from 95 HRC to 103.1 HRC, the impact energies decreased from
17.5 to 14.0 J and percentage elongation also decreased from 35.3 to 16.0 respectively. The wear rate decreases from 0.022 to
0.0091 g/min. The microstructures revealed that the MSA was uniformly distributed within the composites and resulted to the
appreciable increase or decrease in the mechanical properties which were attributed to the oxides present. The composites can be
used in automobile industries where some of these properties can be explored.

Keywords Aluminiun alloy . Composites . Melon shell ash . Mechanical properties . Microstructures . Wear rate

Nomenclature SEM Scanning electron microscopy

MSA Melon shell ash Cu Copper
Al Aluminum Fe Iron
Si Silicon ASTM American Society for Testing & Materials
XRF X-ray fluorescent mA Milliampere
P2O5 Phosphorus pentoxide
SiO2 Silicon dioxide
* I. Y. Suleiman SO3 Sulfur trioxide
idawu.suleiman@unn.edu.ng CTE Coefficient of thermal expansion
ZnO Zinc oxide
Sani A. Salihu
MgO Magnesium oxide
sani.aliero@gmail.com
Na2O Sodium oxide
T. A. Mohammed Al2O3 Alumina
tankoacada1@gmail.com
LOI Loss in ignition
1 μm Micrometer
Department of Metallurgical and Materials Engineering, University
of Nigeria, Nsukka, Nigeria % Percentage
2 MnO Magnesium oxide
Department of Mechanical Engineering, Faculty of Engineering,
Kebbi State University of Science and Technology, Aliero, Kebbi Fe2O3 Hematite
State, Nigeria SiC Silicon carbide
3
Department of Mechanical Engineering, Waziri Umaru Federal K2O Potassium oxide
Polytechnic, Birnin Kebbi, Kebbi State, Nigeria CaO Calcium oxide
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Int J Adv Manuf Technol

1 Introduction Experiments were conducted to assess the mechanical, micro-

structures and wear behaviors of the Al/12%Si/0-20 wt.
The development of low cost metal matrix composites (MSA) composites. Scanning electron microscope (SEM)
(MMC) reinforced with agricultural wastes materials has was used to establish the morphologies of the alloy, compos-
been the major innovations in the field of materials for ites, and wear mechanisms.
sometimes as these developments have positive effects on
both human beings and environments [1, 2]. Aluminum-
based metal matrix composites (AMMCs) have received 2 Materials and methods
increasing attention in recent decades as engineering mate-
rials. The introduction of a ceramic material into a metal 2.1 Preparation of melon shell ash
matrix produces a composite material that results in an at-
tractive combination of physical, chemical and mechanical Metallic drum perforated to allow air circulation for combus-
properties which cannot be obtained with the aluminum tion to occur was used as burner for the preparation of melon
alloys [3]. These materials have shown to possess great po- shell ash. The shell was obtained from the melon of species
tential of applications in the brake discs for railway, pistons Citrullus lanatus, dried and ground to form melon shell pow-
for diesel engines, connecting rods etc. [4]. der. The powder was packed in a graphite crucible and fired at
Various reinforcements such as silicon carbide, graphite, temperature range of 400–650 °C for 120 min and removed
boron, titanium carbide, zirconium, Al2O3, and tungsten have from furnace after 24 h for proper heat-treatment. This is to
been used to developed aluminum matrix composites allow the reduction of the carbonaceous and volatile constitu-
(AMCs). However, these reinforcements had improved the ents of the ash [13, 19]. The ash was ball milled using ball
mechanical properties and wear resistance such as strength, milling machine and sieved to a particle size of 50 μm.
hardness, toughness, ductility resistance, corrosion, and high
temperature resistance among others of the composites [5, 6]. 2.2 Equipment
Synthetic reinforcements such as silicon carbide (SiC) and
alumina (Al2O3) despite their apparent widespread use are Equipment used in this research are electrical resistance fur-
not produced in developing countries. The reliance on impor- nace, (scanning electron microscope (SEM), X-ray fluores-
tation from overseas and the high foreign currency exchange cent XRF, and Pin on Disc machine.
involved implies that the synthetic reinforcements purchased
locally are at relatively high cost [7]. 2.3 Mineralogical characterization of the melon shell
Alternative to the high cost of synthetic reinforcers to ash (MSA)
developing countries currently is to explore some ashes ob-
tained from the controlled burning of agro-wastes such as The elemental analysis of the carbonized melon shell ash was
bamboo leaf, rice husk, baggase, coconut shell, and ground analyzed by energy-dispersive X-ray spectrometer (the ma-
nut shell for the development of AMCs [8–10]. These ashes chine used is Mini pal 4 ED-XRF machine, made by
are not just cost effective but the availability and environ- Panalytical of Netherlands). The sample was weighed and
mental friendly in nature. The results had also shown that ground in mortar and pressed in hydraulic press to produce
agro-waste ashes contain high percentage of refractory ma- pellet. The pellets were loaded in the sample chamber of the
terials such as Al2O3, silica (SiO2), hematite (Fe2O3) dis- spectrometer and a voltage of 30kv and current of 1 mA was
tributed in these wastes [11]. Previous works on the use of applied to the X-rays to excite the sample for 10 min. The
agro-wastes as reinforcing fillers in the development of spectrum from the sample was then analyzed to determine
composites had been carried out by researchers [12–17]. the concentration of the elements in the sample. The chemical
Melon shell is an agriculture waste by product abundantly composition of the MSA is being presented in Table 1.
available across Nigeria in West Africa. The melon shell is a
great environmental threat that can cause damage to the land 2.4 Preparation of Al-12% Si-/(5–20 w%) melon shell
and the surrounding area in which it is dumped [18]. The ash particulate composites
effective way of utilizing the melon shell was to convert to
ash under controlled burning conditions. The composition of aluminum silicon alloy used for this
Therefore, this research focused on the utilization of melon work is being presented in Table 1. Si, Cu, Fe, Mn, and
shell ash (MSA) by dispersing it into the Al/12%Si alloy to Mg have the following weight percentage of 12, 0.006,
produce matrix composites through stir casting route. The 0.020, 0.010 and 0.011 respectively. The remaining weight
weight fractions of melon shell particles (50 μm) were varied percent being aluminum used to prepare Al-Si alloy as stat-
from 0 to 20% wt. at 5% wt. interval in this work. The MSA ed in [20]. The composite required for the investigation was
was characterized by XRF to ascertain the compositions. fabricated by gravity die stir casting procedure. The
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Int J Adv Manuf Technol

Table 1 The XRF analysis of

melon shell ash Oxides SiO2 SO3 K2O CaO MnO Fe2O3 ZnO MgO Na2O Al2O3 LOI

Wt.% 84.30 0.63 4.70 2.11 0.36 1.30 0.47 0.37 0.53 3.54 2.32

composites were cast into the mold size of 30 mm diameter 2.7 Determination of impact toughness
and 100 mm length. The melting process was carried out in
a graphite crucible furnace using oil fired graphite. The The impact specimen was placed on a horizontal stand of the
aluminum alloy was preheated to a temperature of 200 °C Izod Impact Machine. It was arranged such that the notch
for 30 min. The pouring temperature was maintained at was directly opposite to the point of impact of a heavily
720 °C and fluxing, degassing was carried out. The crucible suspended mass. With the gauge set properly, the suspended
furnace was heated up to 800 °C and the melon shell ash of mass was released from a height to hit the specimen. The
particle size of 50 μm was introduced into the alloy. energy absorbed by the specimen was reflected on a cali-
Magnesium ribbon was added into the molten melt to en- brated scale [24].
hance the wettability between the melon shell ash particles
and alloy melt. 2.8 Microstructural examination
Mechanical stirrer made up of stainless steel was utilized
to ensure thorough mixing of the reinforcement of all the The morphologies of the alloys and composites produced
material into pure aluminum matrix. The molds were heated were investigated using scanning electron microscope.
to 350 °C and both the alloy and the composites were poured Samples were polished on emery papers of different grades.
into the molds of 30 mm by 100 mm respectively. The alloy The polishing was carried out on a circular cloth pad on its
and composites were taken out from the split molds for the surface. Rough polishing was done using silicon carbide
analyses. Table 2 shows the composition of the alloy. paste and final polishing operation was carried out using
alumina polishing paste. Etching of the specimen was car-
2.5 Determination of tensile strength ried out using a cotton wool soaked in nital to wipe the
specimen’s polished surface to give a dull reflection surface
The tensile tests were carried out on the samples according to [25]. A Phenom Pro desktop Scanning Electron Microscope
ASTM E08-95 at room temperature (30 °C), using a universal (SEM) was used for the characterizations. The accelerating
testing machine (INSTRON). The test was conducted using voltage was varied from < 1 to 30 kV on the specimens.
strain rate of 2 mm/min. As cast Al alloy and composite tensile Increasing accelerating voltage decreased lens aberrations
test specimens were prepared using lathe machine and shaper and thus better resolution. BSE energy range was wide
machine according to the dimension shown in Fig. 1 [21, 22]. (from 50 eV to that of incident beams energy.
Figure 1 shows the dimensions of standard test bar used in
these tests. The specimens were machined to the standard 2.9 Wear analysis
diameter size 5 mm as specified in BS 2789:2002.
Wear test specimen disc of diameter 25 mm and thickness
5 mm were machined from the as-cast produced compos-
2.6 Determination of the hardness values
ites. The surfaces of each specimen were prepared with 600
grades SiC abrasive papers. A total number of specimens
The hardness test was carried out using Rockwell hardness ma-
chine. The hardness specimen was placed on a flat horizontal
stand, with a preload of the diamond cone indenter was used to 30mm
indent on the surface of the specimen and its hardness value was 28mm
26mm
reflected on a dial gauge of the machine and the readings read
from the calibrated C-scale of the gauge as carried out in [23, 24].

Table 2 Composition of Al-12%Si alloy used

Elements Al Si Cu Fe Mn Mg 5m R
50mm
Wt.% Balance 12.00 0.006 0.020 0.010 0.011
Fig. 1 Dimensions of tensile test specimen
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Int J Adv Manuf Technol

were used for the whole experiment, as for each composi- aluminum alloy matrix. There was good retention and
tion two different loads of 7 and 10 N were used. The wear good interfacial bonding of melon shell ash particles in
test was carried out on the surface of the specimens using the composites with different weight percentage of rein-
an Anton Paar TRN Tribometer (asper ASTM G99-95 forcers. Addition of small quantities of magnesium during
standards). The abrasive medium used was made of stain- stirring also improved the wettability of melon shell ash
less steel ball. An applied load of 7 N and 10 N at 153 rev/ particles. There was increase in the particulates dispersed
min wheel speeds and a dwell time of 3.26 min were used. for the composites containing (5–20) wt% of the MSA in
The sliding speed used was 2 m/s. Weight loss method was the Fig. 2b–e. The results were also in agreement with the
adopted to study the wear behavior. Weight of the speci- previous works [29].
men before and after each test was measured using digital
weigh balance. The mass loss was determined for each 3.3 Mechanical properties
specimen by finding the difference between the initial
and final mass. Weight loss method was used to calculate 3.3.1 Hardness values
the wear rate [11, 26].
The hardness values of the developed composites increased
with an increasing percentage of melon shell ash particle (5–
3 Result and discussion 20%) additions. The hardness value of the Al-12%/(5–20%
MSA) is being illustrated in Fig. 3. It could be observed that
3.1 Melon shell analysis the hardness increases with increase in the weight percent of
MSA in the composites. The hardness value of the Al-
The XRF chemical composition of the melon shell ash (MSA) 12%Si was 95.0HRC and increased to 103.1HRC at
as described in the experimental procedure is presented in 20 wt.% of MSA. Increase of 4.74%, 2.01%, 2.01 and
Table 1. It could be observed from the table that silica 0.39% was observed for the composite with 5, 10, 15 and
(SiO 2 ) has the highest percentage composition of 20 wt% MSA respectively [20].
84.30 wt.% followed by K2O (4.70 wt.%), Al2O3 (3.54) and The increments in the hardness value of the composites
CaO (2.11 wt.%) and Na2O, SO3, were traces respectively. could be attributed to increase of the weight percentage of
hard and brittle phase of the melon shell ash particles in the
3.2 The morphologies of the alloy/composites Al matrix. The XRF analysis showed some hardness mate-
rials in their compositions such as SiO2, Al2O3, Fe2O3, K2O
Microstructure plays an important role in the overall per- presented in Table 1. In addition to the above, melon shell
formance of a composite. The physical properties of the ash particles in the alloy increases the dislocation density at
composites however depend on the microstructure, rein- the particles matrix interfaces as a result of differences in
forcement particle size, shape and distribution in the alloy. coefficient of thermal expansion (CTE) between the hard
Prepared samples were examined using a scanning elec- and brittle reinforced particles. This resulted to elastic and
tron microscope (SEM) of magnification (× 1000) to study plastic incompatibility between the matrix and the rein-
the distribution pattern of melon shell ash as reinforcer in forcement of the MSA [19, 30].
the matrix. The micrograph shown in Fig. 2a depicts the
microstructure of as-cast Al-12% Si alloy. In the Fig. 2a, 3.3.2 Tensile strength
the structure was completely uniform with the solubility
of silicon in the Al matrix. Figure 2b–e revealed the vol- The relation between tensile strength of the Al-12%Si alloy
umes of the reinforcer from 5 to 20% of MSA. At Fig. 2b, and composites with the different weight percentage of
the volume of the MSA shows the metallic phase seems to melon shell ash particles were presented in Fig. 4. It can
be white while the light black portion of silicon dioxide be seen that the tensile strength increased with an increase
(SiO2) and SiO2 was more in the XRF results presented in in the weight percentage of melon shell ash content.
Table 1 (84.30%). Figure 2c–e shows the microstructures Hence, the MSA particles act as barriers to the dislocations
of reinforced with 10, 15, and 20% MSA respectively. when taking up the load applied. The similar observation
The figures revealed the same trend with more volumes was found in [22] for rice husk ash. The improvement
of light black portion of SiO2. It was also found that there observed in tensile strength of the composite was attributed
was good bonding between Al matrix and the filler to the fact that the melon shell as acts filler and possesses
(MSA) particles and no gap was observed between the higher strength which was more resistance. Although there
particle and matrix [27, 28]. The microstructures of the was a decrease in the tensile strength of the samples with
composites revealed small discontinuities and reasonably melon shell ash weight fraction beyond 15 wt%, it had
uniform distribution of melon shell ash particles in the been estimated that there is about 0.978% reduction in
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Int J Adv Manuf Technol

Fig. 2 a The morphology of Al-

12%Si. b Al/12%Si/5MSA. c Al-
12%Si/10 wt.% MSA. d Al/
12%Si/15MSA. e Al-12%Si/
20 wt.% MSA

Fig. 3 Variation of hardness of Al-12%Si/5–20 wt.% MSA particulates Fig. 4 Variation of tensile strength of Al-12%Si/5–20 wt.% MSA particulates
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Int J Adv Manuf Technol

the tensile strength from the ultimate to 20 wt.% MSA. The

observed improvement in tensile strength of the composite
can be attributed to the fact that the filler melon shell ash
possesses higher strength. The decrease in tensile strength
at 20 wt.% MSA reinforced was also due to the effect of
segregation of the oxides particles in tensile testing speci-
mens and may be attributed to the poor wettability of the
reinforcement with the matrix [23].

3.3.3 Percentage elongation

Fig. 6 Variation of impact strength of Al-12%Si/5–20 wt.% MSA
The percentage elongation effect on the alloy and compos- particulates
ite reinforced with melon shell ash was presented in Fig. 5.
From the graph, the ductility of the composite decreases
with the increase in weight fraction of the melon shell ash.
3.4 Wear properties of composite
This was due to the addition of hard, brittle second phase
or clustering in melon shell ash particles in the composites.
The results of the wear rate and SEM were shown in Figs. 7
Previous observations were found by [23, 24].
and 8. From the figures, it was observed that the wear rate
decreases with increased in the weight percentage of melon
shell ash particles. It could be observed that the composites
3.3.4 Impact toughness
exhibited significantly higher wear resistance than the Al-
12%Si due to the addition of melon shell ash which has
Figure 6 shows the result of impact fracture of the alloy and
higher SiO2 that acted as a load bearing constituent. As the
composites. It was observed that the fracture toughness of the
percentage of melon shell ash content increases, the wear
composites containing 5, 10, 15, and 20 wt.% MSA had lower
rate of the composite decreases. An increase in melon shell
fracture toughness values in comparison with the Al-12%Si.
ash in the composite restricts deformation of the matrix
The mechanisms of fracture had been attributed to particle
material with respect to load, hence the wear rate for the
cracking, interfacial cracking or particle [25]. It was also
higher MSA content composite is lower according to Fig. 7
established that ceramic particulates are hard, brittle and al-
and similar to the works of [27].
ways have poor tendency to resist rapid crack propagation
Figure 8 shows the morphologies of Al-12%Si and the
[11]. In this study, the fracture toughness decrease was ob-
composite. From the figure, it can be seen that material
served in 5, 10, and 15 wt%. At 15 and 20 wt%, the toughness
removal of the prepared specimen in (b) occurred through
values became virtually constant. However, it is clear that ad-
micro cutting and chipping processes. Abrasion marks can
dition of 5–20 wt% MSA deteriorated the fracture toughness of
be seen on the surface of the prepared composite specimen
the Al-12%Si reinforced with MSA matrix composites.
with 20 wt.% MSA and the cutting was not too deep when
Similar findings were also found in research works [19, 20].
compared with the Al-12%Si alloy. This is also similar to
the findings of [28–30].

Fig. 5 Variation of percentage elongation of Al-12%Si/5–20 wt.% MSA

particulates Fig. 7 Variation of wear rate with wt.% of melon shell ash particles
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Int J Adv Manuf Technol

Fig. 8 SEM morphology of Al-

12%Si alloy (a) without load (b)
reinforced with 20 wt.% MSA
particles at applied load

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