24-10-2014, 03:54 PM
Abstracts: Aluminium bronze is a type of bronze in which aluminium is the main alloying metal added to copper, in contrast to standard bronze (copper and tin) or brass (copper and zinc). A variety of aluminium bronzes of differing compositions have found industrial use, with most ranging from 9% to 14% aluminium by weight, the remaining mass being copper; other alloying agents such as iron, nickel, manganese and silicon are also sometimes added to aluminium bronzes. The company makes aluminum bronze bush used to prevent wear in shafts. The work piece of composite material of aluminum bronze having composition of 5% Nickel, 5% Iron, 10% Aluminum and 80% Copper. It is prepared by the metal casting process. The Aluminum used belongs to the grade C95500. The material undergoes breakage during machining and due to which the company faces high rejection. Our motto is to try to reduce the reduction rate and resulting in high profitability to the firm. We tried to achieve the result by varying the composition of aluminium in aluminium bronze but by conducting various respective testing we observed that aluminium content should be increased but limited upto 14% in aluminium bronze. Secondly we tried to change the composition of alloying elements like iron, nikel and manganese whose results are mentioned later in the report but we didn’t get satisfying output. We also tired changing the pouring temprature and came to the conclusion that it should be maintained in the range of 1000? to 1300?. Then we checked for the pouring height of the metal but it didn’t play a major role in avoiding oxide formation. Then studying the microstructure which we got through SEM testing we learnt that the formation of slag in the molten metal resulted into the oxide formation in the casting. To avoid it we added composition of flux into molten metal which results in floating of slag above the molten metal and which made it easily removable before poring it into the mould. The casting produced with the use of flux resulted in reduction of oxide formation drastically and the material didn’t break during machining. We also tried to study the effect of heat treatment on various mechanical properties and tried to improve the properties of aluminium bronze alloy which resulted in the increase of its applications.