Preparation of aluminium-fly ash particulate composite by powder metallurgy technique

Aluminium-fly ash mixtures containing different weight percentages of fly ash were prepared and compacted at pressures from 138–414 MPa. The compacts prepared at 414 MPa were sintered in nitrogen atmosphere at 600, 625 and 645°C, respectively. The time of sintering ranged from 0.5–6 h. The densification parameter and the green densities of the compacts were determined as a function of compacting pressure and fly ash weight per cent. Density, hardness and strength of the sintered compacts were determined as a function of weight per cent of fly ash particles. Volume changes during sintering of green compacts were also evaluated as a function of increasing fly ash weight per cent. Microscopic studies of green and sintered compacts were done to study the effectiveness of sintering. Green and sintered density of the compacts were found to decrease with increasing weight per cents of fly ash. Sintering results in slight decrease in density and increase in volume of green compacts within the range investigated. Strength of the sintered compacts decreased with increasing weight per cent of fly ash under the present experimental conditions; however, the hardness was found to increase slightly up to 10 wt% fly ash, beyond which it decreased. This revised version was published online in November 2006 with corrections to the Cover Date.