Optimization by Using Taguchi Method of the Production of Magnesium-Matrix Carbide Reinforced Composites by Powder Metallurgy Method
Abstract
:1. Introduction
2. Materials and Methods
2.1. Preparation of Materials and Experimental Plan
- ρb = Relative density (%);
- ρ = Experimentally measured density (gr/cm3);
- ρk = Theoretical density calculated based on powder mixture ratios (gr/cm3).
- P = Bending strength (MPa);
- F = The force applied to the sample at the moment of the fracture (N);
- L = Distance between support points (mm);
- b = Sample width (mm);
- h = Sample height (mm).
2.2. Taguchi Method
- The bigger, the better;
- The smaller, the better;
- Nominal values are better.
3. Results and Discussion
3.1. Statistical Analysis
3.2. SEM-EDS and XRD Studies
4. Conclusions
- While the all parameters have an effect on relative density (%) and bending strength, the most effective parameters on hardness HB10 are the sintering time and additive type.
- Optimum conditions determined by considering all experiments were sintering temperature of 500 °C, sintering time of 5 min, additive type of B4C, and additive ratio of 2.5%. The results obtained under these conditions were 98.74 (%) for relative density, 87.16 HB10 for hardness, and 193.65 MPa for bending strength.
- Since the optimum conditions determined by the Taguchi method in the laboratory environment can also be produced in real production environments, the results of this study can be very useful for industrial scale machining.
- In the Taguchi method, only selected combinations are tested. These combinations are determined by considering studies in the literature. The parameters that affect the study are known. Experiments are carried out by determining the levels of parameters. However, experiments can be analyzed by using methods such as artificial neural networks, where all the values considered can be tested [29,30].
- SEM studies showed that distribution of the carbides in the MgAl matrix were homogeneous. In addition, the addition of carbide caused the formation of pores.
- According to XRD analysis, Mg, MgO, B4C, TiC, Mo2C, and SiC phases were observed in the composites. The reason for not seeing Al in the graphs is that it was dissolved in Mg and formed a solid solution.
Acknowledgments
Author Contributions
Conflicts of Interest
References
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Parameters | Levels | ||||
---|---|---|---|---|---|
1 | 2 | 3 | 4 | ||
A | Sintering Temperature (°C) | 400 | 450 | 500 | 550 |
B | Sintering Time (min) | 1 | 3 | 5 | 7 |
C | Additive Type | B4C | SiC | Mo2C | TiC |
D | Addition Rate (% by weight) | 0 | 2.5 | 5 | 10 |
No. | Parameters | Parameter Values | ||||||
---|---|---|---|---|---|---|---|---|
A | B | C | D | A | B | C | D | |
1 | 1 | 1 | 1 | 1 | 400 | 1 | B4C | 0 |
2 | 1 | 2 | 2 | 2 | 400 | 3 | SiC | 2.5 |
3 | 1 | 3 | 3 | 3 | 400 | 5 | Mo2C | 5 |
4 | 1 | 4 | 4 | 4 | 400 | 7 | TiC | 10 |
5 | 2 | 1 | 2 | 3 | 450 | 1 | SiC | 5 |
6 | 2 | 2 | 1 | 4 | 450 | 3 | B4C | 10 |
7 | 2 | 3 | 4 | 1 | 450 | 5 | TiC- | 0 |
8 | 2 | 4 | 3 | 2 | 450 | 7 | Mo2C | 2.5 |
9 | 3 | 1 | 3 | 4 | 500 | 1 | Mo2C | 10 |
10 | 3 | 2 | 4 | 3 | 500 | 3 | TiC | 5 |
11 | 3 | 3 | 1 | 2 | 500 | 5 | B4C | 2.5 |
12 | 3 | 4 | 2 | 1 | 500 | 7 | SiC | 0 |
13 | 4 | 1 | 4 | 2 | 550 | 1 | TiC | 2.5 |
14 | 4 | 2 | 3 | 1 | 550 | 3 | Mo2C | 0 |
15 | 4 | 3 | 2 | 4 | 550 | 5 | SiC | 10 |
16 | 4 | 4 | 1 | 3 | 550 | 7 | B4C | 5 |
No. | Compound | Production Parameters | Relative Density (%) | Hardness (HB10) | Bending Strength (MPa) | |||
---|---|---|---|---|---|---|---|---|
MgAl | Additive Material % by Weight | Temperature (°C) | Time (min) | Pressure (MPa) | ||||
1 | 100 | Additive-free | 400 | 1 | 40 | 99.80 | 73.5 | 99.11 |
2 | 97.5 | 2.5% SiC | 400 | 3 | 98.68 | 76.5 | 83.56 | |
3 | 95 | 5% Mo2C | 400 | 5 | 86.14 | 77.2 | 142.61 | |
4 | 90 | 10% TiC | 400 | 7 | 86.82 | 45.5 | 54.16 | |
5 | 95 | 5% SiC | 450 | 1 | 98.39 | 78.5 | 96.74 | |
6 | 90 | 10% B4C | 450 | 3 | 98.14 | 80.5 | 103.17 | |
7 | 100 | Additive-free | 450 | 5 | 99.83 | 74.3 | 143.48 | |
8 | 97.5 | 2.5% Mo2C | 450 | 7 | 92.99 | 80.4 | 139.18 | |
9 | 90 | 10% Mo2C | 500 | 1 | 76.73 | 81.5 | 154.69 | |
10 | 95 | 5% TiC | 500 | 3 | 94.81 | 80.7 | 157.32 | |
11 | 97.5 | 2.5% B4C | 500 | 5 | 99.36 | 80.6 | 183.09 | |
12 | 100 | Additive-free | 500 | 7 | 99.88 | 78.5 | 114.28 | |
13 | 97.5 | 2.5% TiC | 550 | 1 | 98.16 | 80.5 | 146.28 | |
14 | 100 | Additive-free | 550 | 3 | 99.92 | 79.0 | 138.80 | |
15 | 90 | 10% SiC | 550 | 5 | 98.75 | 88.6 | 155.74 | |
16 | 95 | 5% B4C | 550 | 7 | 99.59 | 83.5 | 147.90 |
Parameters | Degree of Freedom | Sum of Squares | Mean Squares | F | Effectiveness | |
---|---|---|---|---|---|---|
A | Sintering Temperature (°C) | 3 | 249.68 | 83.23 | 41.27 | Effective |
B | Sintering Time (min) | 3 | 91.25 | 30.42 | 15.08 | Effective |
C | Additive Type | 3 | 551.28 | 183.76 | 91.12 | Effective |
D | Additive Ratio (% by weight) | 3 | 414.88 | 138.29 | 68.57 | Effective |
- | Error | 19 | 38.32 | 2.02 | - | - |
- | Total | 31 | 1345.40 | - | - | - |
Parameters | Degree of Freedom | Sum of Squares | Mean Squares | F | Effectiveness | |
---|---|---|---|---|---|---|
A | Sintering Temperature (°C) | 3 | 999.55 | 333.18 | 13.33 | Effective |
B | Sintering Time (min) | 3 | 331.83 | 110.61 | 4.43 | Not Effective |
C | Additive Type | 3 | 559.25 | 186.42 | 7.46 | Less Effective |
D | Additive Ratio (% by weight) | 3 | 188.59 | 62.86 | 2.52 | Not Effective |
- | Error | 19 | 474.80 | 24.99 | - | - |
- | Total | 31 | 2554.04 | - | - | - |
Parameters | Degree of Freedom | Sum of Squares | Mean Squares | F | Effectiveness | |
---|---|---|---|---|---|---|
A | Sintering Temperature (°C) | 3 | 16,885.9 | 5628.4 | 63.05 | Effective |
B | Sintering Time (min) | 3 | 8492.2 | 2830.7 | 31.71 | Effective |
C | Additive Type | 3 | 4170.2 | 1390.1 | 15.57 | Effective |
D | Additive Ratio (% by weight) | 3 | 2428.4 | 809.5 | 9.07 | Less Effective |
- | Error | 19 | 1696.0 | 89.3 | - | - |
- | Total | 31 | 33,672.0 | - | - | - |
Parameters | Case | ||
---|---|---|---|
Value | Level | ||
A | Sintering Temperature (°C) | 500 | 3 |
B | Sintering Time (min) | 5 | 3 |
C | Additive Type | B4C | 1 |
D | Addition Rate (% by weight) | 2.5 | 2 |
Observed Values (Respectively, relative density, hardness, and the bending strength) | 98.74 (%), 87.16 HB10 and 193.65 MPa | ||
Predicted Values (Respectively, relative density, hardness, and the bending strength) | 99.36 (%), 80.6 HB10 and 183.09 MPa | ||
Confidence limits of prediction “Se” (Respectively, relative density, hardness, and the bending strength) | ±3.62, ±12.75 and ±24.09 |
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Küçük, Ö.; Elfarah, T.T.K.; Islak, S.; Özorak, C. Optimization by Using Taguchi Method of the Production of Magnesium-Matrix Carbide Reinforced Composites by Powder Metallurgy Method. Metals 2017, 7, 352. https://doi.org/10.3390/met7090352
Küçük Ö, Elfarah TTK, Islak S, Özorak C. Optimization by Using Taguchi Method of the Production of Magnesium-Matrix Carbide Reinforced Composites by Powder Metallurgy Method. Metals. 2017; 7(9):352. https://doi.org/10.3390/met7090352
Chicago/Turabian StyleKüçük, Özkan, Tayeb Taher Kalefe Elfarah, Serkan Islak, and Cihan Özorak. 2017. "Optimization by Using Taguchi Method of the Production of Magnesium-Matrix Carbide Reinforced Composites by Powder Metallurgy Method" Metals 7, no. 9: 352. https://doi.org/10.3390/met7090352