Design analysis of intermetallic compound, Ni3Al for automotive industry

Jayagopi, Mageanragopi (2022) Design analysis of intermetallic compound, Ni3Al for automotive industry. Project Report. Melaka, Malaysia, Universiti Teknikal Malaysia Melaka. (Submitted)

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Abstract

Intermetallic compound is a compound that combines two metals but with unique properties compared to their individual properties and the application of intermetallic compound in this thesis is on automotive industry. One of the main parts of a car is the car chassis which requires a strong and highly strenghten material that can withstand heavy force or load. In the early stage of automotive industry, the material used to build the car chasis was carbon steel and followed by aluminium and titanium according to industry evolution. Eventhough those materials used for car chassis consisting alot of advantages compared to others, there are some drawbacks in using those materials. In order to avoid the disadvantages, a new material should be replaced with them and this thesis discusses how This research paper will consist of the properties, structure and the possibility of material replacement with intermetallic compound. Compared to carbon steel and aluminium, nickel aluminide performed well in most mechanical test, corrosion test and fatigue analysis. The proposed nickel aluminide consisting lesser weight with the density of 6 g/cm3 which is an unique property compared with other metals. Nickel aluminide also consist of ability to withstand higher temperature also higher oxidation together with higher strength and this makes the nickel aluminide to be the best material to be used as raw material for car chasis. Mechanical tests such as tensile testing, Vickers microhardness test were taken in order to gain its mechanical properties while corrosion test for its chemical properties as where rust free material is an important aspect for automotives. The microhardness value increased when the annealing temperature increase while decrease in elongation percentage. The nickel aluminide sample also chemically etched under placed under Scanning Electron Microscope(SEM) and optical microscope to view the microstructure and grain structure of the sample. There were changes in microstructures when the annealing temperature changes also the sample placed under X-Ray Diffraction(XRD) to analyze the crystal structure. The CAD modelling of car chasis were anlayzed under fatigue analysis with different materials and controlled constraints. The result of strength and displacement had been obtained under different annealing temperature and based on the result the nickel aluminide withstands higher temperature compared to other materials. As for the average results the ultimate tensile strength the maximum value recorded was 84.838 MPa which is for non-heated sample of

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