IAETSD JOURNAL FOR ADVANCED RESEARCH IN APPLIED SCIENCES, VOLUME 4, ISSUE 1, JAN-JUNE /2017 ISSN (ONLINE): 2394-8442 Optimization of process parameters of zirconia reinforced aluminium by powder metallurgy using Response Surface Methodology P.V.Rajesh [1] , G.SakthiBalan [2] [1] Assistant Professor, Dept. of Mechanical Engineering, Saranathan College of Engineering, Trichy, Tamilnadu, India [2] Lecturer, Dept. of Mechanical Engineering, Vignesh Polytechnic College, Trichy, Tamilnadu, India [1] pvrajeshmech73@gmail.com, [2] sakthibala33@gmail.com ABSTRACT. Powder metallurgy process is one of the types of fabrication of composites in which both matrix as well as reinforcement exist as solid powders. Optimizing the process parameters of powder metallurgy in the fabrication of aluminium-zirconia composite used in the bone marrow implants has been done for the desirable physical properties. In this research paper, process parameters such as composite ball milling hours, composition of zirconia and compaction pressure were evaluated using RSM. The properties such as particle density and porosity are studied and tabulated for the proposed composite and the influence of different process parameters over these properties were studied by framing 17 experimental runs using Box-Behnken method. Tests were done by considering three factors and two levels. The parameters which significantly affect the properties were identified using ANOVA. The results indicate that the composition of zirconia predominantly influences the physical properties compared to other factors. INDEXTERMS- powder metallurgy, optimization, zirconia, compaction pressure, density.(keywords) INTRODUCTION Powder metallurgy is an important composite forming technique in which a metal and a non metal, both in powdered form are joined together in specific proportion to enhance the mechanical properties so that the properties of the fabricated composite specimens are superior when compared to the individual metal. Metal matrix composites which are fabricated using powder forming process are found to have increased applications in automobile, shipping and aircraft industries. In our study, we are going to replace the bone joints which are generally made up of corrosion resistant steel with aluminium-zirconia composite. Generally ceramics have the properties such as high strength, hardness, corrosion resistance, least wear rate and bio-inertness [1]. But they are vulnerable to brittleness and slow crack growth. Phase stabilized zirconia is having the unique property of excellent fracture toughness and good adhesive property [2]. It is also having least particle weight when compared to other ceramics that makes it to readily combine with the aluminium powder. Aluminum, on the other hand has good strength-to-weight ratio and workability characteristics that makes it the most popular and inevitable material on earth. When zirconia powder is mixed with aluminium powder, it forms a perfect blend. Thus this composite can act as a bio-degradable implant to fuse the bones inside human body [3]. This composite acts as a catalyst in the speedy growth of broken bone joints as it degrades and disappears due to the flow of blood over a period of time. Hence this composite proves to be a bio-compatible material to be used as an alternative for the implants [4] [5]. In the present study, the objective is to determine the optimum process parameters for the preparation of test specimen with respect to the determined responses. MATERIALS AND METHODS A. Selection of Materials Matrix: Aluminium alloy(Al6061) metal powder of size 50μm is selected as the major constituent. The uniform size can be obtained by means of physical separation processes such as filtering through various size sieves. The chemical composition and physical properties of aluminium powder is given below: To Cite This Article: P.V.Rajesh and G.SakthiBalan ,. Optimization of process parameters of zirconia reinforced aluminium by powder metallurgy using Response Surface Methodology. Advances in Natural and Applied Sciences ;Pages: 184-189