Improving the ductility and toughness of nano-TiC/AZ61 composite by optimizing bimodal grain microstructure via extrusion speed

In this study,the nano-TiC/AZ61 composites with different heterogeneous bimodal grain(HBG)structures and uniform structure are obtained by regulating the extrusion speed.The effect of HBG structure on the mechanical properties of the composites is investigated.The increasing ductility and toughening mechanism of HBG magnesium matrix composites are carefully discussed.When the extrusion speed increases from 0.75 mm/s to 2.5 mm/s or 3.5 mm/s,the microstructure transforms from uniform to HBG structure.Compared with Uniform-0.75 mm/s composite,Heterogeneous-3.5 mm/s composite achieves a 116.7%increase in ductility in the plastic deformation stage and almost no reduction in ultimate tensile strength.This is mainly because the lower plastic deformation inhomogeneity and higher strain hardening due to hetero-deformation induced(HDI)hardening.Moreover,Heterogeneous-3.5 mm/s composite achieves a 108.3%increase in toughness compared with the Uniform-0.75 mm/s composite.It is mainly because coarse grain(CG)bands can capture and blunt cracks,thereby increasing the energy dissipation for crack propagation and improving toughness.In addition,the CG band of the Heterogeneous-3.5 mm/s composite with larger grain size and lower dislocation density is more conducive to obtaining higher strain hardening and superior blunting crack capability.Thus,the increased ductility and toughness of the Heterogeneous-3.5 mm/s composite is more significant than that Heterogeneous-2.5 mm/s composite.

Hot extrusion of SiC_p/AZ91 Mg matrix composites

SiC particles reinforced AZ91 Mg matrix composites （SiCp/AZ91） with SiC volume fractions of 5%, 10% and 15% were fabricated by stir casting. After T4 treatment, these composites were extruded at 350 °C with an extrusion ratio of 12：1. In the as-cast composite, particles segregated at a microscopic scale within the intergranular regions. Hot extrusion almost eliminated this particle aggregation and improved the particle distribution of the composites. In addition, extrusion refined the grains of matrix. The results show that hot extrusion significantly improves the mechanical properties of the composites. In the as-extruded composite, with the increase of SiCp contents, the grain size of the extruded composites decreases, the strength and elastic modulus increase but the elongation decreases.

Tensile properties and hot extrusion behavior of Zn O-coated Mg_2B_2O_(5w)/6061 Al composites

The 6061 aluminum matrix composites reinforced with ZnO-coated Mg_2B_2O_5w were fabricated by squeeze casting method and followed by extruded under a technical equivalent condition. The mechanical properties and microstructures of the composites were investigated. The results showed that the elastic modulus of the as-cast composites increased straightly with increasing ZnO coating content. The ultimate tensile strength and yield strength of the as-cast composites rapidly increased initially and then declined with increasing ZnO coating content. However, the elongations of all the as-cast composites had similar values. The elongations of the composites were highly enhanced and the ultimate tensile strength of the composite without ZnO coating was the largest after extrusion. A number of whiskers in the composites with ZnO coating were fractured during the extrusion process, but the whiskers＇ breakage extent was limited with the increase of coating content.

RECIPROCATING EXTRUSION OF IN SITU Mg_2Si REINFORCED Mg-Al BASED COMPOSITE

M92Si reinforced Mg-Al based composite with high amount o/silicon was prepared by permanent mould casting, and then extruded by reciprocating extrusion （RE） after the composite was processed by homogenization heat treatment. The effect of RE processing on the morphology and size of M92Si and the mechanical properties of the com- posite were investigated, to develop new ways to refine the M928i phase and improve its shape. The result showed that RE was very useful in refining the M92Si phase. The more the RE processing passes, the better the refining effect would be. Moreover, the uniform distribution of M928i phases would be more in the composite. After the composite was processed by RE for 12 passes, most M92Si phases were equiaxed, with granular diameter below 20 μm, and distributed uniformly in the matrix of the composite. The mechanical properties of the composite could be increased prominently by RE processing, and were much higher than that in the as-cast state. As the temperature rises, the tensile strength is reduced. For the composite RE processed for 12 passes, the tensile strength, yield strength, and elongation are 325.9 MPa, 211.4 MPa, and 3.3% at room temperature, whereas, 288.2 MPa, ,207.7 MPa, and 7.8%, respectively, at 150℃. In comparison with the properties at room temperature, the tensile strength and yield strength are high and only decrease by 11.6% and 1.8% at 150℃. The M928i reinforced Mg-Al based composite possesses good heat resistance at 150℃. The excellent resistance to effect of heat is attributed to the high melting tempera- ture and good thermal stability of fine Mg2Si phases, which are distributed uniformly in the composite, and effectively hinder the grain boundary gliding and dislocation movement.

Microstructure of aluminum/copper clad composite fabricated by casting-cold extrusion forming

An aluminum/copper clad composite was fabricated by the casting-cold extrusion forming technology and the microstructures of the products were observed and analyzed.It is found that aluminum grains at the interface are refined in the radial profiles of cone-shaped deformation zone,but the grains in the center maintain the original state and the grain size is non-uniform.A clear boundary presents between the refined area and center area.In contrast,the copper grains in the radial profiles have been significantly refined.In the center area of the copper,the grains are bigger than those at the boundary.On the surface of the deformable body,the grain size is the smallest,but with irregular grain morphology.After the product is entirely extruded,all the copper and aluminum grains are refined with small and uniform morphology.In the center area,the average diameter of aluminum grains is smaller than 5 μm,and the copper grain on the surface is about 10 μm.At the interface,the grain size is very small,with a good combination of copper and aluminum.The thickness of interface is in the range of 10-15 μm.Energy spectrum analysis shows that CuAl3 phase presents at the interface.

Effect of Gap Size on Coating Extrusion of Pb-GF Composite Wire by Theoretical Calculation and Experimental Investigation

A new method using lead coated glass fiber to produce continuous wire for battery grid of electric vehicles （EVs） and hybrid electric vehicles （HEVs） was introduced. Under equal flow, both the maximum and minimum theoretical value of gap size were studied and estimation equation was established. The experimental results show that the gap size is a key parameter for the continuous coating extrusion process. Its maximum value （Hmax） is 0.24 mm and the minimum one （Hmin） is 0.12mm. At a gap size of 0.18 mm, the maximum of metal extrusion per unit of time and optimal coating speed could be obtained.

Effects of hot extrusion on microstructure and mechanical properties of Mg matrix composite reinforced with deformable TC4 particles

Mg matrix composites were often reinforced by non-deformable ceramic particles.In this paper,a novel Mg matrix composite reinforced with deformable TC4(Ti-6Al-4 V)particles was fabricated and then extruded.The evolutions of microstructure and mechanical properties of the composite during hot extrusion were investigated.Hoi extrusion refined giains and eliminated the segregation of TC4 particles.TC4 particles,as deformable particles,stimulated the nucleation of dynamic recrystallization during extrusion.However,since the deformation of TC4 particles partly released the stress concentrations around them,the recrystallized grains are just slightly smaller around TC4 particles than that away from them,which is evidently different from the case in Mg matrix composites reinforced by non-deformable ceramic particles.Compared with AZ91 matrix composites reinforced by SiC particles,the present composite possesses the superior comprehensive mechanical properties,which are attributed to not only the strong interfacial bonds between TC4p and matrix but also the deformability of TC4 particles.

Damage prediction for magnesium matrix composites formed by liquid-solid extrusion process based on finite element simulation

A damage prediction method based on FE simulation was proposed to predict the occurrence of hot shortness crocks and surface cracks in liquid-solid extrusion process. This method integrated the critical temperature criterion and Cockcroft ＆ Latham ductile damage model, which were used to predict the initiation of hot shortness cracks and surface cracks of products, respectively. A coupling simulation of deformation with heat transfer as well as ductile damage was carried out to investigate the effect of extrusion temperature and extrusion speed on the damage behavior of Csf/AZ91D composites. It is concluded that the semisolid zone moves gradually toward deformation zone with the punch descending. The amplitude of the temperature rise at the exit of die from the initial billet temperature increases with the increase of extrusion speed during steady-state extrusion at a given punch displacement. In order to prevent the surface temperature of products beyond the incipient melting temperature of composites, the critical extrusion speed is decreased with the increase of extrusion temperature, otherwise the hot shortness cracks will occur. The maximum damage values increase with increasing extrusion speed or extrusion temperature. Theoretical results obtained by the Deform^TM-2D simulation agree well with the experiments.

Novel method of screw extrusion for fabricating Al/Mg(macro-) composites from aluminum alloy 6063 and magnesium granules

A novel method of screw extrusion was used for producing a bimetal composite Al/Mg from granules containing aluminium alloy 6063 （AA6063） and commercial pure magnesium. Up to 12.5%（mass fraction） pure magnesium was added to the aluminium alloy. In general, the material consisted of a fine grained microstructure. In addition to the phases originating from the input materials, intermetallic phases were observed as islands consisting of the Al2Mg3 phase surrounded byγ-Mg17Al12, throughout the microstructure. The mechanical properties of the extruded material showed a gradual increase in strength with increasing the addition of Mg. The highest registered UTS, well above 350 MPa, was observed for the material containing 10%Mg. Examinations of the fracture surfaces indicated that increasing the magnesium content led to a higher degree of brittle fracture and a gradual change of the fracture micro-mechanisms. The optimization of the post-extrusion processing conditions is still ongoing.

NUMERICAL SIMULATION OF EXTRUSION OF COMPOSITE POWDERS PREPARED BY HIGH ENERGY MILLING

Based on the characteristic of high energy milling and the micromechanics of composite material, a plastic constitutive equation is implemented for milled composite powders. To check the equation, the extrusion of Ti/Al composite powders prepared by high energy milling was simulated. It was from the numerical analysis that the predicted extrusion pressure mounted up with milling time and extrusion ratio increasing, which was perfect agreement with experimental results.

Effect of hot extrusion on microstructure and tribological behavior of Al_(2)O_(3p) reinforced 7075 aluminum-matrix composites

The effects of hot extrusion and addition of Al_(2)O_(3p) on both microstructure and tribological behavior of 7075 composites were investigated via optical microscopy(OM),scanning electron microscopy(SEM),energy dispersive spectrometry(EDS),and transmission electron microscopy(TEM).The experimental consequences reveal that the optimal addition of Al_(2)O_(3p) was 2 wt%.After hot extrusion,the Mg(Zn,Cu,Al)2 phases partially dissolve into the matrix and generate many uniformly distributed aging precipitation particles,the Al_(7)Cu_(2)Fe phases are squeezed and broken,and the Al_(2)O_(3p) become uniform distribution.The microhardness of as-extruded 2 wt%Al_(2)O_(3p)/7075 composites reaches HV 170.34,increased by 41.5%than as-cast composites.The wear rate of as-extruded 2 wt%Al_(2)O_(3p)/7075 composites is further lower than that of as-cast composites under the same condition.SEM-EDS analyses reveal that the reinforced wear resistance of composites can put down to the protective effect of the Al_(2)O_(3p) reinforced transition layer.After hot extrusion,the transition layer becomes stable,which determines the reinforced wear resistance of the as-extruded composites.

Production of AZ80/Al composite rods employing non-equal channel lateral extrusion

In order to simultaneously take the advantages of magnesium and aluminum alloys, AZ80/A1 composite rods were produced using non-equal channel lateral extrusion （NECLE） process at different temperatures. Scanning electron microscope （SEM） and energy dispersive spectrometer （EDS） tests as well as the shear punch test were employed to study the quality and strength of the bond between the two alloys. It was found that the process temperature was an important factor affecting the level of interfacial bonding, such that increasing the temperature from 250 to 300℃ has improved the strength by 37% and the thickness of the bond between the layers by 4.5%. Moreover, this temperature rise reduced the maximum required forming load by 13%. However, the hardness tests showed that this increase in the process temperature resulted in 4% decrease in the hardness of the composite bar.

Effect of extrusion on the microstructure and mechanical properties of a low-alloyed Mg-2Zn-0.8Sr-0.2Ca matrix composite reinforced by TiC nano-particles

A low-alloyed Mg-2Zn-0.8Sr-0.2Ca matrix composite reinforced by TiC nano-particles was successfully prepared by semi-solid stirring under the assistance of ultrasonic,and then the as-cast composite was hot extruded.The results indicated that the volume fraction of dynamical recrystallization and the recrystallized grain size have a certain decline at lower extrusion temperature or rate.The finest grain size of~0.30μm is obtained in the sample extruded at 200℃ and 0.1 mm/s.The as-extruded sample displays a strong basal texture intensity,and the basal texture intensity increases to 5.937 mud while the extrusion temperature increases from 200 to 240℃.The ultra-high mechanical properties(ultimate tensile strength of 480.2 MPa,yield strength of 462 MPa)are obtained after extrusion at 200℃ with a rate of 0.1 mm/s.Among all strengthening mechanisms for the present composite,the grain refinement contributes the most to the increase in strength.A mixture of cleavage facets and dimples were observed in the fracture surfaces of three as-extruded nanocomposites,which explain a mix of brittle-ductile fracture way of the samples.

Bonding interface zone of Mg-Gd-Y/Mg-Zn-Gd laminated composite fabricated by equal channel angular extrusion

In order to improve the mechanical properties and corrosion resistance of Mg alloys,the equal channel angular extrusion (ECAE)was employed to fabricate the Mg-5Gd-5Y/Mg-2Zn-1Gd(GW55/ZG21)laminated composites.After fabrication and annealing treatment,the microstructural evolution,phase constitution,microhardness,and bonding strength were investigated on the bonding interface zone of GW55/ZG21 laminated composites.The bonding interface zone of GW55/ZG21 laminated composites comprises a lot of Mg3(Y,Gd)2Zn3 particles along the bonding interface,some rod Mg24(Y,Gd)5 phases on GW55 side,and a precipitation free zone(PFZ)on ZG21 side.After annealing treatment,Mg3(Y,Gd)2Zn3 particles along the bonding interface increase, rod Mg24(Y,Gd)5 phases on GW55 side decrease,and PFZ is broadened.Meanwhile,the hardness on the bonding interface zone decreases and the bonding strength increases from 126 MPa to 162 MPa.

Deformation Processed Cu-15 wt pct Cr Composite Synthesized by Hot Hydrostatic Extrusion of Mechanical Milled Powders

A novel technique was developed for the preparation of Cu-15 wt pct Cr composite with high strength and conductivity. The composite powders with refined microstructure and curly lamellae strengthening phase was first prepared by mechanical milling in favorite milling time and then were hot hydrostatic extruded after pre-densification with sintering or hot pressing. It was shown that the extrusion densified the composite powders well and at the same time the chaos curled strengthening phase was aligned into lines and further deformed as strengthening ribbons. The deformation processed Cu-15 wt pct Cr composite prepared by this technique is of superior conductivity, strength and thermal stability.

Casting-cold extrusion of Al/Cu clad composite by copper tubes with different sketch sections

Casting-cold extrusion technology was presented to fabricate alttminum/copper clad composite, and copper tubes with different sketch sections were designed. The technology of aluminum/copper clad composite fabricated by casting-cold extrusion was simulated by DEFORM software using tubes with four arc grooves. The stress and strain in different deformation zones were analyzed. The groove size reduces gradually and the groove shape drives to triangle during the extrusion procedure. The maximum values of equivalent effective stress and radial stress appear in groove zones, and the maximum equivalent effective strain firstly is obtained also in groove zones. The grain size in groove zones is less than that in other zones. The experimental results are consistent with simulation results, which prove that the copper tubes with sketch section are favorable to the metallurgy bond of boundary interface between aluminum and copper.

Modeling of transverse welds formation during liquid-solid extrusion directly following vacuum infiltration of magnesium matrix composite

Liquid-solid extrusion directly following vacuum infiltration(LSEVI)is an infiltration-extrusion integrated forming technique,and transverse weld between upper residual magnesium alloy and magnesium matrix composites is a common internal defect,which can severely reduce the yield of composite products.To improve current understanding on the mechanism of transverse welding phenomenon,a thermo-mechanical numerical model of LSEVI for magnesium matrix composites was developed.The formation of transverse weld during extrusion was visualized using finite element simulation method,and the formation mechanism was discussed from the aspect of velocity field using a point tracking technique.The simulation results were verified by the experimental results in term of weld shape.

Effect of extrusion ratio on coating extrusion of Pb-GF composite wire by numerical simulation and experimental investigation

The extrusion ratio is one of the key parameters for manufacturing the lead-glass fiber(Pb-GF)composite wire by coating extrusion.The effect of extrusion ratio on coating extrusion of Pb-GF composite wire was studied by finite element numerical simulation with the use of the DEFOEM simulation software.The simulation result shows that the higher the extrusion ratio,the higher the effective stress that the glass fiber bears during extrusion.It is also observed that the extrusion force increases with the increase of the extrusion ratio.The extrusion experiment of Pb-GF composite wire reveals that extrusion ratio is changed by changing the quantity of glass fiber and composite diameter.The rule that increasing the extrusion ratio enhances the coating speed limit suggests that the load on the glass fiber increases with increasing extrusion ratio.Both the simulation and the extrusion experiments show that the extrusion force increases with increasing extrusion ratio.

Powder Extrusion Molding of Nanocrystalline WC-10Co Composite Cemented Carbide

The rods that were shaped from nanocrystalline WC- 10.21 Co-0.42 VC/ Cr3 C2 （ wt% ） composite powders by using powder extrusion molding （PEM） were investigated. The nanocrystalline WC- 10.21 Co- 0. 42 VC/ Cr3 C2 （ wt% ） composite powders were prepared by the spray thermal decomposition-continuous reduction and carburization technology. In order to improve the properties of rods shaped by using powder extrusion molding, the cold isostatic pressing （CIP） technology was used before or after debinding. Specimens were siutered by vacuum siutering and hot isostatic pressing （HIP）. The density, Rockwell A hardness, magnetic coercivity , and magnetic saturation induction of siutered specimen were measured. The microstructure of the green bodies and the siutered specimens was studied by scanning electron microscopy （SEM）. Results show that the rod formed by using powder extrusion molding after debinding and followed by cold isostatic pressing can be siutered to 99.5% density of composite cemented carbide rods with an average grain size of about 200- 300 nm, magnetic coercivity of 30.4 KA / m, Rockwell A hardness of 92.6 and magnetic saturation induction of 85% . Superfine WC- 10 Co cemented carbide rods with excellent properties were obtained.

Forming of tubes and bars of alumina/LY12 composites by liquid extrusion process

Tube and bar products of aluminum alloy composites reinforced by alumina short fiber were formed in a single process with liquid extrusion technology. The microstructure verifies that the reinforcing effect is obvious in the deformation direction since fibers are distributed along this direction, which is resulted from the flow and crystallization under pressure of liquid metal and large plastic deformation of solidified metal in the process. The interface between fiber and matrix belongs to mechanical bonding. The fractograph demonstrates ductile mode. Liquid extrusion process opens up a new way for fabricating tube, bar and shaped products.