Effects of Heating Temperature on Interfacial Microstructure and Compressive Strength of Brazed CBN-AlN Composite Abrasive Grits

CBN-AlN composite abrasive grits and AISI 1045 steel were brazed using Ag-Cu-Ti active filler alloy by heating up to the temperature of 890,900 and 920 ℃,respectively,and then held at the temperature for 8 min.Optical microscope,scanning electron microscope and X-ray diffraction equipment were utilized to study the effects of heating temperature on the microstructure of the joining interface.The compressive strength of the brazed composite grits was also measured.The experimental results show that the atoms of Ti,Al,B and N have preferentially penetrated towards the joining interface of composite grits and filler alloy.The compounds of Ti-nitride,Ti-borides and Ti3AlN were formed in the reaction layer.Degradation effect was not made on the compressive strength of the CBN-AlN composite grits when the brazing process was carried out in the temperature range of 890-920 ℃.

Effect of vibration on interfacial microstructure and mechanical properties of Mg/Al bimetal prepared by a novel compound casting

In this work,a vibration was applied in the preparation of the Mg/Al bimetal by a novel compound casting in order to improve the mechanical properties of the Mg/Al bimetal,and the effect of the vibration on the interfacial microstructure and mechanical properties of the Mg/Al bimetal was investigated.The results indicated that the vibration had a significant effect on the interfacial microstructure and mechanical properties of the Mg/Al bimetal,but it did not change the phase compositions of the interface,which was composed of layerⅠ(Al3Mg2+Mg2Si),layerⅡ(Al_(12)Mg_(17)+Mg_(2)Si)and layerⅢ(Al_(12)Mg_(17)/δ-Mg).Without vibration,the Mg_(2)Si phase with a needle-like morphology mainly aggregated in the layerⅡof the interface.After the application of the vibration,the SEM and EBSD analysis results showed that the Mg_(2)Si and Al3Mg2phases in the interface were obviously refined,and the distribution of the Mg_(2)Si became more uniform,due to the strong forced convection of the molten metal resulting from the vibration.The TEM analysis indicated that the interface between the A_(l3)Mg_(2) and Mg_(2)Si phases was non-coherent,suggesting the Mg_(2)Si particles cannot act as a heterogeneous nucleation base during the solidification process of the interface.Compared to the Mg/Al bimetal without vibration,the shear strength of the Mg/Al bimetal with vibration increased by about 50%from 31.7 MPa on average to 47.5 MPa,and the hardness of the layer I of the interface increased,and the hardness of the layerⅢdecreased.The fracture surface transformed from a flat fracture morphology without vibration to an irregular zigzag fracture morphology.

Effect of a direct magnetic field on the interfacial microstructure between molten aluminium and solid iron

Effect of a direct magnetic field on the interfacial microstructure between molten aluminium and solid iron was studied. The intermetallic phases formed in the intermetallic layers were investigated by means of electron probe microanalysis (EPMA) and X-ray diffraction (XRD). It was found that the DC magnetic field can reduce the average thickness of the intermetallic layer and the average aluminium content in the intermetallic layer. Moreover, the intermetallic phases formed in the intermetallic layers are identified as Al3Fe and Al5Fe2 in the absence of the DC magnetic field, while only Al5Fe2 phase present in the presence of the DC magnetic field.

Interfacial microstructure evolution of 12Cr1MoV/TP347H dissimilar steel welded joints during aging

The interfacial microstructure evolution of 12Cr1MoV/TP347H dissimilar steel welded joints with a nickel-based filler metal during aging was studied in detail to elucidate the mechanism of premature failures of this kind of joints.The results showed that not only a band of granular Cr_(23)C_(6)carbides were formed along the fusion boundary in the ferritic steel during aging,but also a large number of granular or plate-like Cr_(23)C_(6)carbides,which have a cube-cube orientation relationship with the matrix,were also precipitated on the weld metal side of the fu-sion boundary,making this zone be etched more easily than the other zone and become a dark etched band.Stacking faults were found in some Cr_(23)C_(6)carbides.In the as-welded state,deformation twins were observed in the weld metal with a fully austenitic structure.The peak micro-hardness was shifted from the ferritic steel side to the weld metal side of the fusion boundary after aging and the peak value increased signific-antly.Based on the experimental results,a mechanism of premature failures of the joints was proposed.

Influence of TiX (X=B_2 or N) Addition on the Interfacial Microstructure Features of CBN Grains and AgCuTi Composite Filler

Joining experiments of CBN grains to AISI 1045 steel were conducted using Ag-Cu-Ti composite fillers containing TiX （X=B2 or N） particles at 920 ℃ for 5 min. The influences of TiB2 and TiN particles on the interfacial microstructure features between CBN and filler were investigated comparatively. The experimental results show that TiN particles are more effective than TiB2 ones to control the interfacial reaction and particularly the resultants. Thermodynamic analysis reveals that the varied interfacial reaction induced by the addition of TiB2 and TiN particles is mainly atttributed to the activity change of the B and Ti elements in the brazing reaction system.

Effect of Interfacial Microstructure on Mechanical and Tribological Properties of Cu/WS_(2) Self-Iubricating Composites Sintered by Spark Plasma Sintering

In this study,Cu/WS_(2) self-lubricating composites are fabricated by spark plasma sintering.Interfacial microstructure and its effect on mechanical and tribological properties are investigated.High sintering temperature at 850℃promotes decomposition of WS_(2) and its following interfacial reaction with Cu to form Cu_(0.4)W_(0.6) nanoparticles and Cu_(2)S,enhancing mechanical properties as well as wear resistance of the composites.But the destruction of WS_(2) leads to a high friction coefficient.On the contrary,for the composites sintered at 750℃,a nanoscale diffusion zone forms at the Cu/WS_(2) interface.WS_(2) lubricant retains its lamellar structure.The composite shows excellent self-lubrication performance,with a low friction coefficient of 0.16.However,its mechanical properties are low,and the wear rate is one magnitude higher.

Comprehensive study of microstructure and mechanical properties of friction stir welded 5182-O/HC260YD+Z lap joint

The welding of aluminum(Al)and steel has attracted more and more interest due to the weight reduction trend in vehicle and aerospace manufacturing industries.5182-O/HC260YD+Z lap joint was produced by friction stir welding(FSW),and the microstructure and mechanical property of the joint were systemically characterized.The microstructure in horizontal direction of the Al and steel near interface was similar to their corresponding conventional friction stir welded joint.The joint was divided into stir zone of Al(ST-Al),stir zone of interface(ST-I),thermal-mechanically affected zone of steel(TMAZ-Fe)and base material of steel(BM-Fe)according to their distinct microstructure vertically.Three kinds of intermetallic compounds(IMCs)of FeAl_(3),FeAl and Fe_(3)Al were formed at the interface.The horizontal micro hardness distribution exhibited a hat shape and“M”shape in Al and steel,respectively.The hardest region of the joint was located at the ST-I,with a hardness of 175 HV−210 HV.The joint was fractured along the hook structure,with an average shear strength of 73.9 MPa.Fractural morphology of Al and steel indicted a cleavage fracture mode.

Mechanical Properties and Microstructure of Portland Cement Concrete Prepared with Coral Reef Sand

The feasibility of using coral reef sand（CRS） in Portland cement concrete is investigated by testing the mechanical property and microstructure of concrete. The composition, structure and properties of the CRS are analyzed. Mechanical properties and microstructure of concrete with CRS are studied and compared to concrete with natural river sand. The relationship between the microstructure and performance of CRS concrete is established. The CRS has a porous surface with high water intake capacity, which contributes to the mechanical properties of concrete. The interfacial transition zone between the cement paste and CRS is densified compared to normal concrete with river sand. Hydration products form in the pore space of CRS and interlock with the matrix of cement paste, which increases the strength. The total porosity of concrete prepared with CRS is higher than that with natural sand. The main difference in pore size distribution is the fraction of fine pores in the range of 100 nm.

Study on liquid-liquid bimetal composite casting hammers

Crusher hammers for the mineral processing industry must meet the demands of both high wear resistance at the hammer head and high impact toughness at the hammer handle. The crusher hammers made of Hadfield steel have typically low service life of less than 40 hours. To solve the problem, a kind of bimetal crusher hammers made of high chromium cast iron(HCCI) and low alloy steel(LAS) has been successfully developed by using liquid-liquid composite casting. The microstructure and composite interface bonding was analyzed using optical microscope, SEM, EDX and XRD. Micrographs indicate that the composite interface is metallurgically bonded with a zigzag shape across the boundary and without unbound region or void. After heat treatment, the composite hammers have shown excellent properties. The hardness of HCCI is at least 63 HRC and its αk is greater than 3.5 J·cm-2; the hardness of LAS is greater than 35 HRC and its αk is no less than 80 J·cm-2. Diffusion of elements takes place at the interface and forms a transition region. The micro hardness increases from LAS to the interface and then to HCCI. Wear comparison was made separately between the bimetal composite hammer and a Hadfield steel hammer in two quarries of Jilin province and Liaoning province. The results showed that the liquid-liquid bimetal composite hammers did not have the falling off of hammer head or impact fracture phenomenon, and their service life was 3.75 times as long as that of the Hadfield steel hammers.

Micromanufacturing of composite materials:a review

Composite materials exhibit advantages from the combination of multiple properties,which cannot be achieved by a monolithic material.At present,the use of composite materials in miniaturized scale is receiving much attention in the fields of medicine,electronics,aerospace,and microtooling.A common method for producing miniaturized composite parts is micromanufacturing.There has been,however,no comprehensive literature published that reviews,compares,and discusses the ongoing micromanufacturing methods for producing miniaturized composite components.This study identifies the major micromanufacturing methods used with composite materials,categorizes their subclasses,and highlights the latest developments,new trends,and effects of key factors on the productivity,quality,and cost of manufacturing composite materials.A comparative study is presented that shows the potential and versatility associated with producing composite materials along with possible future applications.This review will be helpful in promoting micromanufacturing technology for fabricating miniaturized products made of composite materials to meet the growing industrial demand.

Refill Friction Stir Spot Welding Al Alloy to Copper via Pure Metallurgical Joining Mechanism

The current investigation of refill friction stir spot welding(refill FSSW)Al alloy to copper primarily involved plunging the tool into bottom copper sheet to achieve both metallurgical and mechanical interfacial bonding.Compared to conventional FSSW and pinless FSSW,weld strength can be significantly improved by using this method.Nevertheless,tool wear is a critical issue during refill FSSW.In this study,defect-free Al/copper dissimilar welds were successfully fabricated using refill FSSW by only plunging the tool into top Al alloy sheet.Overall,two types of continuous and ultra-thin intermetallic compounds(IMCs)layers were identified at the whole Al/copper interface.Also,strong evidence of melting and resolidification was observed in the localized region.The peak temperature obtained at the center of Al/copper interface was 591℃,and the heating rate reached up to 916℃/s during the sleeve penetration phase.A softened weld region was produced via refill FSSW process,the hardness profile exhibited a W-shaped appearance along middle thickness of top Al alloy.The weld lap shear load was insensitive to the welding condition,whose scatter was rather small.The fracture path exclusively propagated along the IMCs layer of Cu_(9)Al_(4) under the external lap shear loadings,both CuAl_(2) and Cu_(9)Al_(4) were detected on the fractured surface on the copper side.This research indicated that acceptable weld strength can be achieved via pure metallurgical joining mechanism,which has significant potential for the industrial applications.

Quasi-in-situ Observation of Interfacial Behaviours:Recrystallization and Grain Recombination during Micro-deformed Diffusion Bonding Process

The interfacial behaviours of micro-deformed diffusion bonded joints were systematically revealed.There were two typical bonding interfacial characteristics:“bond line”and migrated grain boundaries.“Bond line”was featured as fine grains and phases on the interface.The critical temperature of joint characterized by“bond line”was 950℃.The increased temperature 1000℃was a critical temperature which interfacial characteristic“bond line”eliminated.The second type was characterized by interfacial migration over 1000℃,in which the bonding interfaces were composed of straight grain boundaries,triple junctions,and protruding and expanding interfacial migrated grains.Additionally,two different interface migration and joint forming mechanisms were observed with elevated bonding temperature:recrystallization and grain recombination.The first one was the discontinuous dynamic recrystallization mechanism,which was observed in the joints bonded at 950℃and 1000℃.The second mechanism was the grain boundary migration mechanism based on the grain growth mechanism,of which the typical bonding temperature was 1050℃.The joint was bonded under two kinds of grain boundary migration,including strain-induced interface grain boundary migration and interface grain boundary migration at triple junction.

Fabrication of Ti/Al/Mg laminated composites by hot roll bonding and their microstructures and mechanical properties

Ti/Al/Mg laminated composites were successfully fabricated by hot roll bonding.The effects of the rolling reduction on the microstructural evolution and mechanical properties of the composites were explored.The results show that Ti/Al/Mg laminated sheets exhibit good interfacial bonding.The rolling reduction has a significant effect on the deformation inhomogeneity through the thickness of the Al layer.The initial grains of the Al layer near the Ti/Al interface are fragmented into fine equiaxed grains,and the grains at the center and near the Al/Mg interface are elongated.The R-cube shear texture of the Al layer forms near the Ti/Al interface and permeates into the center layer in the samples with greater rolling reductions.The b-fiber rolling texture of the Al layer is observed near the Al/Mg interface and increases with the increase of rolling reduction.The stress–strain curves indicate that the fracture appears first in the Mg layer.With the increasing rolling reduction,the ultimate tensile and yield strength values increase,and the elongation up to the Mg layer fracture decreases.

Interlayer engineering for titanium clad steel by hot roll bonding

Hot roll bonding was carried out between commercially pure titanium TA2 and high-strength low-alloy steel Q390 using pure Nb or Mo interlayer at 950 ~C with a total reduction ratio of 86.7%. Interfacial microstructure and bonding properties of titanium clad steel plates were investigated by electron microscopy and mechanical tests. The results showed β-Ti, TiC and Fe2Ti reaction phases were generated at Ti/steel interface for the clad plates with no interlayer. Inserting Nb or Mo interlayer can effectively suppress the formation of brittle phases, while the weak bonding joint transferred to Nb/steel or Mo/steel interface. And some micro-voids were found at the interface of Nb/steel and Mo/steel. The improved shear strength of clad plates with Nb interlayer might be attributed to the elimination of brittle phases at bonding interface. The small size and little quantities of the micro-voids at Nb/steel interface had a relatively weak effect on shear strength. However, the large number and big size of micro-voids were responsible for the degradation of shear strength for the clad plates with Mo interlayer.

Brazing diamond grits onto AA7075 aluminium alloy substrate with Ag–Cu–Ti filler alloy by laser heating

The brazing of diamond is a promising way to fabricate grinding wheels for efficient machining and precision grinding.This work investigated the feasibility of bonding diamond grits onto Aluminium Alloy 7075(AA7075)substrate with a Ag–Cu–Ti filler alloy via laser fusion brazing.The interfacial microstructures and the strength of the brazed diamond joints were studied.The cross-section of the brazed diamond joint consists of a molten filler alloy layer,a molten pool,a heat effect zone,a columnar crystal zone and an equiaxed crystal zone.Within the interface of the filler alloy/substrate metal,microstructures observed possibly were Ag(s.s),Al(s.s),Tix Al,Al2 Cu and Mg intermetallic compounds.A layer of Ti C with a thickness of about 30–50 nm was found at the bonding interface of the diamond/filler alloy.The averaged peak shear force of the brazed joints was found to be approximately 39.8 N.The abrasion grinding test indicated that the diamond/AA7075 brazed joint was adequate for grinding.However,the pulled-off of grit was found to be the primary failure of this type of brazed joint.This work broadened the brazing diamond technique and the range of applications of brazed diamond wheels for efficient grinding.

High Electrical and Thermal Conductivity of Nano-Ag Paste for Power Electronic Applications

The nano-Ag paste consisted of Ag nanoparticles and organic solvents.These organics would be removed by evaporation or decomposition during sintering.When the sintering temperature was 300℃,the resistivity of sintered bulk was 8.35×10^-6Ωcm,and its thermal conductivity was 247 W m^-1 K^-1.The Si/SiC chips and direct bonding copper(DBC)substrates could be bonded by this nano-Ag paste at low temperature.The bonding interface,sintered microstructure and shear strength of Si/SiC chip attachment were investigated by scanning electron microscopy,transmission electron microscopy and shear tests.Results showed that the sintered Ag layer was porous structure and tightly adhered to the electroless nickel immersion gold surface of DBC substrate and formed the continuous Ag–Au interdiffusion layer.The shear strength of Si and SiC chip attachments was higher than 35 MPa when the sintering pressure was 10 MPa.The fracture occurred inside the sintered Ag layer,and the fracture surface had obvious plastic deformation.

Investigation on bonding interfaces of an SA508 steel billet manufactured by additive forging

An experimental steel billet of SA508 reactor pressure vessel material was manufactured by the additive forging method,and microstructure and mechanical properties of the hot-compression bonding interface were systematically investigated.The result indicated that oxidation levels of bonding interfaces were well controlled using vacuum electron beam welding.It was easy to discriminate interfaces from base materials during the optical microstructure observation,since interfaces were characterized by grain or phase boundaries in a straight line.Test results of uniaxial tensile experiments(at 20 and 350°C)and Charpy V-notched impact tests(at 0 and 20°C)showed that fracture behaviour of all those samples appeared at the base material,and bonding interfaces showed advantage of strength and toughness at the forge bonding state.