Synthesis and characterization of 356-SiC_p composites by stir casting and compocasting methods

Stir casting is one of the simplest ways of producing aluminum matrix composites.However,it suffers from poor incorporation and distribution of the reinforcement particles in the matrix.These problems become especially significant as the reinforcement size decreases due to greater agglomeration tendency and reduced wettability of the particles with the melt.Development of new methods for addition of very fine particles to metallic melts which would result in more uniform distribution and effective incorporation of the reinforcement particles into the matrix alloy is therefore valuable.In this work,356-5%SiCp(volume fraction) composites,with average SiCp sizes of about 8 and 3 μm,were produced by injection of different forms of the reinforcement particles into fully liquid as well as semisolid slurries of 356 aluminum alloy and the effects of the injected reinforcement form and the casting method on distribution of the reinforcement particles as well as their porosity,hardness and impact strength were investigated.The results reveal that addition of SiC particles in the form of(Al-SiCp)cp composite powder and casting in semisolid state decreases the SiCp particle size,enhances the wettability between the molten matrix alloy and the reinforcements and improves the distribution of the reinforcement particles in the solidified matrix.It also increases the hardness and the impact energy of the composites and decreases their porosity.

Compocasting of A356-CNT composite

A356 aluminum alloys reinforced with carbon nano-tubes (CNTs) were produced by stir casting and compocasting routes and their microstructural characteristics and hardness were examined.In order to alleviate the problems associated with poor wettability, agglomeration and gravity segregation of CNTs in the melt, CNTs were introduced into the melts by injection of CNT deposited aluminum particles instead of raw CNTs.Aluminum particles with mean diameters of less than 100 μm were first deposited by CNTs using Ni-P electroless plating technique and then injected into the melt agitated by a mechanical stirrer.The slurry was subsequently cast at temperatures corresponding to full liquid as well as 0.15 and 0.30 solid fractions.The results show that addition of CNTs to A356 matrix can significantly refine both full liquid and semi-solid cast microstructures.Hardness of the samples is also significantly increased by addition of CNTs and A356-CNT composite cast at 0.3 solid fraction produces the highest hardness.

Effects of compocasting process parameters on microstructural characteristics and tensile properties of A356-SiC_p composites

The effects of compocasting process parameters on some structural and tensile characteristics of the A356-10% SiCp (volume fraction) composites were studied. Semisolid stirring was carried out at temperatures of 590, 600 and 610 °C with stirring speeds of 200, 400 and 600 r/min for 10, 20 and 30 min. The distribution of the SiC particles within the matrix, porosity content and tensile properties of the obtained samples were examined. The structural evaluations show that by increasing the stirring time and decreasing the stirring temperature, the uniformity in the particle distribution is improved;however, by increasing the stirring speed the homogeneity firstly increases and then declines. It is also found that by increasing all of the processing parameters, the porosity content is enhanced. From the tensile characteristics viewpoint, the optimum values of the speed, temperature and time are found to be 400 r/min, 590 °C and 30 min, respectively. The contribution of the reinforcement distribution uniformity prevails over that of the porosity level to the tensile properties.

Comparison of microstructure and wear resistance of A356-SiC_p composites processed via compocasting and vibrating cooling slope

The influences of SiC content on the microstructure, porosity, hardness and wear resistance of A356？SiCp composites processed via two different methods of compocasting and vibrating cooling slope （VCS） were compared with each other. In the as-cast condition, the matrix of VCS and compocast processed composites exhibited globular and dendritric structures, respectively. While a more uniform distribution of SiC particulates in the matrix alloy as well as higher hardness values were obtained for the VCS processed samples, the composites produced via compocasting exhibited less porosity. The increased SiC content （up to 20% in volume fraction） resulted in a more uniform distribution of SiC particles within the matrix alloy and improved wear resistance for both the composite series. However, for the VCS processed composites, the increased SiC content, resulted in the decreased size and shape factor of globules as well as better tribological properties when compared with compocast composites. It was concluded that the improved properties of the VCS processed composites when compared with their compocast counterparts was a consequence of a more uniform distribution of SiC particulates in the matrix alloy as well as the globular microstructure generated during the VCS process.

Solidified structure and solute segregation in Al_2O_3/A356-La alloy composites

Al2O3/A356-La alloy composites were fabricated by squeeze casting, and the effects of La on the solidified structure and the solute segregation during alloy solidification were studied. The results indicate that the structure of the matrix alloy becomes fine and small by the addition of La. La has been richened at the interface to help improve the wettability between the fiber and Al alloy, but there are no intermetallic compounds richening La found at the interface yet. There is no special influence of La on the Mg segregation in the matrix alloy. The distribution of Mg and La in the composites has been at the same position--near the interface.

Microstructure and properties of in-situ TiB_2 particulates reinforced A356 composite

In order to develop a high damping aluminum alloy with strength, in-situ A356/TiB2 composite fabricated with an exothermic reaction process via K2TiF4 and KBF4 salts were studied. The damping behavior of materials over a temperature range of 30300℃ was investigated using a dynamic mechanical thermal analyzer. Experimental findings indicate that damping capacity of A356/TiB2 composite is higher than that of A356 base alloy. Damping capacity of materials increases with increasing temperature while decreases with increasing frequency. Interestingly, the improvement of both damping capacity and tensile strength is observed simultaneously.

Study on fracture behavior of SiCp/A356 composites

The fracture behavior of SiCp/A356 composite at room and high temperatures was studied. Under tensile stress condition at room temperature, the fracture is mostly a combination of the brittle fracture of SiC particles and ductile fracture of A356 matrix. As the tensile temperature increases, the composite changes the main fracture behavior to the separation fracture of the bonding surface between SiC particles and A356 matrix. When the tensile temperature reaches 573 K, the fracture behavior of the composites is almost the whole separation fracture of the bonding surface, which is the main strengthening mechanism at high temperature. Under the cycle stress condition at room and high temperatures, the main fracture behavior of the composites is always a combination of the brittle fracture of SiC particles and ductile fracture of A356 matrix. However, under the cycle stress at high temperature, cycle behavior of the composites changes from cycle hardening at room temperature to the cycle softening at high temperature.

Investigation of Interfaces in Remelted A356-SiC Particulate Duralcan Metal Matrix Composite

For the manufacture of Al-based metalmatrix composites, the foundry productionroute can provide less expensive products witha greater flexibility in meeting designer’s needsamong a vaviety of fablication routes. Recent-ly, a commercially produced foundry ingot,the Duralcan composite of A356 Al alloy +20

Numerical simulation on thixoforging of electronic packaging shell with SiC_p/A356 composites

Based on the research of modem electronic packaging materials, thixo-forming technology was used to fabricate electronic packaging shell. The process of thixo-extrusion with SiCp/A356 composites was simulated by the finite element software DEFORM-3D, then the flow velocity field, equivalent strain field and temperature field were analyzed. The electronic packaging shell was manufactured by extrusion according to the results from numerical simulation. The results show that thixo-forming technology can be used in producing electronic package shell with SiCp/A356 composites, and high volume fraction of SiCp with homogeneous distribution can be achieved, being in agreement with the requirements of electronic packaging materials.

Microstructures and Dry Sliding Wear Properties of ZrB_2/A356 Composites Synthesized by Magneto-chemistry in situ Reaction

In situ A356-x%PVF （particle volume fraction） ZrB2 （ x=1, 3, 5） composites were prepared via magneto-chemistry in situ reaction and the dry sliding wear properties of the composites were investigated. The experimental results show that ZrB2 reinforcement particle is obtained and its morphology mainly present in spherical and regular hexagon. Wear test results show that the values of wear weight loss of the composites decrease with the increase of value under a given sliding time and a certain load of 60 N. Especially, when x=5, the weight loss of the as-prepared composite is 43.1 mg, which is only 36.4% to that ofA356 alloy, 118 rag. The wear mechanism is changed from adhesion wear to adhesion wear and abrasive wear and then to abrasive wear with the increase of x value.

Effective elastic moduli of in-situ A356/TiB_2 composites

The effective elastic moduli （EEM） of A356/TiB2 composites formed by gravity casting and adjusted pressure casting （APC） were measured and compared. The results show that the EEM of A356/TiB2 composites are improved obviously by TiB2 particles and affected by forming methods. The EEM of the specimens formed by APC are higher than those in the gravity casting case. For 9.5%A356/TiB2（volume fraction）, the EEM of the specimens formed by APC reaches 93GPa, which is 9GPa higher than those in the gravity casting case. An analytic model is established to explain the mechanics of the EEM of composites reinforced with TiB2 particles.

Nano-SiC_P particles distribution and mechanical properties of Al-matrix composites prepared by stir casting and ultrasonic treatment

Nano-ceramic particles are generally difficult to add into molten metal because of poor wettability. Nano-SiC particles reinforced A356 aluminum alloy composites were prepared by a new complex process, i.e., a molten-metal process combined with high energy ball milling and ultrasonic vibration methods. The nano particles were β-SiCp with an average diameter of 40 nm, and pre-oxidized at about 850 ℃ to form an oxide layer with a thickness of approximately 3 nm. The mm-sized composite granules containing nano-SiCp were firstly produced by milling the mixture of oxidized nano-SiCp and pure Al powders, and then were remelted in the matrix-metal melt with mechanical stirring and treated by ultrasonic vibration to prepare the composite. SEM analysis results show that the nano-SiC particles are distributed uniformly in the matrix and no serious agglomeration is observed. The tensile strength and elongation of the composite with 2wt.% nano-SiCp in as-cast state are 226 MPa and 5.5％, improved by 20％ and 44％, respectively, compared with the A356 alloy.

Dispersion of SiC particles in mechanical stirring of A356-SiC_p liquid

In order to clarify the dispersion of SiC particles in straight-blade mechanical stirring of A1-SiCp liquid, the dispersion of SiC particles in A356-3.5% SiCp （volume fraction） liquid in a cylindrical crucible was studied. The relationship between rotating speed of stirrer and radial relative deviation of SiCp content in A356 liquid between the center and the periphery of crucible was established in the conditions of 35° for the gradient angle a of blade and 10 mm/s for the speed of moving up and down of stirrer. The results show that the radial relative deviation of SiCp content increases gradually with increasing the rotating speed of stirrer. When the rotating speed of stirrer is 200 r/min, the vertical dispersion of SiC particles in A356 liquid is even, but the radial relative deviation of SiCp content is 0.24. Consequently, the northomogeneous dispersion of SiC particles in A356 liquid is mainly resulted from the nonhomogeneous radial dispersion of SiC particles.

Development of Al356e-Al_2O_3 Nanocomposite Coatings by High Velocity Oxy-fuel Technique

In this research, development of AI356-AI203 nanocomposite coatings has been investigated. AI356-AI203 composite powders were prepared by mechanical milling of AI356 powder and 5 vol.% micro and nanoscaled alumina particles. The milled powders were used as feedstock to deposit composite coatings on A356-T6 aluminum alloy substrate using high velocity oxy-fuel （HVOF） process. X-ray diffractometry, optical and scanning electron microscopy, microhardness and wear tests were used to characterize the composite powders and coatings. The hardness of composite coatings containing micro and nanosized AI203 were 114.1 ± 5.9 HV and 138.4 ± 6.9 HV, respectively which were higher than those for substrate （79.2 ± 1.1 HV）. Nano and microcomposite coatings revealed low friction coefficients and wear rates, which were significantly lower than those obtained for AI356-T6 substrate. Addition of 5 vol.% micro and nanoscaled alumina particles improved the wear resistance by an average of 85% and 91%, respectively. This is mainly caused by the presence of AI203 in matrix and nanocrystalline structure of matrix. Scanning electron microscopy tests revealed different wear mechanisms on the surface of the wear test specimens.

Enhancing Wear Resistance of A356 Alloy by Adding CNFs Based on Ultrasonic Vibration Casting

A356–carbon nanofibers（CNFs） composites with different contents of CNFs were fabricated by ultrasonic vibration casting to investigate the effect of CNFs in the matrix on the mechanical properties and wear resistance. The worn surfaces were investigated using scanning electron microscopy（SEM）. As the CNFs content was increased, strength,hardness and wear resistance were significantly enhanced and the coefficient of friction was extremely reduced. The nanocomposite containing 1.2 wt% of CNFs exhibited more than 109 HV in hardness and less than 0.35 in the coefficient of friction. Compared with the as-cast matrix, the wear rate of the optimal composite was less than one-third of the matrix sample and the microhardness exhibited about 47% enhancement of the matrix. Meanwhile, steadier and lower friction coefficient was also achieved by the composite. CNFs were observed to be either partially or fully crushed forming a carbon film that covered the surface and acted as a solid lubricant, enhancing the wear behavior significantly.