Experimental study and numerical analysis on dry friction and wear performance of co-continuous SiC/Fe-40Cr against SiC/2618 Al alloy composites

The dry friction and wear behaviors of co-continuous composites SiC/Fe–40Cr against SiC/Al 2618 alloy were investigated on a ring-on-ring friction and wear tester at sliding speed of 30-105 m/s under the load of 1.0-2.5 MPa. The experimental result reveals that the characteristic of two body abrasive wear and oxidation wear mechanisms are present for SiCn/2618 Al composite under higher load and sliding speed. SiC ceramic continuous network as the reinforcement can avoid composite from the third body wear that usually occurs in traditional particle reinforced composite. The mechanically mixed layer (MML) controls greatly the wear rate and friction coefficient of the composites. The composites tested at higher sliding speed exhibit higher value of friction coefficient and fluctuation, which is associated with the intermittent formation and removal of the MML. The wear and stress—strain behaviors of SiCn/Fe–40Cr against SiCn/Al 2168 at 30-105 m/s under 1.0-2.5 MPa were analyzed by finite element method with the software Solidwork2012 Simulation, respectively. The wear and stress–strain behavior of the composite predicted by the FEM correlated well with the experimental results.

Characterization and evaluation of interface in SiC_p/2024 Al composite

35% SiCp/2024 Al（volume fraction） composite was prepared by powder metallurgy method. The microstructures of Si Cp/Al interfaces and precipitate phase/Al interfaces were characterized by HRTEM, and the interface conditions were evaluated by tensile modules of elasticity and Brinell hardness measurement. The results show that the overall Si Cp/Al interface condition in this experiment is good and three kinds of Si Cp/Al interfaces are present in the composites, which include vast majority of clean planer interfaces, few slight reaction interfaces and tiny amorphous interfaces. The combination mechanism of Si C and Al in the clean planer interface is the formation of a semi-coherent interface by closely matching of atoms and there are no fixed or preferential crystallographic orientation relationships between Si C and Al. MgAl2O4 spinel particles act as an intermediate to form semi-coherent interface with SiC and Al respectively at the slight reaction interfaces. When the composite is aged at 190 °C for 9 h after being solution-treated at 510 °C for 2 h, numerous discoid-shaped and needle-shaped nanosized precipitates dispersively exist in the composite and are semi-coherent of low mismatch with Al matrix. The Brinell hardness of composites arrives peak value at this time.

Electrodeposition of Ni-W Amorphous Alloy and Ni-W-SiC Composite Deposits

Ni-W alloys and their composite deposits are electroplated on the metals when an appropriate complex agent is selected on the base of the theories of electrochemistry and complex chemistry, and the principle of induced codeposition. Effects of the bath composition, pH value, temperature and current density on the electrode position of Ni-W alloys and their composite deposits have been investigated, and the effect of heat treatment temperature on the hardness, structure and cohesive force of the amorphous Ni-W alloys and their composite deposits are also discussed. Results showed that the alloys containing more than 44 wt pct W content and the composite deposits containing 7.8 wt pct SiC content could be obtained by making use of the appropriate bath composition and plating conditions. Alloys and their composite deposits with over 44 wt pct W content show amorphous structure. The hardness of amorphous Ni-W alloys and their composite deposits increases obviously when heated, and can reach to 1350 HV and 1520 HV respectively for 46 wt pct W content. The cohesion on Cu, carbon steel and stainless steel is very good.

Effect of Ni content on the wear behavior of Al-Si-Cu-Mg-Ni/SiC particles composites

In recent years,the addition of Ni has been widely acknowledged to be capable of enhancing the mechanical properties of Al-Si alloys.However,the effect of Ni on the wear behaviors of Al-Si alloys and Al matrix composites,particularly at elevated temperat-ures,remains an understudied area.In this study,Al-Si-Cu-Mg-Ni/20wt%SiC particles(SiCp)composites with varying Ni contents were prepared by using a semisolid stir casting method.The effect of Ni content on the dry sliding wear behavior of the prepared compos-ites was investigated through sliding tests at 25 and 350℃.Results indicated that theθ-Al_(2)Cu phase gradually diminished and eventually disappeared as the Ni content increased from 0wt%to 3wt%.This change was accompanied by the formation and increase inδ-Al_(3)CuNi andε-Al_(3)Ni phases in microstructures.The hardness and ultimate tensile strength of the as-cast composites improved,and the wear rates of the composites decreased from 5.29×10^(−4)to 1.94×10^(−4)mm^(3)/(N∙m)at 25℃and from 20.2×10^(−4)to 7×10^(−4)mm^(3)/(N∙m)at 350℃with the increase in Ni content from 0wt%to 2wt%.The enhancement in performance was due to the presence of strengthening network structures and additional Ni-containing phases in the composites.However,the wear rate of the 3Ni composite was approximately two times higher than that of the 2Ni composite due to the fracture and debonding of theε-Al_(3)Ni phase.Abrasive wear,delamination wear,and oxidation wear were the predominant wear mechanisms of the investigated composites at 25℃,whereas delamination wear and oxid-ation wear were dominant during sliding at 350℃.

Electroless plating and growth kinetics of Ni-P alloy film on SiC_p/Al composite with high SiC volume fraction

After Sn/Pd activating, the SiCp/Al composite with 65% SiC (volume fraction) was coated by electroless Ni?P alloy plating. Surface morphology of the composite and its effect on the Ni?P alloy depositing process and bonding action of Ni and P atoms in the Ni?P alloy were studied. The results show that inhomogeneous distribution of the Sn/Pd activating points results in preferential deposition of the Ni?P alloy particles on the Al alloy and rough SiC particle surfaces and in the etched caves. The Ni?P alloy film has an amorphous structure where chemical bonding between Ni and P atoms exists. After a continuous Ni?P alloy film formed, electroless Ni?P alloy plating is not affected by surface morphology and characteristics of the SiCp/Al composite any longer, but by the electroless plating process itself. The Ni?P alloy film follows linear growth kinetics with an activation energy of 68.44 kJ/mol.

Microstructure and properties of Al/Si/SiC composites for electronic packaging

The Al/Si/SiC composites with medium volume fraction for electronic packaging were fabricated by gas pressure infiltration.On the premise of keeping the machinability of the composites,the silicon carbide particles,which have the similar size with silicon particles（average 13 μm）,were added to replace silicon particles of same volume fraction,and microstructure and properties of the composites were investigated.The results show that reinforcing particles are distributed uniformly and no apparent pores are observed in the composites.It is also observed that higher thermal conductivity（TC） and flexural strength will be obtained with the addition of SiC particles.Meanwhile,coefficient of thermal expansion（CTE） changes smaller than TC.Models for predicting thermal properties were also discussed.Equivalent effective conductivity（EEC） was proposed to make H-J model suitable for hybrid particles and multimodal particle size distribution.

Microstructures and properties of Al-50%SiC composites for electronic packaging applications

Al？50%SiC （volume fraction） composites containing different sizesofSiC particles （average sizesof 23, 38 and 75 μm） were prepared by powder metallurgy. The influences of SiC particle sizes and annealing on the propertiesof the compositeswere investigated. The results show that SiC particles are distributed uniformly in the Al matrix. The coarse SiC particles result in higher coefficient of thermal expansion （CTE） and higher thermal conductivity （TC）, while fine SiC particles decrease CTE and improve flexural strength of the composites. The morphology and size of SiC particles in the composite are not influenced by the annealing treatment at 400℃for 6h. However, the CTE and the flexural strength of annealed composites are decreased slightly, and the TCis improved. The TC, CTE and flexural strength of the Al/SiC composite with averageSiC particlesize of75 μm are 156 W/（m·K）, 11.6×10^-6K^-1 and 229 MPa, respectively.

Rolling of Al-SiC_p Composites

Aluminum based metal matrix composites are offering o utstanding properties in a number of automotive and aircraft components and body structures. The major advantages of these composite materials are their high st rength to weight ratio, high stiffness, high hardness, wear resistance, low coef ficient of thermal expansion, superior dimensional stability and versatility to designer. In addition to these their isotropic properties, good forming characte ristics, easy availability of cheaper reinforcements along with the availability of comparatively low cost, high volume production methods have made them a prom ising material for future growth. Weight reduction is a major goal of automotive innovations. Lighter vehicles/ ai rcraft means less fuel consumption, reduced emissions, and improved performance. Components made from highly loaded aluminium matrix composites are attractive r elative to iron based materials because of their low density, high stiffness (eq uivalent to nodular iron) and better heat transfer characteristics. The basic co st of materials is higher with these advanced composites; however, manufacturing the part to near net shape may offset basic material costs. A good aluminium based material design can improves safety. The aluminium-based composites can give cars better acceleration and braking, improved handling, ex cellent durability, and ease of repair. Tha aluminum-based composite performs a s well or better in crash than conventional steel-structured cars because of th eir larger volume, which can absorb more crash energy. Another excellent advanta ge of Al-SiC p composite in auto design is better stability and response, and reduced noise, vibration/harshness (NHV). These advantages stem from reduced veh icle weight combined with high structural stiffness and also lead to improved st ability and turning response. In the present work Al-SiC p composite plates of 10 to 12 mm thickness w ere cast using sand casting as well as die casting process. The plates were furt her machined to 3 to 4 mm thicknesses. The machined plates were subjected to col d as well hot rolling. The cold rolling of Al-3 wt.% SiC composite plates was done on 2 high experimental cold rolling mill at Indian Oil Corporation Ltd., R esearch and Development centre, Faridabad. For hot rolling, the Al-5 weight % SiC p composite plates were heat treated at 500 ℃ temperature and Al-15 weight % SiC p composite plates were heat treate d at 550 ℃ temperature for 20 minutes. The plates were hot rolled on 2 high ro lling mill of one ton capacity at IIT Delhi. The maximum percentage reduction ob tained after hot rolling of Al-5 weight % SiC p composite and Al- 15 weight % SiC p composite plates for 10 passes was 11 % and 6 % respectively. During col d rolling of Al-SiC p composites cracks (particle fracture) were observed due to the low ductility of Al-SiC p composties at room temperature. The various m echanical properties such as tensile strength, hardness and wear resistance were measured for the rolled and un-rolled Al-SiC p composite plates. The tensile strength of un-rolled and rolled Al-5wt.% SiC p composites are shown in Tab. 1. Table shows that the tensile strength decreases after rolling. This may be du e to the damage of the bonding between aluminum and silicon carbide particulates . The Rockwell hardness values of Al-5 wt.% SiC p composites measured before a nd after hot rolling are shown in Tab.2. The hardness was found to decrease afte r hot rolling, which may be due to the annealing of composites during heating. T he Rockwell hardness values of Al-3 wt.% SiC p composites before and after cold rolling are shown in Tab.3. The Table shows that the Rockwell hardness of Al-SiC p compostes increases after cold rolling due to the workhardening effec t. The wear resistance of rolled and un-rolled Al-SiC p composites were teste d on reciprocating ball on flat wear testing machine. The wear resistance of Al -SiC p composites decreases after hot rolling due to decrease in hardness

Thermal analysis for brake disks of SiC/6061 Al alloy co-continuous composite for CRH3 during emergency braking considering airflow cooling

The mass of high-speed trains can be reduced using the brake disk prepared with SiC network ceramic frame reinforced 6061 aluminum alloy composite （SiCn/Al）. The thermal and stress analyses of SiCn/Al brake disk during emergency braking at a speed of 300 km/h considering airflow cooling were investigated using finite element （FE） and computational fluid dynamics （CFD） methods. All three modes of heat transfer （conduction, convection and radiation） were analyzed along with the design features of the brake assembly and their interfaces. The results suggested that the higher convection coefficients achieved with airflow cooling will not only reduce the maximum temperature in the braking but also reduce the thermal gradients, since heat will be removed faster from hotter parts of the disk. Airflow cooling should be effective to reduce the risk of hot spot formation and disc thermal distortion. The highest temperature after emergency braking was 461 °C and 359 °C without and with considering airflow cooling, respectively. The equivalent stress could reach 269 MPa and 164 MPa without and with considering airflow cooling, respectively. However, the maximum surface stress may exceed the material yield strength during an emergency braking, which may cause a plastic damage accumulation in a brake disk without cooling. The simulation results are consistent with the experimental results well.

Development of Fundamental Research of SiC_w / Al Composites in HIT Part Ⅱ: Mechanical Behaviour of Squeeze-cast SiC_w / Al Composites

Studies on the mechanical behaviour of squeeze-cast SiCw / Al composites have been revjewed. The results show that SiCw / Al composites exhibit improved mechan ical properties and cyclic hard ening. The reasons leading to the above results are discussed. Localized deformation near SiC whiskers plays an important role in the initiation of microcracks in the composites, and the fracture of the composites is caused by the abrupt linking of microcracks

Preparation and Mechanical Properties of-SiC Nanoparticle Reinforced Aluminum Matrix Composite by a Multi-step Powder Metallurgy Process

β-SiC nanoparticle reinforced A1 matrix （nano-SiCp/A1） composite was prepared by a multi- step powder metallurgy strategy including presureless sintering, hot compacting process and hot extrusion. The microstructures of the as-prepared composites were observed by scanning electronic microscopy （SEM）, and the mechanical properties were characterized by tensile strength measurement and Brinell hardness test. The experimental results revealed that the tensile strength of the composite with the addition of 5wt%/3-SIC nanoprtieles could be increased to 215 MPa, increasing by 110% compared with pure A1 matrix. Comparative experiments reflected that theβ-SIC nanoprticles showed significant reinforcement effect than traditional a-SiC micro-sized particles. The preparation process and sintering procedure were investigated to develop a cost effective preparation strategy to fabricate nano-SiCp/A1 composite.

Optimization of Machining Characteristics for Al/SiCp Composites using ANN/GA

The present work is focused on optimization of machining characteristics of AI/SiCp composites. The machining characteristics such as specific energy, tool wear and surface roughness were studied. The parameters such as volume fraction of SiC, cutting speed and feed rate were considered. Artificial neural networks (ANN) was used to train and simulate the experimental data. Genetic algorithms (GA) was interfaced with ANN to optimize the machining conditions for the desired machining characteristics. Validation of optimized results was also performed by confirmation experiments.

Role of particle stimulated nucleation in recrystallization of hot extruded Al 6061/SiC_p composites

Studies on texture and microstructure evolution in hot extruded Al 6061 aluminium alloy reinforced with uncoated and nickel coated SiC p were carried out by electron backscattered diffraction technique.Textures of both the alloy and its composite with nickel coated SiC p do exhibit strong β fiber with its axis parallel to the direction of extrusion.In addition to the dominant cube texture（001） 100,fully recrystallized grains with partially equiaxed structure have been observed in the alloy reinforced with uncoated SiC p.The recrystallization texture of this composite can be attributed to the particle stimulated nucleation（PSN） due to the presence of SiC p with size less than 5 μm.Under these conditions,the low value of Zener-Hollomon,Z（～1012s-1） confirms that PSN is one of the dominant mechanisms for recrystallization and is governed by formation of deformation zone rather than stored energy.

Vacuum brazing of Si/SiC ceramic composite and Invar alloy using TiSOCu-W filler metals

Si/SiC ceramic composite and lnvar alloy were successfidly joined by vacuum brazing using Ti5OCu-W filler metals into which W was added to release the thermal stress of the brazed joint. Microstructures of the brazed joints were irwestigated by scanning electron micrascope （SEM） and energy dispersive spectrometer （EDS）. The mechanical properties of the brazed joints were measured by shearing tests. The results showed that the brazed joints were composed of Ti-Cu phase, W phase and Ti-Si phase. W had no effect on the wettability and mobility of the .filler metals. The growth of Ti2 Cu phase was restrained, and the reaction between ceramic composite and filler metals was weakened. The specimen, brazed at 970°C for 5 rain, had the maximum shear strength of 108 MPa at room temperature.

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.

Microstructure and wear performance of Al5083/CeO_2/SiC mono and hybrid surface composites fabricated by friction stir processing

Friction stir processing（FSP） was utilized to produce surface composites by incorporating nano-sized cerium oxide（CeO2） and silicon carbide（SiC） particles individually and in combined form into the Al5083 alloy matrix. The study signified the role of these reinforcements on microstructure and wear behavior of the resultant surface composite layers. The wear characteristics of the resultant mono and hybrid surface composite layers were investigated using a pin-on-disc wear tester at room temperature. The microstructural observations of FSPed regions and the worn out surfaces were performed by optical and scanning electron microscopy. Considerable grain refinement and uniform distribution of reinforcement particles were achieved inside the nugget zone. All the composite samples showed higher hardness and wear resistance compared to the base metal. Among the composite samples, the hybrid composite（Al5083/CeO2/SiC） revealed the highest wear resistance and the lowest friction coefficient, whereas the Al5083/SiC composite exhibited the highest hardness, i.e., 1.5 times as hard as that of the Al5083 base metal. The enhancement in wear behavior of the hybrid composites was attributed to the solid lubrication effect provided by CeO2 particles. The predominant wear mechanism was identified as severe adhesive in non-composite samples, which changed to abrasive wear and delamination in the presence of reinforcing particles.

Effect of heat treatment on microstructure and thermophysical properties of diamond/2024 Al composites

50%diamond particle （5μm） reinforced 2024 aluminum matrix （diamond/2024 Al） composites were prepared by pressure infiltration method. Diamond particles were distributed uniformly without any particle clustering, and no apparent porosities or significant casting defects were observed in the composites. The diamond-Al interfaces of as-cast and annealed diamond/2024 Al composites were clean, smooth and free from interfacial reaction product. However, a large number of Al2Cu precipitates were found at diamond-Al interface after aging treatment. Moreover, needle-shaped Al2MgCu precipitates in Al matrix were observed after aging treatment. The coefficient of thermal expansion （CTE） of diamond/2024 Al composites was about 8.5×10-6 °C-1 between 20 and 100 °C, which was compatible with that with chip materials. Annealing treatment showed little effect on thermal expansion behavior, and aging treatment could further decrease the CTE of the composites. The thermal conductivity of obtained diamond/2024 Al composites was about 100 W/（m？K）, and it was slightly increased after annealing while decreased after aging treatment.

Microstructural and abrasive wear properties of SiC reinforced aluminum-based composite produced by compocasting

The effect of SiC particles reinforcement with average size of 1, 5, 20 and 50 μm and volume fraction of 5%, 10% and 15% on the microstructure and tribological properties of Al-based composite was investigated. Composites were produced by applying compocasting process. Tribological properties of the unreinforced alloy and composites were studied using pin-on-disc wear tester, under dry sliding conditions at different specific loads. The influence of secondary mechanical processing with different rolling reductions on the dry sliding wear characteristics of Al matrix composites was also assessed. Hardness measurement and scanning electron microscopy were used for microstructural characterization and investigation of worn surfaces and wear debris. The proper selection of process parameter such as pouring temperature, stirring speed, stirring time, pre-heated temperature of reinforcement can all influence the quality of the fabricated composites. The porosity level of composite should be minimized and the chemical reaction between the reinforcement and matrix should be avoided.

Comparison of effect of SiC and MoS2 on wear behavior of Al matrix composites

In order to improve dry sliding wear resistance of pure aluminum against steel, aluminum-based composites reinforced with different contents of SiC,MoS2 and SiC/MoS2 particles were synthesized by press and sintering of the corresponding powder mixtures. The microstructural evaluations showed a dense microstructure which were in good agreement with the result of density and hardness measurements. The results of pin on disk wear tests performed against an AISI 52100 steel pin at a constant load and sliding velocity showed that there was a critical content for both types of the reinforcements at which the lowest wear rate was obtained, i.e. 10 vol.% and 2 vol.%, respectively,for Al/SiC and Al/MoS2 composites. However,the lowest wear rate and friction of coefficient were attained for Al/10 SiC/2 MoS2 hybrid composite. According to the scanning electron microscope observations, the predominant wear mechanism was changed from adhesion to abrasion mostly whenMoS2 particles were incorporated in the pure aluminum. Mild delamination was identified as the main wear mechanism for Al/SiC and Al/SiC/MoS2 composites. The frictional traces and worn surfaces of Al/SiC/MoS2 composites approached to those of Al/SiC composites,indicating the dominant role of SiC particles in tribological behavior of the hybrid composites.

Characterization of cast A356 alloy reinforced with nano SiC composites

The microstructure and mechanical properties of nano composites processed via stir casting were studied. The composites were based on the A356 aluminum alloy reinforced with nano SiC particles. The density measurements show that the samples contain little porosity and the amount of porosity in the composites increases with increasing volume fraction of SiC. The microstructures of the composites were examined using optical microscope and transmission electron microscope. Microscopic observations of the microstructures reveal that the dispersion of the particles is uniform. The yield strength, ultimate tensile strength and the elastic modulus are improved with the addition of nano particles although some reduction in ductility is observed. The highest yield strength and ultimate tensile strength are obtained with the addition of 3.5% SiC nano-particles. A relatively ductile fracture in tensile fractured samples was observed by fractography examination.