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

Fatigue crack growth mechanism in cast hybrid metal matrix composite reinforced with SiC particles and Al_2O_3 whiskers

The fatigue crack growth(FCG) mechanism of a cast hybrid metal matrix composite(MMC) reinforced with SiC particles and Al2O3 whiskers was investigated. For comparison, the FCG mechanisms of a cast MMC with Al2O3 whiskers and a cast Al alloy were also investigated. The results show that the FCG mechanism is observed in the near-threshold and stable-crack-growth regions.The hybrid MMC shows a higher threshold stress intensity factor range, ?Kth, than the MMC with Al2O3 and Al alloy, indicating better resistance to crack growth in a lower stress intensity factor range, ?K. In the near-threshold region with decreasing ?K, the two composite materials exhibit similar FCG mechanism that is dominated by debonding of the reinforcement–matrix interface, and followed by void nucleation and coalescence in the Al matrix. At higher ?K in the stable- or mid-crack-growth region, in addition to the debonding of the particle–matrix and whisker–matrix interface caused by cycle-by-cycle crack growth at the interface, the FCG is affected predominantly by striation formation in the Al matrix. Moreover, void nucleation and coalescence in the Al matrix and transgranular fracture of SiC particles and Al2O3 whiskers at high ?K are also observed as the local unstable fracture mechanisms.However, the FCG of the monolithic Al alloy is dominated by void nucleation and coalescence at lower ?K, whereas the FCG at higher ?K is controlled mainly by striation formation in the Al grains, and followed by void nucleation and coalescence in the Si clusters.

Microstructure and interface thermal stability of C/Mo double-coated SiC fiber reinforced γ-TiAl matrix composites

C/Mo duplex coating interfacially modified SiC fiber-reinforced γ-TiAl matrix composite （SiCf/C/Mo/γ-TiA1） was prepared by foil-fiber-foil method to investigate its interfacial modification effect. SiCf/C/TiAl composites were also prepared under the same processing condition for comparision. Both kinds of the composites were thermally exposed in vacuum at 800 and 900℃ for different durations in order to study thermal stability of the interfacial zone. With the aids of scanning electron microscope （SEM） and energy dispersive spectrometer （EDS）, the interracial microstructures of the composites were investigated. The results reveal that, although adding the Mo coating, the interfacial reaction product of the SiCf/C/Mo/TiAl composite is the same with that of the SiCf/C/TiA1 composite, which is TiC/Ti2AlC between the coating and the matrix. However, C/Mo duplex coating is more efficient in hindering interfacial reaction than C single coating at 900 ℃ and below. In addition, a new layer of interfacial reaction product was found between Ti2AlC and the matrix after 900 ℃, 200 h thermal exposure, which is rich in V and close to the chemical composition of B2 phase.

Corrosion Behavior of SiC_p/2024 Al Matrix Composites in 3.5 wt pct Sodium Chloride

The influences of volume fraction and particle size of SiC particulate reinforcements on the corrosion characteristics of SiCp/2024 Al metal matrix composites in aerated 3.5 wt pct NaCI aqueous solution were investigated. The electrochemical behavior was investigated by potentiodynamic polarization and electrochemical impedance spectroscopy, the general corrosion behavior of the composites was studied further by immersion tests. The results showed that pitting susceptibility was about the same for the composites and the alloy. The corrosion potentials were also independent of SiC phase. The corrosion resistance for the composites decreased as the volume fraction increased or particle size decreased.

Microstructure and damping behavior of SiC_p/Gr/2024Al metal matrix composites by squeeze casting technology

SiCp/Gr/2024Al metal matrix composites were processed by squeeze casting technology. The microstructure of composites was observed by SEM and TEM, and the effects of graphite particulates and SiC particulates on the damping behaviors of composites were also investigated. The results show that the microstructure of composites was dense and homogeneous, without any interfacial reactivity among reinforcement/matrix interfaces. Compared with the damping capacity of 2024A1, the damping capacity of composites was enhanced significantly by addition of SiC or graphite particulates. The main damping mechanisms of SiCp/Al composites were ascribed to the dislocation damping, and those of SiCp/Gr/2024Al were attributed to the intrinsic damping and interface damping.

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.

Research on the Characters of the Cutting Force in Vibration Cutting Particle Reinforced Metal Matrix Composites SiC_p/Al

In this paper, turning experiments of machining particle reinforced metal matri x composites(PRMMCs) SiC p/Al with PCD tools have been carried out. The cutting force characteristics in ultrasonic vibration turning compared with that in com mon turning were studied. Through the single factor experiments and multiple fac tor orthogonal experiments, the influences of three kinds of cutting conditions such as cutting velocity, amount of feed and cutting depth on cutting force were analyzed in detail. Meanwhile, according to the experimental data, the empirica l formula of main cutting force in ultrasonic vibration turning was conclude d. According to the test results, the cutting force is direct proportion to cutt ing depth basically according to the relation between cutting force and other fa ctors, which is similar to that of common cutting, so is the feed rate, but the influence is not so big. The influence of cutting speed is larger than that of f eed rate on cutting force because the efficient cutting time increases in vibrat ion cycle with the increase of cutting speed, which causes cutting force to incr ease. The research results indicate: (1) Ultrasonic vibration turning possesses much lower main cutting force than that in common turning when adopting smaller cutting parameters. If using larger cutting parameters, the difference will inco nspicuous. (2) There are remarkable differences of cutting force-cutting veloci ty characteristics in ultrasonic vibration turning from that in common turning m ainly because built-up edge does not emerge in ultrasonic turning unlike common turning in corresponding velocity range. (3) In ultrasonic vibration cutting, t he influence of cutting velocity on cutting force is most obvious among thre e cutting parameters and the influence of feed is smallest. So adopting lower cu tting velocity and larger cutting depth not only can reduce cutting force effect ively but also can ensure cutting efficiency. (4) The conclusions are useful in precision and super precision manufacturing thin-wall pieces.

Corrosion Behavior and Protection Efficiency of 2024Al and SiC_p/2024Al Metal Matrix Composite

The corrosion resistance of 2024 Al and SiC particle reinforced 2024 Al metal matrix composite (SiCp?024AI MMC) in 3.5% NaCl solution was investigated with electrochemical method and immersion test, and the corrosion protection of sulfuric acid anodized coatings on both materials was evaluated by electrochemical impedance spectroscopy. The results showed that the SiCp?024AI MMC is more susceptible to corrosion than its matrix alloy in 3.5% NaCI. For 2024AI, the anodized coating provides excellent corrosion resistance to 3.5% NaCI. The anodized coating on the SiCp?024AI provides satisfactory corrosion protection, but it is not as effective as that for 2024AI because the structure of the anodized layer is affected by the SiC particulates.

Preparation technique of SiCp reinforced Al matrix composite

A new preparation technique-"block dispersal and cast" method is introduced, and three kinds of powder mixing methods, vertical, horizontal and inclining styles, are compared. The results demonstrate that the inclining style is the best way to mix powders. The Al and nano SiC powders are pressed into blocks, dipped into molten Al, stirred into mold so that SiC/Al matrix composites can be obtained at last. The microstructure of SiC particle reinforced Al matrix composite prepared by "block dispersal and cast" method have been studied using scanning electron microscopy (SEM). Phase analysis has also been conducted by means of X-ray diffraction (XRD). The results show that nano SiC particles can be dispersed uniformly in Al matrix. Thus, it is feasible to prepare SiC particle reinforced Al matrix composites by this method.

Microstructures and properties of A356-10%SiC particle composite castings at different solidification pressures

A356-based metal matrix composites with 10% SiC particles of 10 rtm were fabricated by stir casting and direct squeeze casting process under applied pressures of 0.1 （gravity）, 25, 50 and 75 MPa. The microstructures and mechanical properties of the as-cast and T6 heat-treated castings were investigated. The results show that as the applied pressures increase, the casting defects as particle-porosity clusters reduce and the incorporation between the particles and matrix can be improved. The tensile strength, hardness, and coefficients of thermal expansion （CTE） increase with the increase of the pressures. Compared with the as-cast composite castings, the tensile strength and hardness of the heat-treated casting are improved whereas CTEs tend to decrease in T6-treated condition. For the gravity cast composites, there are some particle-porosity clusters on the fracture surface, and the clusters are hardly detected on the fracture surface of the samples solidified at the external pressures. Different fracture behaviors are found between the composites solidified at the gravity and imposed pressures.

Mixed rare earth metal conversion coatings on 2024 alloy and Al6061/SiC_p metal matrix composites

The processes of mixed rare earth metal (REM) conversion coatings on 2024 alloy and Al6061/SiC p metal matrix composites (MMC) were introduced. The coatings were examined to be honeycomb like feature by scanning electron microscope. X ray diffraction analysis revealed that the coatings are amorphous structure. The results of X ray photoelectron spectroscopy indicated that the mixed REM conversion coatings consist predominantly of Ce and O, the contents of other rare earth elements (such as La, Pr) are relatively low, the coatings are about 2～4 μm thickness with excellent adhesion and wearability. The results of mass loss test showed that the mixed REM conversion coatings produce corrosion resistant surface of 2024 alloy and Al6061/SiC p. [

Dry Sliding Wear Behaviour of SiC Particles Reinforced Zinc-Aluminium (ZA43) Alloy Metal Matrix Composites

The present paper reveals the wear behaviour of Zinc - Aluminium alloy reinforced with SiC particulate metal matrix composite. The composite is prepared using liquid metallurgy technique. The unlubricated pin-on disc wear test is conducted to find the wear behaviour of the ZA43 alloy based composite. The sliding wear test is conducted for different load, speed and time. The result reveals that wear rates of composite is reduced as reinforcement increases. For the same working conditions wear rate increases with increasing load and with increasing speed. The tested samples are examined by taking micro structure photos and analyzed for the type of wear. Dominating wear types observed are delamination and abrasion.

Wear Behaviour of Al-SiCp Metal Matrix Composites and Optimization Using Taguchi Method and Grey Relational Analysis

Aluminium metal matrix composite is a relatively new material that has proved its position in automobile, aerospace and other engineering design applications due to its wear resistance and substantial hardness. Need for improved tribological performance has led to the design and selection of newer variants of the composite. The present investigation deals with the study of wear behaviour of Al-SiCp metal matrix composite for varying reinforcement content, applied load, sliding speed and time. Aluminium metal matrix composites reinforced with SiC particles are prepared by liquid metallurgy route using LM6 aluminium alloy and silicon carbide particles (size ~ 37 μm) by varying the weight fraction of SiC in the range of 5% - 10%. The material is synthesized by stir casting process in an electric melting furnace. The materials are then subjected to wear testing in a multitribotester using block on roller configuration. A plan of experiments based on L27 Taguchi orthogonal array is used to acquire the wear data in a controlled way. An analysis of variance is employed to investigate the influence of four controlling parameters, viz., SiC content, normal load, sliding speed and sliding time on dry sliding wear of the composites. It is observed that SiC content, sliding speed and normal load significantly affect the dry sliding wear. The optimal combination of the four controlling parameters is also obtained for minimum wear. The microstructure study of worn surfaces indicates nature of wear to be mostly abrasive.

Effect of particle size on mechanical properties of SiC_p/5210 Al metal matrix composite

SiCp/5210 Al metal matrix composites with a high volume fraction(50%) of SiC particles were fabricated by squeeze casting method. The effect of particle size on the mechanical properties of the composites was studied. The results show that with the decreasing of particle size,the bending strength of the composites increases,while the fracture toughness of the composites decreases. The bending strength and fracture toughness of 10 μm SiCp/5210 Al metal matrix composite are 825 MPa,10.0 MPa·m1/2,and the fracture toughness of 63 μm SiCp/5210 Al metal matrix composite reaches 12.8 MPa·m1/2. The main fracture mechanism changes from particle crack to particle/matrix interface de-bonding with the decreasing of particle size.

Effect of applied pressure on microstructure and mechanical properties of Mg-Zn-Y quasicrystal-reinforced AZ91D magnesium matrix composites prepared by squeeze casting

The Mg-Zn-Y quasicrystal-reinforced AZ91 D magnesium matrix composites were prepared by squeeze casting process. The effects of applied pressure on microstructure and mechanical properties of the composites were investigated. The results show that squeeze casting process is an effective method to refine the grain. The composites are mainly composed of α-Mg, β-Mg17Al12 and Mg3Zn6Y icosahedral quasicrystal phase（I-phase）. With the increase of applied pressure, the contents of β-Mg17Al12 phase and Mg3Zn6 Y quasicrystal particles increase, further matrix grain refinement occurs and coarse dendritic α-Mg transforms into equiaxed grain structure. The composite exhibits the maximum ultimate tensile strength and elongation of 194.3 MPa and 9.2% respectively when the applied pressure is 100 MPa, and a lot of dimples appear on the tensile fractography. Strengthening mechanisms of quasicrystal-reinforced AZ91 D magnesium matrix composites are chiefly fine-grain strengthening and quasicrystal particles strengthening.

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 Mechanical Behavior of Squeeze Cast SiC_w/AZ91 Magnesium Matrix Composites

The interfacial microstructure and tensile properties of the squeeze cast SiCw/AZ91 Mg composites were characterized. There exist uniform, line and discrete MgO particles at the interface between SiC whisker and magnesium in the composites using acid aluminum phosphate binder. The interfacial reaction products MgO are beneficial to interfacial bonding between SiCw and the Mg matrix. resulting in an improvement of the mechanical properties of the composite.

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.

Microstructural characteristics and properties in centrifugal casting of SiC_p/Zl104 composite

The microstructural characteristics and Brinell hardness of a cylinder produced by centrifugal casting were investigated using 20%(volume fraction)SiCp/Zl104 composites.Macrostructure and XRD analysis show that most of SiC particles segregate to the external circumference of the cylinder,the other SiC particles maintain in the inner circumference of the cylinder,and a free particle zone is left in the middle circumference of the cylinder.Microstructural characteristics and quantitative assessment of SiC particles show that most of congregated SiC particles in 20%SiCp/Zl104 composites are dispersed by centrifugal force,and the other congregated SiC particles and most of alumina oxide are segregated to the inner circumference of the cylinder.The SiC particles in aluminum melt can promote the refinement of primaryα(Al)during solidification,and fine primaryα(Al)grains can also promote the uniform distribution of SiC particles.Brinell hardness of SiCp/Zl104 composites is connected with not only the volume fraction of SiC particles,but also the distribution of SiC particles in matrix alloy.