Influence of TiB2 particles on machinability and machining parameter optimization of TiB2/Al MMCs

In situ formed TiB2 particle reinforced aluminum matrix composites （TiB2/Al MMCs） have some extraordinary properties which make them be a promising material for high performance aero-engine blade. Due to the influence of TiB2 particles, the machinability is still a problem which restricts the application of TiB2/Al MMCs. In order to meet the industrial requirements, the influence of TiB2 particles on the machinability of TiB2/Al MMCs was investigated experimentally. Moreover, the optimal machining conditions for this kind of MMCs were investigated in this study. The major conclusions are： （1） the machining force of TiB2/Al MMCs is bigger than that of non- reinforced alloy and mainly controlled by feed rate; （2） the residual stress of TiB2/AI MMCs is compressive while that of non-reinforced alloy is nearly neutral; （3） the surface roughness of TiB2/Al MMCs is smaller than that of non-reinforced alloy under the same cutting speed, but reverse result was observed when the feed rate increased; （4） a multi-objective optimization model for surface roughness and material removal rate （MRR） was established, and a set of optimal parameter combinations of the machining was obtained. The results show a great difference from SiC particle reinforced MMCs and provide a useful guide for a better control of machining process of this material.

Compressive response and microstructural evolution of in-situ TiB_(2)particle-reinforced 7075 aluminum matrix composite

The hot forming behavior,failure mechanism,and microstructure evolution of in-situ TiB_(2)particle-reinforced 7075 aluminum matrix composite were investigated by isothermal compression test under different deformation conditions of deformation temperatures of 300−450℃ and strain rates of 0.001^(−1)s^(−1).The results demonstrate that the failure behavior of the composite exhibits both particle fracture and interface debonding at low temperature and high strain rate,and dimple rupture of the matrix at high temperature and low strain rate.Full dynamic recrystallization,which improves the composite formability,occurs under conditions of high temperature(450℃)and low strain rate(0.001 s^(−1));the grain size of the matrix after hot compression was significantly smaller than that of traditional 7075Al and ex-situ particle reinforced 7075Al matrix composite.Based on the flow stress curves,a constitutive model describing the relationship of the flow stress,true strain,strain rate and temperature was proposed.Furthermore,the processing maps based on both the dynamic material modeling(DMM)and modified DMM(MDMM)were established to analyze flow instability domain of the composite and optimize hot forming processing parameters.The optimum processing domain was determined at temperatures of 425−450℃ and strain rates of 0.001−0.01 s^(−1),in which the fine grain microstructure can be gained and particle crack and interface debonding can be avoided.

Kinetic behaviour of TiB particles in Al melt and their effect on grain refinement of aluminium alloys

Solidification experiments were carried out to investigate the kinetic behaviour of TiB2 particles in Al melt and their effect on the grain refinement of commercially-pure Al.A model was proposed to describe the kinetic behaviour of TiB2 particles during the whole process from the addition of TiB2 to the melt to the freezing of the melt.The results indicate that TiB2 particles are not stable in Al melt.They may dissolve and coarsen during the holding period and grow during the cooling period of the melt.The kinetic behaviour of TiB2 particles in the melt has a great influence on their number density and the grain refinement.Solute Ti addition can suppress the dissolution,Ostwald ripening and growth behaviours of TiB2 particles.

Comparative study on high temperature deformation behavior and processing maps of Mg-4Zn-1RE-0.5Zr alloy with and without in-situ sub-micron sized TiB2 reinforcement

Mg-4Zn-1RE-0.5Zr (ZE41) Mg alloy is extensively used in the aerospace and automobile industries.In order to improve the applicability and performance,this alloy was engineered with in-situ Ti B2reinforcement to form Ti B2/ZE41 composite.The high temperature deformation behavior and manufacturability of the newly developed Ti B2/ZE41 composite and the parent ZE41 Mg alloy were studied via establishing constitutive modeling of flow stress,deformation activation energy and processing map over a temperature range of 250℃-450℃ and strain rate range of 0.001 s-1-10 s-1.The predicted flow stress behavior of both materials were found to be well consistent with the experimental values.A significant improvement in activation energy was found in Ti B2/ZE41 composite (171.54 k J/mol) as compared to the ZE41 alloy (148.15 k J/mol) due to the dispersed strengthening of in-situ Ti B2particles.The processing maps were developed via dynamic material modeling.A wider workability domain and higher peak efficiency (45%) were observed in Ti B2/ZE41 composite as compared to ZE41 alloy (41%).The Dynamic recrystallization is found to be the dominating deformation mechanism for both materials;however,particle stimulated nucleation was found to be an additional mode of deformation in Ti B2/ZE41 composite.The twinning and stress induced cracks were observed in both the materials at low temperature and high strain rate.A narrow range of instability zone is found in the present Ti B2/ZE41 composite among the existing published literature on Mg based composites.The detailed microstructural characterization was carried out in both workability and instability domains to establish the governing deformation mechanisms.

Microstructural evolution of copper-titanium alloy during in-situ formation of TiB_2 particles

Bulk Cu-Ti alloy reinforced by TiB2 nano particles was prepared using in-situ reaction between Cu 3.4%Ti and Cu-0.7%B master alloys along with rapid solidification and subsequent heat treatment for 1-10 h at 900 ℃. High-resolution transmission electron microscopy （HRTEM） characterization showed that primary TiB2 nano particles and TiB whiskers were formed by in-situ reaction between Ti and B in the liquid copper. The formation of TiB whiskers within the melt led to coarsening of TiB2 particles. Primary TiB2 particles were dispersed along the grain boundaries and hindered grain growth at high temperature, while the secondary TiB2 particles were formed during heat treatment of the alloy by diffusion reaction of solute titanium and boron inside the grains. Electrical conductivity and hardness of the composite were evaluated during heat treatment. The results indicated that the formation of secondary TiB2 particles in the matrix caused a delay in hardness reduction at high temperature. The electrical conductivity and hardness increased up to 8 h of heat treatment and reached 33.5% IACS and HV 158, respectively.

Microstructure, mechanical properties and wear behaviour of Zn-Al-Cu-TiB_2 in situ composites

Zn-Al-Cu-TiB2（ZA27-TiB2） in situ composites were fabricated via reactions between molten aluminum and mixed halide salts（K2TiF6 and KBF4） at temperature of 875 °C. The microstructure, mechanical properties and wear behavior of the composites were investigated. Microstructure analysis shows that fine and clean TiB2 particles distribute uniformly through the matrix. The mechanical properties of the composites increase with the increase in TiB2 content. As TiB2 content increases to 5%（mass fraction）, an improvement of HB 18 in hardness and 49 MPa in ultimate tensile strength（UTS） is achieved. The overall results reveal that the composites possess low friction coefficients and the wear rate is reduced from 5.9×10-3 to 1.3×10-3 mm3/m after incorporating 5% TiB2. Friction coefficient and worn surface analysis indicate that there is a change in the wear mechanism in the initial stage of wear test after introducing in situ TiB2 particles into the matrix.

Atomic insights into heterogeneous nucleation and growth kinetics of Al on TiB_(2) particles in undercooled Al-5Ti-1B melt

Titanium diboride(TiB_(2))is an effective grain refiner of Al alloys in the industry that facilitates casting processes by forming uniformly refined microstructures.Although our understanding of the underlying refinement mechanisms has advanced,the atomic kinetics of heterogeneous nucleation of Al on TiB2 remains unknown.Here,we report atomic-scale observations of the heterogeneous nucleation and growth kinetics of Al on self-formed TiB_(2) particles by in situ heating of undercooled Al-5Ti-1B films.We demonstrate that an ordered Al monolayer forms on the Ti-terminated{0001}TiB_(2) surface;then,the surrounding Al atoms are initiated to form an island-shaped Al nucleus with face-centered cubic{111}stacking without the assistance of a Ti-rich buffer layer.The interfacial lattice mismatch between{111}Al and{0001}TiB_(2) causes remarkable out-of-plane strain that decreases gradually with Al nucleus layers increasing to 6 atomic layers.The elastic strain energy originating from this interfacial strain increases the free energy of the Al/TiB2 heterostructure,hence impeding the rapid growth of the Al nucleus.We found that TiB2 particles stabilize the Al nuclei rather than activating their free growth into grains when the experimental undercoolingΔT is lower than the onset undercoolingΔT fg in Greer's free growth model.Our findings provide an atomic-scale physical image of the heterogeneous nucleation and growth mechanisms of Al with inoculator participation and elucidate the strain-dependent growth kinetics of Al nuclei.

Microstructure and mechanical properties of Al-TiB_2/TiC in situ composites improved via hot rolling

A kind of Al-TiB2/TiC in situ composite with a homogenous microstructure was successfully prepared through in situ reaction of pure Ti and Al-B-C alloy with molten aluminum.In order to improve the distribution of the particles and mechanical properties of the composites,subsequent hot rolling with increasing reduction was carried out.The microstructure evolution of the composites was characterized using field emission scanning electron microscopy(FESEM)and the mechanical properties were studied through tensile tests and microhardness measurement.It is found that both the microstructure uniformity and mechanical properties of the composites are significantly improved with increasing rolling reduction.The ultimate tensile strength and microhardness of the composites with90%rolling reduction reach185.9MPa and HV59.8,respectively,140%and35%higher than those of as-cast ones.Furthermore,the strengthening mechanism of the composite was analyzed based on the fracture morphologies.

Processing and characterization of the microstructure and mechanical properties of Al6061–TiB_(2) composite

In the present research,aluminum metal matrix composites were processed by the stir casting technique.The effects of TiB2 reinforcement particles,severe plastic deformation through accumulative roll bonding(ARB),and aging treatment on the microstructural characteristics and mechanical properties were also evaluated.Uniaxial tensile tests and microhardness measurements were conducted,and the microstructural characteristics were investigated.Notably,the important problems associated with cast samples,including nonuniformity of the reinforcement particles and high porosity content,were solved through the ARB process.At the initial stage,particle-free zones,as well as particle clusters,were observed on the microstructure of the composite.However,after the ARB process,fracturing phenomena occurred in brittle ceramic particles,followed by breaking down of the fragments into fine particles as the number of rolling cycles increased.Subsequently,composites with a uniform distribution of particles were produced.Moreover,the tensile strength and microhardness of the ARB-processed composites increased with the increase in the reinforcement mass fraction.However,their ductility exhibited a different trend.With post-deformation aging treatment(T6),the mechanical properties of composites were improved because of the formation of fine Mg2Si precipitates.