Development of 3D bicontinuous metal-intermetallic composites through subsequent alloying process after liquid metal dealloying

This study presents a novel process for the fabrication of metal-intermetallic composites with a 3D bicontinuous structure, achieved through a combination of liquid metal dealloying(LMD) and subsequent alloying. Initially, porous Ti structures are produced using the LMD process, followed by immersion in a molten Mg-3Al(wt%) metal. Due to the higher thermodynamic miscibility of Al with Ti compared to Mg, the concentration of Al in the Ti matrix increases as the immersion time increases. This results in a sequential phase transition within the Ti matrix: α-Ti → Ti_(3)Al → Ti Al. The phase transition considerably affects the hardness and strength of the composite material,with the Mg-Ti_(3)Al-Ti Al composite exhibiting a maximum hardness nearly twice as high as that of the conventional Mg-Ti composite. This innovative process holds potential for the development of various bicontinuous metal-intermetallic composites.

Design,preparation,microstructure and mechanical property of the lightweight radiation-shielding Mg-Ta-Al composites basing differential temperature hot rolling

A novel lightweight,radiation-shielding Mg-Ta-Al layered metal-matrix composite(LMC)was successful designed by doping the extremely refractory metal(Ta)into Mg sheets.These Mg-based LMCs sheets shows excellent radiation-dose shield effect,about 145 krad·a^(−1),which is about 17 times of traditional Mg alloy,while its surface density is only about 0.9 g·cm^(−2),reducing by 60%than that of pure Ta.The quantitate relationship between radiation-dose and the materials’thickness was also confirmed to the logistic function when the surface density is in the range of 0.6-1.5 g·cm^(−2).Meantime,the rolling parameters,interface microstructure and mechanical properties in both as-rolled and annealing treated samples were evaluated.The sheets possess a special dissimilar atoms diffusion transitional zone containing an obvious inter-diffusion Mg-Al interface and the unique micro-corrugated Ta-Al interface,as well as a thin Al film with a thickness of about 10μm.The special zone could reduce the stress concentration and enhance the strength of Mg-Ta-Al LMCs.The interface bonding strength reaches up to 54-76 MPa.The ultimate tensile strength(UTS)and yield strength(TYS)of the Mg-Ta-Al sheet were high to 413 MPa and 263 MPa,respectively,along with an elongation of 5.8%.The molecular dynamics(MD)analysis results show that the two interfaces exhibit different formation mechanism,the Mg-Al interface primarily depended on Mg/Al atoms diffusion basing point defects movement,while the Ta-Al interface with a micro-interlock pining shape formed by close-packed planes slipping during high temperature strain-induced deformation process.

Effect of heat treatment on the microstructure,mechanical properties and fracture behaviors of ultra-high-strength SiC/Al-Zn-Mg-Cu composites

A high-zinc composite,12vol%SiC/Al-13.3 Zn-3.27 Mg-1.07Cu(wt%),with an ultra-high-strength of 781 MPa was success-fully fabricated through a powder metallurgy method,followed by an extrusion process.The effects of solid-solution and aging heat treat-ments on the microstructure and mechanical properties of the composite were extensively investigated.Compared with a single-stage sol-id-solution treatment,a two-stage solid-solution treatment(470℃/1 h+480℃/1 h)exhibited a more effective solid-solution strengthen-ing owing to the higher degree of solid-solution and a more uniform microstructure.According to the aging hardness curves of the com-posite,the optimized aging parameter(100℃/22 h)was determined.Reducing the aging temperature and time resulted in finer and more uniform nanoscale precipitates but only yielded a marginal increase in tensile strength.The fractography analysis revealed that intergranu-lar cracking and interface debonding were the main fracture mechanisms in the ultra-high-strength SiC/Al-Zn-Mg-Cu composites.Weak regions,such as the SiC/Al interface containing numerous compounds and the precipitate-free zones at the high-angle grain boundaries,were identified as significant factors limiting the strength enhancement of the composite.Interfacial compounds,including MgO,MgZn2,and Cu5Zn8,reduced the interfacial bonding strength,leading to interfacial debonding.

Ballistic performance of titanium-based layered composites made using blended elemental powder metallurgy and hot isostatic pressing

Metal matrix composites tiles based on Ti-6Al-4V(Ti64)alloy,reinforced with 10,20,and 40(vol%)of either TiC or TiB particles were made using press-and-sinter blended elemental powder metallurgy(BEPM)and then bonded together into 3-layer laminated plates using hot isostatic pressing(HIP).The laminates were ballistically tested and demonstrated superior performance.The microstructure and properties of the laminates were analyzed to determine the effect of the BEPM and HIP processing on the ballistic properties of the layered plates.The effect of porosity in sintered composites on further diffusion bonding of the plates during HIP is analyzed to understand the bonding features at the interfaces between different adjacent layers in the laminate.Exceptional ballistic performance of fabricated structures was explained by a significant reduction in the residual porosity of the BEPM products by their additional processing using HIP,which provides an unprecedented increase in the hardness of the layered composites.It is argued that the combination of the used two technologies,BEPM and HIP is principally complimentary for the materials in question with the abilities to solve the essential problems of each used individually.

Research progress in friction stir processing of magnesium alloys and their metal matrix surface composites: Evolution in the 21^(st )century

Rising concerns about climate change drive the demand for lightweight components.Magnesium(Mg)alloys are highly valued for their low weight,making them increasingly important in various industries.Researchers focusing on enhancing the characteristics of Mg alloys and developing their Metal Matrix Composites(MMCs)have gained significant attention worldwide over the past decade,driven by the global shift towards lightweight materials.Friction Stir Processing(FSP)has emerged as a promising technique to enhance the properties of Mg alloys and produce Mg-MMCs.Initially,FSP adapted to refine grain size from the micro to the nano level and accelerated the development of MMCs due to its solid-state nature and the synergistic effects of microstructure refinement and reinforcement,improving strength,hardness,ductility,wear resistance,corrosion resistance,and fatigue strength.However,producing defect-free and sound FSPed Mg and Mg-MMCs requires addressing several variables and their interdependencies,which opens up a broad range of practical applications.Despite existing reviews on individual FSP of Mg,its alloys,and MMCs,an attempt has been made to analyze the latest research on these three aspects collectively to enhance the understanding,application,and effectiveness of FSP for Mg and its derivatives.This review article discusses the literature,classifies the importance of Mg alloys,provides a historical background,and explores developments and potential applications of FSPed Mg alloys.It focuses on novel fabrication methods,reinforcement strategies,machine and tool design parameters,material characterization,and integration with other methods for enhanced properties.The influence of process parameters and the emergence of defects are examined,along with specific applications in mono and hybrid composites and their microstructure evolution.The study identifies promising reinforcement materials and highlights research gaps in FSP for Mg alloys and MMCs production.It concludes with significant recommendations for further exploration,reflecting ongoing advancements in this field.

Shear banding-inducedslip enables unprecedented strength-ductility combination of laminated metallic composites

Shear bands in metallic materials have been reported to be catastrophic because they normally lead to non-uniform plastic deformation. Ductility of laminated metallic composites deteriorates with increasing processing strain, particularly for those having hexagonal-close-packed(hcp) constituents due to inadequate slip systems and consequently prominent shear banding. Here, we propose a design strategy that counterintuitively tolerates the bands with localized strains, i.e. the shear banded laminar(SBL) structure, which promotes <c+a> dislocation activation in hcp metals and renders unprecedented strengthductility combination in hcp-metal-based composites fabricated by accumulative roll bonding(ARB). The SBL structure is characterized with one soft hcp metal constrained by adjacent hard metal in which dislocations have been accumulated near the bimetal interfaces. High-energy X-ray diffraction astonishingly reveals that more than 90% of dislocations are non-basal in Ti layers of the SBL Ti/Nb composite processed by eight ARB cycles. Moreover, <c+a> dislocations occupy a high fraction of ~30%, promoting further <c+a>cross slip. The unique stress field tailored by both shear banding and heterophase interface-mediated deformation accommodation triggers important <c+a> slip. This SBL design is of significance for developing hcp-based laminates and other heterostructured materials with high performances.

Processing of nanostructured metallic matrix composites by a modified accumulative roll bonding method with structural and mechanical considerations

Particulate reinforced metallic matrix composites have attracted considerable attention due to their lightweight, high strength, high specific modulus, and good wear resistance. A1/B4C composite strips were produced in this work by a modified accumulative roll bonding process where the strips were rotated 90° around the normal direction between successive passes. Transmission electron microscopy and X-ray diffraction analyses reveal the development of nanostructures in the Al matrix after seven passes. It is found that the B4C reinforcement distribution in the matrix is improved by progression of the process. Additionally, the tensile yield strength and elongation of the processed materials are increased with the increase of passes.

Effects of infiltration parameters on mechanical and microstructural properties of tungsten wire reinforced Cu_(47)Ti_(33)Zr_(11)Ni_6Sn_2Si_1 metallic glass matrix composites

Cu47Ti33Zr11Ni6Sn2Si1-based bulk metallic glass matrix composites reinforced with tungsten wires were fabricated by infiltration process at different temperatures （850, 900, 950 and 1000 °C） and time （10, 20 and 30 min） in a quartz or a steel tube. The mechanical tests were carried out by scanning electron microscopy （SEM） and X-ray diffraction （XRD）. The results show that the maximum strength and total strain of the composite are 1778 MPa and 2.8% fabricated in steel tube at 900 °C for 10 min, and 1582 MPa and 3.6% fabricated in quartz tube at 850 °C for 10 min, respectively.

Synthesis,structure and mechanical properties of Zr-Cu-based bulk metallic glass composites

The unusual glass-forming ability（GFA） of the Zr48Cu36Ag8Al8 alloy and the high ductility of the Zr48Cu36Ag8Al8 metallic glass-matrix composites containing Ta powder were reported.The bulk metallic glass rod with a diameter of 25 mm was successfully synthesized using copper mold casting for the Zr48Cu36Ag8Al8 alloy.High GFA of this alloy was found to be related to a large supercooled liquid region and a quaternary eutectic point with low melting temperature.The bulk metallic glass matrix composites were prepared by introducing extra Ta particles into the Zr48Cu36Ag8Al8 melt.The composites consist of Ta particles homogenously distributed in the Zr48Cu36Ag8Al8 metallic glass matrix.The optimum content of Ta powder is 10at%for the composite with the highest plasticity,which shows a plastic strain of 31%.

Damping performance of SiC nanoparticles reinforced magnesium matrix composites processed by cyclic extrusion and compression

This work dealt with the damping performance and its underlying mechanism in SiC nanoparticles reinforced AZ91D composite(SiC_(np)/AZ91D)processed by cyclic extrusion and compression(CEC).It was found that the CEC process significantly affects the damping performance of the composite due to alterations in the density of dislocations and grain boundaries in the matrix alloy.Although there would be dynamic precipitation of the Mg17Al12 phase during processing which increases the phase interface and limits the mobility of dislocations and grain boundaries.The results also showed that the damping capacity of 1%SiC_(np)/AZ91D composite continuously decreases with adding CEC pass number and it consistently increases with rising the applied temperature.Considering the first derivative of the tanδ-T curve,the dominant damping mechanism based on test temperature can be divided into three regions.These three regions are as follows(i)dislocation vibration of the weak pinning points(≤T_(cr)),(ii)dislocation vibration of the strong pinning points(T_(cr)∼T_(V)),and(iii)grain boundary/interface sliding(≥T_(V))

Comparative study of bulk metallic glass composites with high-volume-fractioned dendritic and spherical b. c. c. phase precipitates

A dendritic β-phase reinforced bulk metallic glass(BMG) composite named as D2 was prepared by rapid quenching of a homogenous Zr60Ti14.67Nb5.33Cu5.56Ni4.44Be10 melt, and characterized by means of X-ray diffraction(XRD), scanning electron microscopy(SEM) observation and room-temperature compression test. The microstructure and mechanical properties were compared with those of the spherical β-phase reinforced composite named as composite S2. It was found that the composite D2 contains β-phase dendrites up to 56% in volume-fraction, and exhibits a ductile compressive behavior with plastic strain of 12.7%. As the high-volumefractioned β-phase dendrites transferred to coarse spherical particles of about 20 μm in diameter in the composite S2, a much improved plastic strain up to 20.4% can be achieved. Micrographs of the fractured samples reveal different interaction modes of the propagating shear bands with the dendritic and spherical β phase inclusions, resulting in different shear strains in the composite samples. The matrix of composite S2 undergoes a significantly larger shear strain than that of the composite D2 before ultimate failure, which is thought to be mainly responsible for the greatly increased global plastic strain of the S2 relative to D2.

Development and Characterization of Aluminium-Based Metal Matrix Composites

Aluminum based metal matrix composites were fabricated using stir casting where silicon carbide and alumina were the reinforcements. Different types of properties (physical-density, mechanical-tensile, hardness, chemical-corrosion etc.) were measured and compared with base metals/alloys. The properties were significantly varied. The highest density was obtained for pure aluminium with 5% Al2O3 whereas the lowest was obtained for AA-4032 alloy. The highest hardness was obtained for AA-4032 with 5% Al2O3 whereas the lowest was obtained for pure Al with 5% Al2O3. The highest strength was obtained for AA-6061 with 5% coarse SiC whereas the lowest was obtained for pure Al. The highest impact strength was obtained for AA-4032 with 5% Al2O3 whereas the lowest was obtained for AA-6061. The corrosion resistance of all composites was lower than that of the base materials.

Hot deformation behaviors of 35% SiC_p/2024Al metal matrix composites

The hot deformation behaviors of 35%SiCp/2024 aluminum alloy composites were studied by hot compression tests using Gleeble-1500D thermo-mechanical simulator at temperatures ranging from 350 to 500 °C under strain rates of 0.01-10 s-1. The true stress-true strain curves were obtained in the tests. Constitutive equation and processing map were established. The results show that the flow stress decreases with the increase of deformation temperature at a constant strain rate, and increases with the increase of strain rate at constant temperature, indicating that composite is a positive strain rate sensitive material. The flow stress behavior of composite during hot compression deformation can be represented by a Zener-Hollomon parameter in the hyperbolic sine form. Its activation energy for hot deformation Q is 225.4 kJ/mol. To demonstrate the potential workability, the stable zones and the instability zones in the processing map were identified and verified through micrographs. Considering processing map and microstructure, the hot deformation should be carried out at the temperature of 500 °C and the strain rate of 0.1-1 s-1.

Development of Al-12Si-xTi system active ternary filler metals for Al metal matrix composites

To improve the wettability of Al metal matrix composites（Al-MMCs） by common filler metals,Al-12Si-xTi（x=0.1,0.5,1,3.0;mass fraction,%） system active ternary filler metals were prepared.It was demonstrated that although the added Ti existed within Ti（Al1-xSix）3（0≤x≤0.15） phase,the shear strength and shear fracture surface of the developed Al-12Si-xTi brazes were quite similar to those of traditional Al-12Si braze due to the presence of similar microstructure of Al-Si eutectic microstructure with large volume fraction.So,small Ti addition（～1%） did not make the active brazes brittle and hard compared with the conventional Al-12Si braze.The measured melting range of each Al-12Si-xTi foil was very similar,i.e.,580-590 ℃,because the composition was close to that of eutectic.For wettability improvement,with increasing Ti content,the interfacial gap between the Al2O3 reinforcement and filler metal（R/M） could be eliminated,and the amount of the remainder of the active fillers on the composite substrate decreased after sessile drop test at 610 ℃ for 30 min.So,the wettability improvement became easy to observe repeatedly with increasing Ti content.Additionally,the amount and size of Ti（AlSi）3 phase were sensitive to the Ti content（before brazing） and Si content（after brazing）.

MACHINING OF METAL MATRIX COMPOSITES

Two types of aluminium-based composites reinforced respectively with 20 vol short fibre alumina and with a hybrid of 15 vol SiC particle and 5 vol short alumina fibre are machined with different tool materials:cemented carbide,ceramic,cubic boron nitride(CBN)and polycrystalline diamond(PCD).The analysis on tool wear shows that the various tool materials exhibite different tool wear behaviours,and the tool wear mechanisma are discussed.Apparently,PCD tools do not necessarily guarantee dimensional stability but they can provide the most economic means for machining all sorts of composites.Consequently,a suitable tool material is suggested for machining each metal matrix composite(MMC) from the standpoints of tool wear and machined surface finish.

Damping capacity of BaTiO_3/Al composites fabricated by hot extrusion

To develop new type of high damping metal matrix composites, large grain size barium titanate （BaTiO3） ceramic was sintered and added into Al powder to fabricate BaTiO3/Al composites through the powder metallurgy method and hot extrusion. The damping properties of BaTiO3 ceramic, Al matrix and BaTiO3/Al composites were examined by dynamic mechanical analysis in the temperature range from 273 K to 573 K. The results show that although BaTiO3 exhibits high damping （tan δ=0.12） below 400 K, the damping capacity of 10%BaTiO3/Al （mass fraction） composites below 400 K is not increased as compared to the Al matrix. On the other hand, the damping capacity above 450 K is greatly enhanced due to the motion of dislocations at the interfaces between ceramic particles and Al matrix. The failure of exerting the intrinsic damping of BaTiO3 particles in the composites is attributed to the poor interface bonding between the particles and the matrix. The tensile strength of the composite is 42% higher than that of the Al matrix, which indicates the possibility of obtaining high strength and high damping composites via interface improvement and the addition of high volume fraction of large grain BaTiO3 particles.

Preparation of multi-walled carbon nanotube-reinforced TiNi matrix composites from elemental powders by spark plasma sintering

Carbon nanotube (CNT)-reinforced TiNi matrix composites were synthesized by spark plasma sintering (SPS) employing elemental powders.The phase structure,morphology and transformation behaviors were studied.It was found that thermoelastic martensitic transformation be-haviors could be observed from the samples sintered above 800 ℃ even with a short sintering time (5min),and the transformation tempera-tures gradually increased with increasing sintering temperature because of more Ti-rich TiNi phase formation.Although decreasing the sin-tering temperature and time to 700 ℃ and 5min could not protect defective MWCNTs from reacting with Ti,still-perfect MWCNTs re-mained in the specimens sintered at 900 ℃.This method is expected to supply a basis for preparing CNT-reinforced TiNi composites.

A Novel Method to Fabricate Steel-Al Foam Sandwich Panel with Metallic Bonding

Al foam sandwich panel(AFS) with metallic bonding was fabricated by foaming a hotpressed three-layer composite with two steel facesheets and a melt route precursor as core. The melt route precursor was fabricated by dispersing undecomposed blowing agent into molten Al, followed by solidification. Microstructures of the joints during fabrication process were analyzed by scanning electron microscopy(SEM) and energy dispersive spectroscopy(EDS). Static three-point bending was conducted to evaluate joint quality of the AFS. It was found that a primary bonding was achieved by hot-pressing and significant diffusion layer of Fe-Al intermetallic compounds was sustained between steel and Al foam core by foaming. Damage modes of the AFS under three-point bending were dominated by indentation, plastic hinges, core shear and crack. Delamination between steel and foam was absent, implying that reliable metallic bonding was achieved. This method allows for producing large-scale AFS with steel facesheets.

Arbitrary skin metallization by pencil-writing inspired solid-ink rubbing for advanced energy storage and harvesting

The development of a durable metallic coating on diverse substrates is both intriguing and challenging,particularly in the research of metal-conductive materials for applications such as batteries,soft electronics,and beyond.Herein,by learning from the pencil-writing process,a facile solid-ink rubbing technology(SIR-tech)is invented to address the above challenge.The solid-ink is exampled by rational combination of liquid metal and graphite particles.By harnessing the synergistic effects between rubbing and adhesion,controllable metallic skin is successfully formed onto metals,woods,ceramics,and plastics without limitation in size and shape.Moreover,outperforming pure liquid-metal coating,the composite metallic skin by SIR-tech is very robust due to the self-lamination of graphite nanoplate exfoliated by liquid-metal rubbing.The critical factors controlling the structures-properties of the composite metallic skin have been systematically investigated as well.For applications,the SIR-tech is demonstrated to fabricate high-performance composite current collectors for next-generation batteries without traditional metal foils.Meanwhile,advanced skin-electrodes are further demonstrated for stable triboelectricity generation even under temperature fluctuation from-196 to 120℃.This facile and highly-flexible SIR-tech may work as a powerful platform for the studies on functional coatings by liquid metals and beyond.

MgO-attached graphene nanosheet(MgO@GNS)reinforced magnesium matrix nanocomposite with superior mechanical,corrosion and biological performance

Magnesium(Mg)alloys are gaining great consideration as body implant materials due to their high biodegradability and biocompatibility.However,they suffer from low corrosion resistance and antibacterial activity.In this research,semi-powder metallurgy followed by hot extrusion was utilized to produce the magnesium oxide@graphene nanosheets/magnesium(MgO@GNS/Mg)composite to improve mechanical,corrosion and cytocompatibility characteristics.Investigations have revealed that the incorporation of MgO@GNS nanohybrids into Mg-based composite enhanced microhardness and compressive strength.In vitro,osteoblast cell culture tests show that using MgO@GNS nanohybrid fillers enhances osteoblast adhesion and apatite mineralization.The presence of MgO@GNS nanoparticles in the composites decreased the opening defects,micro-cracks and micro-pores of the composites thus preventing the penetration of the corrosive solution into the matrix.Studies demonstrated that the MgO@GNS/Mg composite possesses excellent antibacterial properties because of the combination of the release of MgO and physical damage to bacterium membranes caused by the sharp edges of graphene nanosheets that can effectively damage the cell wall thereby facilitating penetration into the bacterial lipid bilayer.Therefore,the MgO@GNS/Mg composite with high mechanical strength,antibacterial activity and corrosion resistance is considered to be a promising material for load-bearing implant applications.