Preparation, microstructures and deformation behavior of SiCP/6066Al composites produced by PM route

Preparation, microstructures and deformation behavior of 12 vol.% SiC_P/6066Al composites fabricated by a powder metallurgy (PM) route have been systemically reported in this paper. The experimental results indicated that SiC particles were distributed homogeneously in the aluminum matrix, and that the constituents of the matrix were Al, needle-shaped β′-Mg₂Si phases and a small amount of dispersoids (Fe, Mn, Cu)₃Si₂Al₁₅ (BCC structure with lattice parameter a ≈ 12.8 Å). A well-bonded SiC/Al interface consisting of a thin and clean layer of polycrystalline structure of metal matrix with segregation of Mg element has been observed. The SiC particle cracking and the ductile-tearing of SiC/Al interfaces caused the rupture of the composites. The experimental data coincided well with the theoretical results predicted by an extended effective model assumption (EMA). The current study indicates that load transfer between the matrix and reinforcements, grain refinement of metal matrix, and dislocation strengthening are the main strengthening mechanisms of SiC_P/Al composites. The ductile-tearing of SiC_P/Al interfaces and the SiC particle cracking are the dominating failure modes and the deformation behavior of SiC_P/Al composites strongly depends on the properties of matrix alloy.     

有限元模拟SiC增强Al基复合材料的力学行为

采用有限元方法和轴对称单胞模型模拟了增强体(SiC)形状、体积分数以及不同基体类型对铝基复合材料力学行为的影响。模拟结果表明:增强体的加入会阻碍基体的塑性流变,使基体内发生非均匀变形,在增强体尖角处出现应力集中;椭圆柱形增强体对基体塑性变形的阻力最大,传递载荷的能力最强,因此强化效果最好。在一定范围内,随着增强体体积分数的增加,基体与增强体之间的比表面积增大,有利于载荷的传递;增强体体积分数的增加导致颗粒间距减小,几何必须位错自由运动的路径减少,复合材料的强度也随之增加。此外,不同类型基体自身的塑性流变能力不同,Al-Zn-Mg基体强度最高,在拉伸变形过程中,受到增强体的阻碍作用最大,会有更多的载荷从基体传递到增强体,以Al-Zn-Mg为基体的复合材料的强度最高。     

真空压力浸渗制备SiCp/AZ91复合材料的显微组织、力学性能和磨损行为

采用真空压力浸透法制备SiC_p/AZ91复合材料,研究其显微组织、力学性能和耐磨性。结果表明,SiC颗粒均匀分布于金属基体中,并与基体界面结合良好。Mg₁₇Al₁₂相在SiC颗粒附近优先析出,SiC与AZ91基体的热膨胀系数失配导致高密度位错的产生,加速基体的时效析出。与AZ91合金相比,SiC颗粒的加入提高了复合材料的硬度和抗压强度,这主要是由于载荷传递强化和晶粒细化强化机制。此外,由于SiC具有优异的耐磨性,在磨损过程中形成稳定的支撑面保护基体。     

高压扭转圈数对碳化硅颗粒铝基复合材料组织和性能的影响

采用高压扭转(high-pressure torsion,HPT)工艺,成功将8.75%体积分数SiC颗粒与Al的混合粉末制成金属基复合材料,并用金相显微镜、显微维氏硬度计、万能材料试验机和扫描电镜等,分析了扭转圈数对SiCp/Al复合材料的显微组织、显微硬度、拉伸性能和拉伸断口形貌的影响。结果显示,扭转圈数从0.5圈增加到4圈,基体的变形抗力降低,SiC颗粒在剪应力的作用下易于与基体协调变形,SiC颗粒分布均匀化程度显著提高;随着扭转圈数增加,试样所受到的剪切作用增大,极易引起位错的运动和增殖,基体晶粒得到细化,单位体积内的晶界增多,使试样显微硬度得到提高;扭转圈数越多,拉伸断口韧窝数量明显增多,且尺寸变小。     

铸造ZL101A／SiCp复合材料的研究

采用真空搅拌复合工艺制备了铸造ZL101A／SiC复合材料,研究了变质和细化处理对复合材料组织的影响。结果表明：变质和细化处理铸造 ZL101A／SiC复合材料制备工艺的重要处理措施,可明显改善复合材料的组织。利用透射电镜对AL／SiC界面特征及界面反应进行分析,同时对该复合材料的铸造性能（熔体合金流动性能、线收缩、体收缩和热裂倾向）以及力学和物理性能进行了测试。     

Physical,Mechanical, and Tribological Attributes of Stir-Cast AZ91/SiCp Composite

In the present investigation, composites with silicon carbide particle （SiCp） as reinforcement and AZ91 magnesium alloy as matrix have been synthesized using liquid metal stir-casting technique with optimized processing conditions. The composites with good particle distribution in the matrix, and better grain refinement and good interfacial bonding between the matrix and reinforcement have been obtained. The effect of SiCp content on the physical, mechanical, and tribological properties of Mg-based metal matrix composite （MMC） is studied with respect to particle distribution, grain refinement, and particle/matrix interfacial reactions. The electrical conductivity, coefficient of thermal expansion, microas well as macro-hardness, tensile and compressive properties, and the fracture behavior of the composites along with dry sliding wear of the composites have been evaluated and compared with the base alloy.     

加工道次对FSP制备高熵合金增强铝基复合材料组织和性能的影响

采用搅拌摩擦加工制备了以AlCoCrFeNi_2.1高熵合金为增强相的6061铝合金复合材料(AlCoCrFeNi_2.1/6061Al),重点研究了加工道次对复合材料组织均匀性、界面结合以及力学性能的影响. 结果表明,随搅拌摩擦加工道次的增加,AlCoCrFeNi_2.1/6061Al复合材料组织均匀性及力学性能均得到明显改善. 复合材料中基体与增强相界面结合良好,界面处扩散层厚度随加工道次增加而增大. 相较于不添加增强相的6道次搅拌摩擦加工铝合金,AlCoCrFeNi_2.1增强相颗粒的引入可进一步细化晶粒并提高抗拉强度,且随着加工道次增加,复合材料抗拉强度及断后伸长率均显著升高. 2,4道次下的断口存在明显的颗粒聚集区,而6道次下断口表面颗粒分布均匀且呈现大量韧窝,为典型的韧性断裂. 该现象主要归因于载荷传递效应、弥散强化和细晶强化3大强化机制.     

Superplastic behavior of PM SiCp/6061 aluminum alloy composites at high strain rates

The superplastic behavior of a powder-metallurgy processed 6061 Al composite was investigated as a function of SiC content increasing from 0% to 30% at 10% increments over a wide temperature range from 430°C to 610°C. The materials were found to be high-strain-rate superplastic. In the temperature range where grain boundary sliding (GBS) controlled the plastic flow, the strength of the composite was lower than that of the unreinforced matrix alloy even after compensating for grain size and threshold stress. This “particle weakening” was in contrast with the particle strengthening observed in the low temperature range where dislocation climb creep was found to control the plastic flow. In the GBS regime, the strength differential between the materials was a function of SiC content and temperature, which increased with the increase in SiC content and temperature. Strong Mg segregation was detected at interfaces between SiC and Al phases in the composites. Evidence for interfacial reaction reported in the Si₃N₄ reinforced 6061 Al composites could not be detected in the current composites. Extensive formation of whisker-like fibers was observed at the fractured surface of the tensile samples above the critical temperature where particle weakening begins to be exhibited. This result suggests the possibility that partial melting in the solute-enriched region near SiC interfaces is responsible for the particle weakening in the SiC reinforced 6061 Al composite.     

Processing,Microstructure and Mechanical Properties of Ti6Al4V Particles-Reinforced Mg Matrix Composites

Novel Ti6Al4V particles-reinforced AZ91 Mg matrix composites were successfully fabricated by stir casting method. The stirring time in semisolid condition directly affected the particle distribution and the quality of the ingots.Furthermore, the optimal speed of the heating and the liquid stirring could overcome particle settlement caused by the density difference between the matrix and the particles. Ti6Al4V particles distributed uniformly in the composites with different particle contents. The average grain size decreased with the increase in the particle contents. The Ti6Al4V particles bonded pretty well with the alloy matrix. In addition, there were some interfacial reactions in the composites.There were rod-like Al_3Ti phases at the interface. The precipitates extended from the particle surface to the matrix, and they might improve the interfacial bonding strength. The ultimate tensile strength, yield strength and elastic modulus were enhanced as the particle contents increased, and the elongation was much better than that of the same matrix material reinforced with SiC particles. Thus, the novel composites exhibit better comprehensive mechanical properties.     

Effect of limited matrix–reinforcement interfacial reaction on enhancing the mechanical properties of aluminium–silicon carbide composites

An unconventional approach to strengthening Al/SiC composites through controlled matrix–reinforcement interfacial reactions was studied. Composites with two distinct interfacial microstructures were prepared by varying the contact time between the SiC particles and molten aluminium during processing. The formation of a thin Al₄C₃ reaction layer along the particle–matrix interface was found to increase the composite yield strength, ultimate tensile strength, work-hardening rate and work-to-fracture, and change the fracture pattern from one involving interfacial decohesion to one where particle breakage was dominant. These changes were attributed to a stronger interface bond, which is thought to result from the tendency for the Al₄C₃ reaction layer to form semicoherent interfaces and orientation relationships with the aluminium matrix and SiC particles and for it to be mechanically “keyed-in” to both these phases. The stronger interface bond also enhanced the levels of plastic constraint which, when coupled with the greater work hardening, promoted local matrix failure, thereby reducing the composite ductility.     

Effect of Particle Size on the Microstructures and Mechanical Properties of SiC-Reinforced Pure Aluminum Composites

This article examined the effects of particle size and extrusion on the microstructures and mechanical properties of SiC particle-reinforced pure aluminum composites produced by powder metallurgy method. It has been shown that both particle size and extrusion have important effects on the microstructures and mechanical properties of the composites. The SiC particles distribute more uniformly when the ratio of the matrix powder size and SiC particle size approaches unity, and the smaller-sized SiC particles tend to cluster easily. The voids are found to coexist with the clustered and large-sized SiC particles, and they significantly decrease the density and mechanical properties of the composites. Extrusion can redistribute the SiC particles in the matrix and decrease the number of pores, thus make the SiC particles distribute more uniformly in the matrix, and enhance the interfacial bonding strength. The decrease in the SiC particle size improves the tensile strength and yield strength, but decreases the ductility of the composites.     

废弃玻璃／铝基复合材料的组织和性能

利用搅拌熔铸法将废弃玻璃颗粒加入到熔融的基体合金ZL105中,制备出了废弃玻璃／铝基复合材料,研究了复合材料的微观组织,力学性能及断裂机理,结果表明,玻璃颗粒较均匀地分布于基体中,与基体发生界面反应;与基体合金相比,废弃玻璃颗粒的加入提高了复合材料的硬度和抗拉强度,在低载荷下,复合材料的摩擦性能优于基体合金,由于玻璃颗粒形状较尖锐,尺寸大小不均,并存在加工缺陷,有碍于大幅度提高复合材料的性能。     

Effect of Ti-6Al-4V particle reinforcements on mechanical properties of Mg-9Al-1Zn alloy

Mg-9Al-1Zn (AZ91) magnesium matrix composites reinforced by Ti-6Al-4V (TC4) particles were successfully prepared via powder metallurgical method. The yield strength (YS), ultimate tensile strength (UTS), and elongation (EL) showed a mountain-like tendency with the increase of the TC4 content. The mechanical properties of AZ91 magnesium matrix composites reached the optimal point with TC4 content of 10 wt.%, realizing YS, UTS, and EL of 335 MPa, 370 MPa, and 6.4%, respectively. The improvement of mechanical properties can be attributed to the effective load transfer from the magnesium matrix to the TC4 particles, dislocations associated with the difference in the coefficient of thermal expansion, good interfacial bonding between the Mg matrix and TC4 particles, and grain refinement strengthening.     

Mechanical properties and fracture mechanisms of aluminum matrix composites reinforced by Al_9(Co,Ni)_2 intermetallics

The microstructures and mechanical properties of Al matrix composites reinforced by different volume fractions of Al-Ni-Co intermetallic particles were investigated. Three different volume fractions of Al-Ni-Co particles were added to pure Al matrix using a stir-casting method. Microstructural analysis shows that with the increasing of the reinforcement volume fraction, the matrix grain size decreases and the porosity increases. The mechanical properties of the composites are improved over the matrix materials, except for the decreasing of the ductility. Fracture surface examination indicates that there is a good interfacial bonding between the Al matrix and the Al-Ni-Co particles and the fracture initiation does not occur at the particle-matrix interface.     

Effect of Particle Size on Mechanical Properties and Fracture Behaviors of Age-Hardening SiC/Al-Zn-Mg-Cu Composites

15 vol.％ SiC/Al-6.5Zn-2.8 Mg-l.7Cu (wt％) composites with varying particle sizes (3.5,7.0,14 and 20 μm),i.e.,C-3.5,C-7.0,C-14,and C-20,respectively,were fabricated by powder metallurgy (PM) method and subjected to microstructural examination.The effect of particle size on mechanical properties and fracture behaviors of the T6-treated composites was revealed and analyzed in detail.Element distribution and precipitates variations in the composites with varying particle sizes were emphatically considered.Results indicated that both tensile strength and plasticity of the T6-treated composites increased first and then decreased with particle size decreasing.The C-7.0 composite simultaneously exhibited the highest ultimate tensile strength (UTS) of 686 MPa and best elongation (El.) of 3.1％.The smaller-sized SiC particle would intro-duce more oxide impurities,which would react with the alloying element in the matrix to cause Mg segregation and deple-tion.According to strengthening mechanism analysis,the weakening of precipitation strengthening in the T6-treated C-3.5 composite was the main cause of the lower tensile strength.Additionally,the larger SiC particle,the more likely to fracture,especially in the composites with high yield strength.For the T6-treated C-20 composites,more than 75％ SiC particles were broken up,resulting in the lowest plasticity.As decreasing particle size,the fracture behaviors of the T6-treated composites would change from particle fracture to matrix alloy fracture gradually.     

超声振动辅助切削SiCp/Al复合材料的加工机理及试验

切削加工过程中材料损伤形式对加工表面质量会产生较大影响,现有仿真分析难以模拟真实颗粒失效行为,通过建立二维微观多相有限元模型能够深入了解材料损伤与表面质量的关系。基于常规切削（Conventional cutting,CC）与超声振动辅助切削（Ultrasonic vibration-assisted cutting,UVAC）两种加工方式,通过有限元仿真软件 Abaqus 对 20%SiCp / Al 复合材料的切削过程进行仿真模拟,阐释加工过程中刀具与工件的相互作用机理,并在同一参数下验证有限元仿真的准确性。通过设计单因素试验,对比两种加工方式及不同加工参数对切削力和表面粗糙度的影响规律,得出最佳加工参数组合,并对最佳加工参数下表面形貌进行分析。模拟和试验结果表明,SiC 颗粒断裂、颗粒耕犁、颗粒拔出以及 Al 基体撕裂是影响 SiCp / Al 复合材料加工质量的主要原因,刀具与颗粒不同的相对作用位置会产生不同的损伤形式。与常规切削相比,施加超声振动后可以有效抑制颗粒失效和基体损伤,使加工中的平均切削力（主切削力）降低 33%,工件已加工表面粗糙度值最大减小量为 531 nm,显著提高了表面质量。所建立的二维微观多相有限元模型,能够有效模拟铝基复合材料的加工缺陷和裂纹损伤问题, 对提高难加工材料的高质量表面制备有重要借鉴意义。     

等温锻造对碳化硅颗粒增强铝基复合材料断裂韧性的影响

开展了粉末冶金法制备的20%SiC_p/2009Al复合材料坯锭的等温锻造实验,通过金相观察、扫描电镜(SEM)、拉伸和断裂韧性测试等方法研究了不同变形量对锻件微观组织和力学性能的影响。结果表明,随着等温锻造变形量的增大,SiC颗粒分布更加均匀,锻件的强度和塑性显著提高。通过SEM对材料断裂韧性裂纹扩展路径观察发现,主裂纹扩展发生在SiC颗粒偏聚区域的铝基体中。复合材料的断裂方式为以基体韧性断裂和增强体脆性断裂这2种方式为主。     

Contribution of microstructural parameters to strengthening in an ultrafine-grained Al–7% Si alloy processed by severe deformation

An Al–7% Si alloy was severely deformed by equal channel angular pressing to study the refinement of the microstructure and associated changes of mechanical properties. The initial coarse dendritic structure was broken into an elongated submicron grain/subgrain structure, with a high dislocation density and distributed fine Si particles. The Si particles in the composite are seen to induce a high dislocation density during deformation and lead to faster structural refinement than in a monolithic alloy with the same composition as the matrix. The additional strengthening of the composite relative to the monolithic alloy is due to both the finer grain size and the high retained dislocation density. Severe plastic deformation also leads to an improvement in the ductility of the strong material due to the refinement of both the matrix microstructure and the Si particles.     

改善颗粒增强金属基复合材料塑性和韧性的途径与机制

评述了影响颗粒增强金属基复合材料塑性和韧性的各种因素,在此基础上深入研究了颗粒形状对ＳｉＣｐ／ＬＤ２复合材料塑性和断裂韧性的影响规律。采用有限单元法分析不同形状的ＳｉＣ颗粒增强的ＬＤ２复合材料的微区力学环境和整体力学行为,结果表明颗粒的尖锐化导致基体内应变集中和颗粒尖端断裂的可能性加剧,因而降低材料的塑性;而在外加载荷的作用下,由于复合材料基体整体均处于较高的加工硬化状态,因此颗粒形状对材料断裂韧     

Microstructures and mechanical properties of Al 2519 matrix composites reinforced with Ti-coated SiC particles

Ti-coated SiC_p particles were developed by vacuum evaporation with Ti to improve the interfacial bonding of SiC_p/Al composites. Ti-coated SiC particles and uncoated SiC particles reinforced Al 2519 matrix composites were prepared by hot pressing, hot extrusion and heat treatment. The influence of Ti coating on microstructure and mechanical properties of the composites was analyzed by scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS). The results show that the densely deposited Ti coating reacts with SiC particles to form TiC and Ti₅Si₃ phases at the interface. Ti-coated SiC particle reinforced composite exhibits uniformity and compactness compared to the composite reinforced with uncoated SiC particles. The microstructure, relative density and mechanical properties of the composite are significantly improved. When the volume fraction is 15%, the hardness, fracture strain and tensile strength of the SiC_p reinforced Al 2519 composite after Ti plating are optimized, which are HB 138.5, 4.02% and 455 MPa, respectively.