Effect of SiC content on the processing, compaction behavior, and properties of Al6061/SiC/Gr hybrid composites

Aluminum matrix composites reinforced with SiC and graphite (Gr) particles are a unique class of advanced engineered materials that have been developed to use in tribological applications. The conventional techniques for producing these composites have some drawbacks. In this study, a new method, namely In situ Powder Metallurgy (IPM), is applied for the preparation of Al6061/SiC/Gr hybrid composites. In this method, the stir casting and the powder metallurgy synthesizing processes are combined into an integrated net shape forming process. 0?C40 vol.% of SiC particles with an average size of 19 ??m, along with 9 vol.% of uncoated Gr particles, were introduced to the molten 6061 aluminum alloy. Then, the slurries were stirred in a specified time?Ctemperature regime resulting in mixtures of the SiC, Gr, and aluminum powder particles. The powder mixtures were cold pressed in six different pressures (between 250 and 750 MPa) and sintered. Finally, the produced composites were heat treated and their hardness and wear properties were investigated. Homogenous distribution of the SiC and Gr particles within the powder mixtures and the hybrid composites is clear from the SEM images. The results also show that the SiC particles decrease the compressibility of the hybrid powders and improve the hardness of composites. The best wear resistance is achieved in the hybrid composite containing 20 vol.% SiC particles.     

SiC matrix composites containing transition metal boride particulates internally synthesised by carbothermal reaction

SiC matrix composites reinforced with the various borides of the transition metals in group IV a-VI a, which were synthesized from the transition metal oxide, boron carbide and carbon mixed with SiC powder. Dense composites containing boride particulates of titanium, zirconium, niobium and chromium were prepared through reactive hot-pressing. The morphology of the internally synthesized boride particles reflected that of the starting oxide powders. SiC-NbB₂ composites with four-point flexural strength of 500 to 600 MPa and better oxidation resistance than SiC-TiB₂ were prepared even through pressureless sintering process. Pressureless-sintered and HIPed SiC-20 vol% NbB₂ exhibited the four-point flexural strength of 760 MPa at 20 °C and 820 MPa at 1400 °C.     

Microstructure and mechanical properties of hot extruded 6016 aluminum alloy/graphite composites

The incorporation of graphite particles into AA6016 aluminum alloy matrix to fabricate metal/ceramic composites is still a great challenge and various parameters should be considered. In this study, dense AA6016 aluminum alloy/(0-20 wt%) graphite composites have successfully been fabricated by powder metallurgy process. At first, the mixed aluminum and graphite powders were cold compacted at 200 MPa and then sintered at 500 ℃ for 1 h followed by hot extrusion at 450 ℃. The influence of ceramic phases(free graphite and in-situ formed carbides) on microstructure, physical and mechanical properties of the produced composites were finally investigated. The results show that the fabricated composites have a relative density of over 98%. SEM observations indicate that the graphite has a good dispersion in the alloy matrix even at high graphite content. Hardness of all the produced composites was higher than that of aluminum alloy matrix. No cracks were observed at strain less than 23% for all hot extruded materials.Compressive strength, reduction in height, ultimate tensile stress, fracture stress, yield stress, and fracture strain of all Al/graphite composites were determined by high precision second order equations. Both compressive and ultimate tensile strengths have been correlated to microstructure constituents with focusing on the in-situ formed ceramic phases, silicon carbide(SiC) and aluminum carbide(Al_4 C_3). The ductile fracture mode of the produced composites became less dominant with increasing free graphite content and in-situ formed carbides. Wear resistance of Al/graphite composites was increased with increasing graphite content. Aluminum/20 wt% graphite composite exhibited superior wear resistance over that of AA6016 aluminum alloy.     

Manufacture of fibrous β-Si3N4-reinforced biomorphic SiC matrix composites for bioceramic scaffold applications

The manufacturing of the Si₃N₄ reinforced biomorphic microcellular SiC composites for potential medical implants for bone substitutions with good biocompatibility and physicochemical properties was performed in a two step process. First, wood-derived porous Si/SiC ceramics with various porosities were produced by liquid silicon infiltration (LSI) at 1550 °C with static nitrogen atmosphere protection (0.1 MPa), followed by subsequent partial removing of the Si in vacuo at 1700 °C for different periods of time. Secondly, the final porous Si₃N₄ fiber/SiC composite was obtained by further chemical reaction of nitrogen with the infiltrated residual silicon at 1400 °C for 4 h under high concentration flowing nitrogen atmospheres (0.5 MPa). The bending strengths of the porous Si₃N₄ fiber/SiC composite at axial and radial direction were measured as 180.03 MPa and 90 MPa respectively. The improvement in bending strength was primarily attributed to grain pull-out and bridging enhanced by the elongated β-Si₃N₄ grains cross-linked in the depth of the pore channels. The TG analysis showed an obvious improvement in oxidation resistance of the nitride specimens.     

Fabrication of AA6061/Al2O3p composites from elemental and alloy powders

The tensile properties and microstructures of AA6061/Al₂O_3p composites fabricated by the pressureless infiltration method under a nitrogen atmosphere were examined. Since the spontaneous infiltration of molten metal into elemental powders bed as well as alloy powders bed occurred at 700°C for 1 hour under a nitrogen atmosphere, it was possible to fabricate 6061 Al matrix composite reinforced with Al₂O_3p irrespective of the type of metal powders. Both MgAl₂O₄ and MgO were formed at interfaces between Al₂O₃ and the matrix. In addition, MgAl₂O₄ was formed at within the matrix by in situ reaction during composite fabrication. Fine AlN was formed by in situ reaction in both composites. A significant strengthening in the composites occurred due to the formation ofin situ AlN particle and addition of Al₂O₃ particles, as compared to the commercial alloy, while tensile properties in the both elemental and alloy powders composites showed similar trend.     

Combustion synthesis and microwave absorption property of SiC(Fe) solid solution powder under different reaction time

SiC(Fe) solid solution powders were synthesized via combustion reaction of the Si and C system in a 0.1 MPa nitrogen atmosphere using iron as the dopant and PTFE as the chemical activator, under different reaction time. The microstructures of prepared powders have been characterized by the SEM, EDS, XRD and Raman spectra, respectively. Results indicate that the prepared powders have fine spherical particles and narrow particle size distribution. The electric permittivities of SiC samples were determined in the frequency range of 8.2–12.4 GHz. Results show that the permittivity of SiC decreases with the increasing reaction time. The Fe doped SiC powder with reaction time of 45 min with 2 mm or 2.5 mm thickness exhibit the best microwave absorption properties in the X-band range(8.2–12.4 GHz). A method to predict absorbing property in the other frequency range has been presented.     

Utilization of Chemically Synthesized Fine Powders of SiC/Al2O3 Composites for Sintering

Fine powders of (Al₂O₃)_100–x(SiC)_x (0 ≤ x ≤ 50) composites were prepared by chemical route (named as pyrophoric technique) to achieve a uniform mixture of SiC in an alumina matrix. The chemically synthesized fine SiC/Al₂O₃ composite powders were sintered to form composites at 1450°C which is well below the sintering temperature of SiC. Sintering was performed in an argon atmosphere. Highly dense SiC/Al₂O₃ microstructures were achieved. An improvement in bulk density and hardness has been achieved for SiC/Al₂O₃ composites with 20 wt% of SiC. Hexagonal-shaped grains have been obtained in (Al₂O₃)₅₀(SiC)₅₀ composite with well-connected grain boundaries. The peak position of alumina in SiC/Al₂O₃ composites shifts toward lower wavenumbers in Fourier transform infrared spectroscopy and higher wavenumbers in Raman spectroscopy due to the incorporation of SiC in the composites. The optical band gap decreases with the addition of SiC and the composite behaves more like a semiconductor rather than an insulator. These properties make SiC/Al₂O₃ composites attractive for various industrial applications.     

Different reinforcement strategies of hybrid surface composite AA6061/(B4C+MoS2) produced by friction stir processing

Aluminum surface composites have gained huge importance in material processing due to their noble tribological characteristics. The reinforcement of solid lubricant particles with hard ceramics further enriches the tribological characteristics of surface composites. In the current study, friction stir processing was chosen to synthesize hybrid surface composites of aluminum containing B₄C and MoS₂ particles with anticipated improved tribological behavior. B₄C and MoS₂ powder particles in 87.5: 12.5 ratio were reinforced into the AA6061 by hole and groove method. Microstructural observations indicated that reinforcement particles are well distributed in the matrix. The hardness and wear resistance of hybrid surface composites improved as compared to the base material, due to well distributed abrasive B₄C and solid lubricant MoS₂ particles in AA6061. The hybrid surface composites achieved ∼32 % increased average hardness as compared to the base material. Hole method revealed ∼13 % better wear resistance compared to the groove method for friction stir processed hybrid surface composite, attributing to an improved homogeneity of particle distribution shown by zigzag hole pattern. Moreover, friction stir processed AA6061 without reinforcement particles exhibited reduced hardness and wear resistance due to loss of strengthening precipitates during multi-pass friction stir processing.     

Effects of copper addition on the sintering behavior and mechanical properties of powder processed Al/SiC<Subscript><Emphasis Type="Bold">p</Emphasis></Subscript> composites

The effect of copper addition on powder processed Al-10 vol% SiC composites was studied in regards to their sintering responses. Copper was mixed with aluminum powder either as elemental powders or as the coated layer on SiC particles. After sintering at 600°C for 1 h, Al-SiC composites with no copper addition showed little densification. It also demonstrated very low bend strengths of 49 and 60 MPa, indicating poor bonding between the powders in the sintered composite. The addition of 8% copper to the Al/SiC system effectively improved the sintering response, producing over 95% theoretical density, a bend strength of 231 MPa with the copper coated SiC, and a 90% density with over 200 MPa bend strength with the admixed copper.The as-sintered microstructures of the Al–SiC composites clearly revealed particle boundaries and sharp pores, indicating that only a limited neck growth occurred during sintering. In the case of Al–Cu–SiC composites, however, a liquid phase was formed and spread through particle boundaries filling the interfaces or voids between SiC particles and the matrix powders. The coated copper on SiC particles produced a somewhat better filling of the interface or voids, resulting in a little more densification and better sintered strength. Since the solubility of copper in aluminum is less than 2% at the sintering temperature, the alloying of copper in the aluminum matrix was limited. Most of the copper added was dissolved in the liquid phase during the sintering and precipitated as CuAl₂ phase upon cooling.     

Microstructure and properties of BN/Ni-Cu composites fabricated by powder technology

Microsize Powders of Ni and Cu were prepared by water atomization technique to fabricate metal matrix composites containing various percentages of nanosized boron nitride particles (1, 2, 3, 4, 5 wt. % of BN in a matrix containing (20 wt. %Ni and 80 wt. %Cu). The prepared mixtures were cold compacted under 400 MPa, and sintered for 2 h at 1000 °C in a controlled atmosphere of 3:2 N₂/H₂ gas mixtures. The microstructure and the chemical composition of the prepared powders as well as the consolidated composites were investigated by X-ray diffraction as well as field emission scanning electron microscope (FESEM) equipped with an energy dispersive spectrometer (EDS). The produced Cu and Ni powders have spheroid shape of size less than 100 microns, but the investigated BN has an equiaxed particle shape and particle size of ～ 500 nm. It has been also observed that BN and Ni particles were homogeneously distributed in the Cu matrix of the present BN/Ni-Cu composites. The density, electrical resistivity, saturation magnetization and hardness of the composites were measured. It was observed that, by increasing BN content, the relative density was decreased, while the saturation magnetization, electrical resistivity and hardness were increased.     

Pressureless-sintered and HIPed SiC-TiB2 composites from SiC-TiO2-B4C-C powder compacts

Dense SiC-TiB₂ composites with prescribed compositions were obtained through pressureless sintering of SiC-TiO₂-B₄C-C powder compacts. During the process, TiO₂, B₄C and C reacted to form TiB₂, followed by the consolidation of SiC matrix with the aid of excess B₄C and C. The effects of the composition of the starting powders on the final density were investigated and the mechanical properties of the composite were evaluated. The sintered body with additional HIPing at 1900 °C exhibited the average four-point flexural strength of more than 700 MPa at both 20 and 1400 °C.     

Densification and microstructural evolution during laser sintering of A356/SiC composite powders

This article reports experimental results on laser sintering of A356 aluminum alloy and A356/SiC composite powders. Effects of scan rate, sintering atmosphere, hatch spacing, and SiC volume fraction (up to 20%), and particle size (7 and 17 μm) on the densification were studied. The phase formation and microstructural development were analyzed by X-ray diffraction (XRD) and scanning electron microscopy (SEM) coupled with energy-dispersive X-ray spectroscopy (EDS). Laser sintering under argon atmosphere exhibited higher densification compared to nitrogen. A faster sintering kinetics was observed as the scan rate decreased. Except at a low SiC content (5 vol%), the composite powders exhibited lower densification kinetics. The densification was improved when finer SiC particles were utilized. Microstructural studies revealed directional solidification of aluminum melt to form columnar grains with inter-columnar silicon precipitates. In the presence of SiC particles, aluminum melt reacted with the ceramic particles to form Al₄SiC₄ plates.     

Development of Al3Ti and Al3Zr intermetallic particulate reinforced aluminum alloy AA6061 in situ composites using friction stir processing

Aluminum rich intermetallic particles are potential reinforcements for discontinuously reinforced aluminum matrix composites (DRAMCs). The objective of the present work is to produce AA6061/Al₃Ti and AA6061/Al₃Zr composites using in situ casting technique and applying friction stir processing (FSP) to enhance the distribution and morphology of Al₃Ti and Al₃Zr particles. AA6061/Al₃Ti and AA6061/Al₃Zr DRAMCs were produced by the in situ reaction of inorganic salts K₂TiF₆ and K₂ZrF₆ with molten aluminum. The microstructure was observed using optical and scanning electron microscopy. AA6061/Al₃Ti DRAMC exhibited clusters of Al₃Ti particles while the segregation of needle shape Al₃Zr particles was observed in AA6061/Al₃Zr DRAMC. The prepared composites were subjected to FSP. Significant changes in the distribution and morphology of Al₃Ti and Al₃Zr particles were observed after FSP. The changes in microhardness and sliding wear behavior of AA6061/Al₃Ti and AA6061/Al₃Zr DRAMCs before and after FSP is detailed in this paper.     

Effect of the SiC particle size on the dry sliding wear behavior of SiC and SiC–Gr-reinforced Al6061 composites

The effect of size of silicon carbide particles on the dry sliding wear properties of composites with three different sized SiC particles (19, 93, and 146 μm) has been studied. Wear behavior of Al6061/10 vol% SiC and Al6061/10 vol% SiC/5 vol% graphite composites processed by in situ powder metallurgy technique has been investigated using a pin-on-disk wear tester. The debris and wear surfaces of samples were identified using SEM. It was found that the porosity content and hardness of Al/10SiC composites decreased by 5 vol% graphite addition. The increased SiC particle size reduced the porosity, hardness, volume loss, and coefficient of friction of both types of composites. Moreover, the hybrid composites exhibited lower coefficient of friction and wear rates. The wear mechanism changed from mostly adhesive and micro-cutting in the Al/10SiC composite containing fine SiC particles to the prominently abrasive and delamination wear by increasing of SiC particle size. While the main wear mechanism for the unreinforced alloy was adhesive wear, all the hybrid composites were worn mainly by abrasion and delamination mechanisms.     

Microstructure of AA2024-SiC nanostructured metal matrix composites

Nanostructured metal matrix composites (NMMCs) in large-dimension billets were fabricated by hot isostatic pressing (HIPing) of cryomilled powders consisting of AA2024 alloy reinforced by 25 wt.% SiC particles. Microstructure of the bulk nanostructured composites and cryomilled powders was characterized by X-ray diffraction (XRD), scanning electron microscopy (SEM), and transmission electron microscopy (TEM). In addition, mechanical properties of the bulk nanocomposites were also addressed.     

Particle effects on friction and wear of aluminium matrix composites

Particle effects on friction and wear of 6061 aluminium (6061 Al) reinforced with silicon carbide (SiC) and alumina (Al₂O₃) particles were investigated by means of Vickers microhardness measurements and scratch tests. Unreinforced 6061 Al matrix alloy was also studied for comparison. To explore the effect of heat treatment, materials subjected to three different heat treatment conditions, i.e. under-aged, over-aged and T6, were used. Multiplescratch tests using a diamond and a steel indentor were also carried out to simulate real abrasive wear processes. Vickers microhardness measurements indicated that T6 heattreated composites had the highest hardness. Single-scratch tests showed that the variation of friction coefficient was similar to that of Vickers hardness and the peak-aged composites exhibited the best wear resistance. The wear rate of fine particle-reinforced composites was mainly affected by hardness. However, the wear rate of large particle-reinforced composites was influenced by both the hardness and fracture of the particles.     

Extrusion textures in Al, 6061 alloy and 6061/SiCp nanocomposites

The 6061 alloy matrix composites reinforced with 10 wt.% and 15 wt.% of SiC nanoparticles with an average diameter of ~ 500 nm were hot extruded in strip shape from ball milled powders. The microstructures and textures of the hot extruded nanocomposites have been investigated by means of three dimensional orientation distribution functions and electron backscatter diffraction (EBSD) techniques. Pure Al and 6061 alloy extruded strips from atomised powders have been produced for comparison purposes. The results show that the non-deformable SiC particulates have a strong influence on the formation of extrusion textures in the matrix. Pure Al and 6061 alloy develop a typical β fibre texture after extrusion in strip shape. For 6061/SiC_p nanocomposites, the intensities of major texture components decrease with increasing amount of SiC particles. The total intensities of Brass, Dillamore and S components have decreased by 19% for 6061/10 wt.% SiC_p and 40% for 6061/15 wt.% SiC_p composites when compared with the 6061 alloy. EBSD analysis on local grain orientations shows limited Al grain rotations in SiC rich zones and decreased texture intensities.     

Processing,microstructure and properties of in-situ reinforced SiC matrix composites

SiC matrix composites were fabricated by in-situ formation of transition metal boride and carbide particles from oxide powders by carbothermal reactions. Dense composites with various microstructures were produced by pressureless sintering and additional hot-isostatic pressing. The microstructures and mechanical properties of the composites were dependent upon the pressureless-sintering temperature. The use of submicron-sized TiO₂ lead to fine and equiaxial TiB₂ particulates. The composites exhibited high flexural strengths (>700 MPa). At higher sintering temperatures, the grain growth of SiC swept the boride into clusters with larger sizes and anisotropic shapes, which improved the fracture toughness of the composite at the expense of strength.     

Ceramization process of polyvinylsilane as a precursor for SiC-based material

A SiC-based material was synthesized from polyvinylsilane (PVS) by pyrolysis at 1400 K in Ar gas atmosphere. In the ceramization process of PVS, several kinds of gases such as hydrogen, silanes, and hydrocarbons were evolved in the temperature range from 500 to 800 K. The total ceramic yield from PVS was about 36%. PVS was heat-treated using several temperature programmes by reflux heat treatment with a view to increase the ceramic yield. The total ceramic yield increased to 59% by the reflux heat treatment at 600 K. The apparent SiC crystallite size and the atomic ratio of carbon to silicon (C/Si) of the SiC-based material obtained by pyrolysis at 1400 K were almost the same for the PVS reflux-treated and the PVS not heat-treated; an apparent SiC crystallite size of about 2.4 nm, and C/Si of about 1.5.     

Preparation of SiC hollow particles by gas-phase reaction in the SiH4-CH4-H2 system

The formation of SiC hollow particles by gas-phase reaction in the silane-methane-hydrogen system was studied at temperatures from 1200 to 1400° C. Synthesized powders were analysed by means of the thermogravimetry, X-ray diffraction, transmission electron microscopy, infrared irradiation, etc. The powders synthesized at 1200 to 1300° C consisted ofβ-SiC and silicon phases, but they became almost hollowβ-SiC particles at 1400° C. The composition, particle size, and shell thickness of the synthesized particles were dependent on the reaction conditions. From lattice parameter measurements, a certain amount of excess silicon was verified to be incorporated into theβ-SiC lattice. On the other hand, excess carbon existed, for the most part, as an amorphous phase not forming solid solutions withβ-SiC. Transmission electron microscopy observations and infrared absorption measurements have shown that excess carbon is contained within the shells of hollow particles, while unreacted excess silicon exists as a crystalline phase mostly in the cores of the particles.