Microstructural characteristics of alumina-based composite prepared by in situ reaction of alumina-silicon carbide-nickel system

 In situ reaction of nickel and silicon carbide has been attempted to prepare alumina-based composites containing some kinds of dispersed phases. The composites were fabricated by reducing and sintering of Al₂O₃/NiO/SiC mixtures. Reaction products (Ni₃Si and C) and metallic Ni were found to disperse at the matrix grain boundaries, while Ni was partly trapped into Al₂O₃ grains. In addition, carbon nanoballs encapsulating Ni₃Si were produced and dispersed in the composites. The carbon cages were approximately 80–100 nm in diameter with polyhedral shape, and had lattice spacing of 0.35 nm that was typical for the graphite. Encapsulated Ni₃Si had facet planes which were parallel to the carbon layers surrounding. Production of metal encapsulated carbon nanoball within ceramic materials is the first successive result that might promote researches on such novel ceramic composites. Received: 2 January 1997 / Accepted: 15 March 1997     

Electrical properties tailoring in Ni-particle-dispersed (Ba0.95Ca0.05)(Ti0.96Zr0.04)O3 composites

Ni-particle-dispersed (Ba_0.95Ca_0.05)(Ti_0.96Zr_0.04)O₃ (BCTZ/Ni) piezoceramic composites were prepared via sintering at 1300 °C in industrial N₂ gas. Structural characterizations showed that the metallic Ni was not oxidized and the BCTZ preserved the perovskite structure. The Ni particles were uniformly distributed in the BCTZ ceramic matrix. The relative dielectric constant ?_r of the BCTZ/Ni composites increased from 1362 to 3910 with increasing Ni content from 0 to 20 vol.%, which is explained by the Maxwell equation as well as the micro-capacitor model. The percolation theory of insulator–metal transitions is also applied to correlate the rapid increase of dielectric constant with Ni content. The piezoelectric constant d₃₃ gradually decreased from 230 to 50 pC N⁻¹, giving a gradient profile of piezoelectric property. We demonstrate that the electrical properties can be effectively tailored by dispersing metal particles into piezoceramics.     

Electrical properties of Ni-particle-dispersed alkaline niobate composites sintered in a protective atmosphere

Co-firing of piezoceramics with metals is drawing ever-increasing attention. This article reports Ni-particle-dispersed [Li_0.06(K_0.5Na_0.5)_0.94]NbO₃ (LKNN/Ni) lead-free piezoelectric composites that were sintered in a protective atmosphere of nitrogen gas. The base metal Ni was not oxidized and the piezoelectric LKNN preserved the perovskite structure. The microstructure observations show that Ni particles were uniformly dispersed in LKNN ceramics matrix. With increasing Ni content from 0 to 20 vol%, the piezoelectric constant d₃₃ of the LKNN/Ni composites decreased from 165 to 23 pC/N, and the corresponding dielectric constant ?_r greatly increased. The 95%LKNN-5%Ni composite still exhibited a typical ferroelectric loop; however, the P-E curves measured for Ni > 5 vol% composites demonstrated some metallic characteristics. The LKNN/Ni composites could find applications in piezoelectric actuators with functionally graded microstructure (FGM).     

Oxidation kinetics of metallic inclusions in a composite with an Al2O3‐ZrO2 matrix

Many studies have been conducted to obtain toughness in ceramic‐ceramic and metal‐ceramic composites, using new processing techniques or by addition of metallic inclusions in the ceramic matrix. The oxidation behavior of metallic inclusions, niobium and nickel metallic particles embedded in an Al₂O₃‐ZrO₂ matrix, was measured through thermogravimetric analysis. In this work oxidation mechanisms were proposed and kinetic parameters defined using a software module for the kinetic analysis of thermal measurements by means of multiple linear or non‐linear regression. The morphology of the oxidized surfaces of the samples was examined by using scanning electron microscopy. Oxides were identified by X‐ray diffraction. The oxidation kinetics of metallic particles of niobium and nickel are highly complex, for they depend on various factors, i.e., metal’s characteristics, processing of the composite, oxygen diffusion through the matrix, grain boundaries, and heating rate applied to the material.     

Processing,spark plasma sintering,and mechanical behavior of alumina/titanium composites

This paper focuses on the study of the processing and mechanical properties, (flaw tolerance and R-curve behavior) of alumina–titanium ceramic–metal composites produced by spark plasma sintering. In order to obtain homogenously dispersed composites, a rheological study was carried out by measuring the flow behavior in different conditions of solid content, amount of dispersant and shear stress. It has been found that, with the suitable conditions (80 wt% solids and 3 wt% deflocculant), a ceramic–metal homogeneously dispersed (Al₂O₃–Ti) composite can be obtained. After sintering, the composites were mechanically tested and the cermet showed an important improvement in the flaw tolerance and R-curve behavior when compared with the monolithic material. It has been demonstrated by scanning electronic microscopy that this improvement is a consequence of the reinforcement mechanisms provided by the metallic particles that interact with the crack producing a notable increase in toughness up to ~8 MPa m^1/2.     

B4C包覆ZTA颗粒增强铁基复合材料制备与性能

ZTA (ZrO₂增韧Al₂O₃)陶瓷颗粒表面包覆B₄C微粉,将其制备成蜂窝状结构陶瓷预制体。采用传统重力浇注工艺将陶瓷预制体与熔融的高铬铸铁(HCCI)金属溶液进行复合,获得ZTA陶瓷颗粒增强高铬铸铁基复合材料。对复合材料中ZTA陶瓷颗粒增强相与高铬铸铁基体之间的界面及复合材料的耐磨料磨损性能进行了研究。结果表明,ZTA陶瓷颗粒与高铬铸铁界面结合处形成了明显的过渡区域,界面过渡区域的存在提高了陶瓷颗粒与金属基体的结合,从而提升了复合材料的整体稳定性能。同时,三体磨料磨损试验表明该复合材料的耐磨料磨损性能是高铬铸铁的3.5倍左右。     

Preparation of nickel-coated powders as precursors to reinforce MMCs

The preparation of nickel-coated ceramic particles as precursors for MMC fabrication was studied. Al₂O₃ and SiC powders of three different particle sizes were successfully coated with Ni using an electroless metal plating technique. Uniform and continuous nickel films were deposited on both, alumina and silicon carbide powders, with a final composition ranging from 1.6 to 1.9wt% phosphorus, 18–21wt% of metallic nickel and the balance is ceramic. XRD showed that the Ni-P deposit was predominantly amorphous. However, after heat treatment, the metallic deposits crystallize into Ni and Ni₃P phases, as confirmed by DSC analyses. Preliminary results showed that the use of Ni-coated powders enhances the wettability between the matrix and ceramic phase when processing particulate MMCs by infiltration techniques. The coating promoted easy metal flow through the preform, compared to the non-infiltration behavior of the uncoated counterpart samples.     

A Multiscale Understanding of the Thermodynamic and Kinetic Mechanisms of Laser Additive Manufacturing

Selective laser melting (SLM) additive manufacturing (AM) technology has become an important option for the precise manufacturing of complex-shaped metallic parts with high performance. The SLM AM process involves complicated physicochemical phenomena, thermodynamic behavior, and phase transformation as a high-energy laser beam melts loose powder particles. This paper provides multiscale modeling and coordinated control for the SLM of metallic materials including an aluminum (Al)-based alloy (AlSi10Mg), a nickel (Ni)-based super-alloy (Inconel 718), and ceramic particle-reinforced Al-based and Ni-based composites. The migration and distribution mechanisms of aluminium nitride (AlN) particles in SLM-processed Al-based nanocomposites and the in situ formation of a gradient interface between the reinforcement and the matrix in SLM-processed tungsten carbide (WC)/Inconel 718 composites were studied in the microscale. The laser absorption and melting/densification behaviors of AlSi10Mg and Inconel 718 alloy powder were disclosed in the mesoscale. Finally, the stress development during line-by-line localized laser scanning and the parameter-dependent control methods for the deformation of SLM-processed composites were proposed in the macroscale. Multiscale numerical simulation and experimental verification methods are beneficial in monitoring the complicated powder-laser interaction, heat and mass transfer behavior, and microstructural and mechanical properties development during the SLM AM process.     

Microstructure and mechanical properties of chromium and chromium/nickel particulate reinforced alumina ceramics

A range of Al₂O₃-Cr and Al₂O₃-Cr/Ni composites have been made using either pressureless sintering in the presence of a graphite bed or hot pressing. Examination of the microstructures shows that they are fully dense (typically 98–99% of the theoretical density) and that the micrometre-scale metallic particles remain discrete and homogeneously dispersed in all composites. All of the hot pressed specimens had higher flexural strengths than the sintered materials. Within each processing route, the composites had slightly lower strength values than the equivalent monolithic alumina specimens. This was attributed to weak interfacial bonding. Fracture toughness behaviour was investigated using indentation and double cantilever beam methods. All of the composites were found to be tougher than the parent alumina and to show resistance-curve behaviour. For the composites, maximum fracture toughness values were 5–6 MPa m^1/2 (about double the value for alumina) for process zone sizes of a few millimetres, although steady state was not reached in the limited number of specimens tested. Examination of fracture surfaces and indentation cracks showed that the toughening potential of the metal particles was not exploited to any significant extent. This was mainly due to weak metal-Al₂O₃ interfaces, but also because of carbon embrittlement of the metallic particles in which chromium was the major constituent.     

A novel in-situ polymer derived nano ceramic MMC by friction stir processing

Friction stir processing (FSP) is a solid state technique used for material processing. Tool wear and the agglomeration of ceramic particles have been serious issues in FSP of metal matrix composites. In the present study, FSP has been employed to disperse the nanoscale particles of a polymer-derived silicon carbonitride (SiCN) ceramic phase into copper by an in-situ process. SiCN cross linked polymer particles were incorporated using multi-pass FSP into pure copper to form bulk particulate metal matrix composites. The polymer was then converted into ceramic through an in-situ pyrolysis process and dispersed by FSP. Multi-pass processing was carried out to remove porosity from the samples and also for the uniform dispersion of polymer derived ceramic particles. Microstructural observations were carried out using Field Emission Scanning Electron Microscopy (FE-SEM) and Transmission Electron Microscopy (TEM) of the composite. The results indicate a uniform distribution of ~ 100 nm size particles of the ceramic phase in the copper matrix after FSP. The nanocomposite exhibits a five fold increase in microhardness (260HV₁₀₀) which is attributed to the nano scale dispersion of ceramic particles. A mechanism has been proposed for the fracturing of PDC particles during multi-pass FSP.     

Ultrafine magnetic metal dispersed carbons prepared from anisotropic pitch and metal acetylacetonate complexes

Transition metal (Fe, Co or Ni) dispersed carbon composites were prepared using the mixtures of metal acetylacetonate complex as a source of metal particles and an anisotropic coal-tar pitch as a carbon matrix precursor by heat treatment at the temperatures up to 1000°C. Mixing of the metal complexes and the pitch by dissolving in quinoline permitted the notable fine dispersion of the complex in the pitch. Then the resulting mixtures were easily converted to the metal dispersed carbons by pyrolysis under an inert atmosphere. The appeared particles were Fe₃O₄/-Fe/Fe₃C, -Co or Ni when using the corresponding metal complex. Besides, their particle diameters were much less than 30 nm and distributed evenly throughout the carbon matrix. The magnetic properties of the metal dispersed carbons were evaluated with a vibrating sample magnetometer, and it was found that saturation magnetization and coercive force ranged from 1.03 × 10^–5 to 5.65 × 10^–5 Wb · m/kg and from 0.21 × 10⁴ to 3.06 × 10⁴ A/m, respectively.     

Aluminium based composites strengthened with metallic amorphous phase or ceramic (Al2O3) particles

Two methods were used to obtain amorphous aluminium alloy powder: gas atomization and melt spinning. The sprayed powder contained only a small amount of the amorphous phase and therefore bulk composites were prepared by hot pressing of aluminium powder with the 10% addition of ball milled melt spun ribbons of the Al₈₄Ni₆V₅Zr₅ alloy (numbers indicate at.%). The properties were compared with those of a composite containing a 10% addition of Al₂O₃ ceramic particles. Additionally, a composite based on 2618A Al alloy was prepared with the addition of the Al₈₄Ni₆V₅Zr₅ powder from the ribbons used as the strengthening phase. X-ray studies confirmed the presence of the amorphous phase with a small amount of aluminium solid solution in the melt spun ribbons. Differential Scanning Calorimetry (DSC) studies showed the start of the crystallization process of the amorphous ribbons at 437 °C. The composite samples were obtained in the process of uniaxial hot pressing in a vacuum at 380 °C, below the crystallization temperature of the amorphous phase. A uniform distribution of both metallic and ceramic strengthening phases was observed in the composites. The hardness of all the prepared composites was comparable and amounted to approximately 50 HV for those with the Al matrix and 120 HV for the ones with the 2618A alloy matrix. The composites showed a higher yield stress than the hot pressed aluminium or 2618A alloy. Scanning Electron Microscopy (SEM) studies after compression tests revealed that the propagation of cracks in the composites strengthened with the amorphous phase shows a different character than these with ceramic particles. In the composite strengthened with the Al₂O₃ particles cracks have the tendency to propagate at the interfaces of Al/ceramic particles more often than at the amorphous/Al interfaces.     

Alumina powder assisted carbon nanotubes reinforced Mg matrix composites

Mg matrix composites reinforced by carbon nanotubes (CNTs)-Al₂O₃ mixture, which was synthesized by in situ growing CNTs over Al₂O₃ particles through chemical vapor deposition (CVD) using Ni catalyst, were fabricated by means of powder metallurgy process, followed by hot-extrusion. By controlling synthesis conditions, the as-grown CNTs over Al₂O₃ particles possessed high degree of graphitization, ideal morphology, higher purity and homogeneous dispersion. Due to the ‘vehicle’ carrying effect of micrometer-level A₂O₃, CNTs were easy to be homogeneously dispersed in Mg matrix under moderate ball milling. Meanwhile, Al₂O₃ particles as catalyst carriers, together with CNTs, play the roles of synergistic reinforcements in Mg matrix. Consequently, the Mg matrix composites reinforced by CNTs-Al₂O₃ mixture exhibited remarkable mechanical properties.     

Opportunities for new graphitic aluminium metal matrix composite

Abstract

Nickel coated graphite particles have been incorporated into aluminium with a second particulate phase to produce graphitic aluminium metal matrix composites (Gr A-Ni) with improved processing, wear, and scuffing resistance. Excellent wear behaviour is provided by a combination of solid lubrication by graphite as well as high temperature strengthening of the matrix alloy by nickel present as Al₃ Ni intermetallics. Applications being developed include cylinder liners, pistons, connecting rods, various types of brakes, air diffusers and bushings. Neutral buoyancy of two particles, one of which is lighter and the other heavier than the aluminium matrix alloy, makes this a readily sand and die castable material. The presence of graphite and Al₃Ni intermetallics reduces the amount of ceramic particulate required to achieve the desired wear properties, with resulting improved machinability. The composition of the material can be tailored to the application. All these factors influence the finished part cost.     

Characterization of the alumina oxide,copper and nickel powders and their processing intended for fabrication of the novel hybrid composite: A comparative study

The aim of this study was the fabrication and characterization of the novel hybrid composite from the Al₂O₃/Cu/Ni system. The research included the production of composite specimens by uniaxial pressing and their further sintering. The influence of the ceramic and metallic powders and their sintering temperature on the microstructure of composites was investigated. The firing process was conducted in reducing the atmosphere at three different temperatures, selected on the basis of the copper-nickel phase diagram: 1100 °C, 1260 °C, 1400 °C. Reference samples of Al₂O₃/Cu were also produced in the same way for comparative purposes. The addition of the third component, which together with copper will form a Ni−Cu solid solution, was intended to improve the wettability of ceramic matrix through a liquid metallic phase, and thus to reduce the phenomenon of the liquid metal flow on samples surface during sintering. However, it had an impact on physical and mechanical properties.     

Verbundwerkstoffe mit Metallmatrix

Metal Matrix Composites Conventional metallic materials have been tailored in the past close to their ultimate properties. New technological requirements ask for further improved materials. Metal-matrix composites (MMC) promise to reach this goal. MMC can be described as materials whose microstructures comprise a continuous metallic phase (the matrix) into which a second phase has been artificially introduced during processing, as reinforcement. Presently the interest in MMC is primarily focused on light alloys reinforced with fibrous or particulate phase to achieve major jumps in selected mechanical properties or thermal stability. This new interest is mainly related to the fact that ceramic based reinforcement constituents became recently available, which are comparatively inexpensive. Al₂O₃ or SiC-based fibres, whiskers and particles, but also carbon fibres are used to reinforce aluminium, magnesium or titanium matrix alloys.     

Potential new experiments on fabrication of cast particulate composites in space

Recent developments in fabrication of cast metal ceramic particle composites by liquid metallurgy techniques are outlined. Difficulties encountered in preparing cast composites in the ground environment (including non-uniform distribution and agglomeration of dispersed particles and relatively poor bonding between dispersoids and matrix) and how these can be overcome in a microgravity environment have been discussed. This paper also reviews experiments performed by various space agencies including NASA and ESA on fabrication of composites in space. Some new experiments concerning fabrication of cast composites like dispersion of submicron ceramic particles in molten metals, preparation of cermets with very large volume fractions of ceramic particles and dispersion of flake-type ceramic particles to achieve grain refinement have been proposed.     

Interface tailoring to enhance mechanical properties of carbon nanotube reinforced magnesium composites

This study highlights the use of a metallic coating of nanoscale thickness on carbon nanotube to enhance the interfacial characteristics in carbon nanotube reinforced magnesium (Mg) composites. Comparisons between two reinforcements were targeted: (a) pristine carbon nanotubes (CNTs) and (b) nickel-coated carbon nanotubes (Ni–CNTs). It is demonstrated that clustering adversely affects the bonding of pristine CNTs with Mg particles. However, the presence of nickel coating on the CNT results in the formation of Mg₂Ni intermetallics at the interface which improved the adhesion between Mg/Ni–CNT particulates. The presence of grain size refinement and improved dispersion of the Ni–CNT reinforcements in the Mg matrix were also observed. These result in simultaneous enhancements of the micro-hardness, ultimate tensile strength and 0.2% yield strength by 41%, 39% and 64% respectively for the Mg/Ni–CNT composites in comparison with that of the monolithic Mg.     

Preparation and properties of NiAl(Si)/Al2O3 co-continuous composites obtained by reactive metal penetration

Reactive metal penetration was used to prepare intermetallic–ceramic composites with co-continuous structure, starting from silica glass preforms. Two subsequent metal penetrations were performed: first, the silica was immersed in a liquid Al bath, obtaining an Al(Si)/Al₂O₃ composite, then Ni was put in contact with the composite at high temperature, bringing to the substitution of Al with a Ni–Al intermetallic. The obtained composites present both phases continuous, and the whole process is a near net-shape one. The intermetallic phase is based on the Ni–Al system, with small Si content (lower than 2%) and its composition ranges from Al₃Ni₂ to a mixture of NiAl and Ni₃Al depending on the Ni content during the second penetration step.The composites present high hardness and melting point, low thermal expansion coefficient and good mechanical properties.     

Polymer/filler derived NbC composite ceramics

NbC containing ceramic composites were manufactured from poly(siloxane)/Nb/NbC filler mixtures by a high temperature reaction bonding process. During heating in an inert atmosphere the Si—O—C ceramic residue of the polymer reacted with the metallic Nb filler to form Nb _x Si _y , NbO and NbC. Samples with a high Nb/NbC ratio showed reduced porosity and increased hardness after pyrolysis at 1200°C.