Effect of thermal cycling on the expansion behavior of Al/SiCp composite

The coefficient of thermal expansion (CTE) and accumulated plastic strain of the pure aluminum matrix composite containing 50% SiC particles (Al/SiC_p) during thermal cycling (within temperature range 298–573 K) were investigated. The composite was produced by infiltrating liquid aluminum into a preform made by SiC particles with an average diameter of 14 μm. Experiment results showed that the relationship between the CTE of Al/SiC_p and temperature is nonlinear; CTE could reach a maximum value at about 530 K. The theoretical accumulated plastic strain of Al/SiC_p composites during thermal cycling has also been calculated and compared with the experimental results.     

Size-independent stresses in Al thin films thermally strained down to −100 °C

Size and temperature dependencies of thermal strains of {1 1 1} textured Al thin films were determined by in situ X-ray diffraction (XRD) in the temperature range of −100 to 350 °C. The experiments were performed on 50–2000 nm thick Al films sputter-deposited on oxidized silicon (1 0 0) substrates. The in-plane stresses were assessed by measuring the {3 3 1} lattice plane spacing at each temperature in steps of 25 °C during thermal cycling. At high temperatures, the films could only sustain small compressive stresses. The obtained stress–temperature evolutions show the well-known increase of flow stresses with decreasing film thickness for films thicker than 400 nm. However, for thinner films, the measured stress on cooling is independent of the film thickness. This lack of size effect is caused by the flow stresses in the thinnest films exceeding the maximum stress that can be applied to these samples using thermomechanical loading down to −100 °C. Thus, the measured stresses of ∼770 MPa in the thinnest film represent a lower limit for the actual flow stresses. The observed stresses are also discussed taking microstructural information and possible constraints on dislocation processes into account.     

Microstructure of the cBN/WC6Co composite produced by the pulse plasma sintering (PPS) method

The cBN/WC6Co composite with the relative density of 99.8% and hardness of 2130 HV5 was produced by sintering at a temperature of 1150 °C under a pressure of 100 MPa for 5 min. The composite was sintered using electric pulses generated periodically by discharging a capacitor battery. The constituent phases of the composite, as identified by the NBED method, were the cBN, WC, and Co phases. The HR STEM observations have shown that the interfaces between the individual phases are continuous and no pores or precipitates of other phases can be seen there. Thanks to the specific heating realized by electric pulses, the composite is heated during each current pulse to a temperature of 1950 °C at a rate of 10⁵ °C/s. As a result of these quick changes of the temperature, transient thermal compressive stresses of about 3 GPa are induced in the composite, which results in the grains of the WC composite matrix being refined and defected.     

In situ neutron diffraction study of residual stress development in MgO/SiC ceramic nanocomposites during thermal cycling

Ceramic nanocomposites often contain large residual stresses due to differing thermal contraction between phases upon cooling from processing temperatures. Their role in affecting the mechanical properties is not fully understood, but is certainly of importance. This investigation used neutron diffraction to quantify the residual stresses in MgO/SiC nanocomposites throughout a thermal cycle to 1550 °C. The results showed that average stresses in 10 vol.% SiC samples at 100 °C approached −4 GPa in the particles and were +560 MPa in the matrix. The stresses showed good agreement with an elastic model with a stress-free temperature of 1600 °C. A small amount of inelastic relaxation (15%) was observed after cooling back to room temperature. Modelling suggested that this was due to relaxation of the stresses in grain boundary particles at a rate limited by diffusional processes in the MgO/SiC interface. The effect of particle size on stress level is discussed.     

Controlling Al/Cu composite diffusion layer during hydrostatic extrusion by using colloidal Ag

In this study, intermetallic compound formation at the interface between aluminum and copper during hydrostatic extrusion was simulated by performing a solid state diffusion bonding experiment with various processing parameters, including bonding temperature and pressure and holding time, and by inserting an Ag colloid layer between the aluminum and copper. Regression equations were developed to predict thickness of diffusion layer and interface hardness.An intermetallic compound formed at the interface between the Al and Cu during diffusion bonding at 420 °C and 240 MPa for 60 min, and it was effectively controlled by inserting an Ag colloid. These experimental data will be useful for setting up processing parameters to prepare Al/Cu matrix composite materials by using hydrostatic extrusion.     

Structural evolution and grain growth kinetics of the Fe–28Al elemental powder during mechanical alloying and annealing

The structural evolution and grain growth kinetics of the Fe–28Al (28 at.%) elemental powder during mechanical alloying and annealing were studied. Moreover, the alloying mechanism during milling the powder was also discussed. During mechanical alloying the Fe–28Al elemental powder, the solid state solution named Fe(Al) was formed. The lattice parameter of Fe(Al) increases and the grain size of Fe(Al) decreases with increasing milling time. The Fe and Al particles were first deformed, and then, the composite particles of the concentric circle-like layers were generated. Finally, the composite particles were substituted by the homogeneous Fe(Al) particles. The continuous diffusion mixing mechanism is followed, mainly by the diffusion of Al atoms into Fe. During annealing the milled Fe–28Al powder, the order transformation from Fe(Al) to DO₃-Fe₃Al and the grain growth of DO₃-Fe₃Al occurred. The grain growth kinetic constant, K = 1.58 × 10⁻⁹ exp(−540.48 × 10³/RT) m²/s.     

Microstructure and mechanical properties of Ni3Al base alloy reinforced with Cr particles produced by powder metallurgy

The microstructural evolution of a powder metallurgy (PM) Ni₃Al–8Cr (at.%) alloy reinforced with Cr particles has been correlated with its mechanical properties. The material was synthesised using rapidly solidified Ni₃Al–8Cr powders which were mixed with a Cr volume fraction of 10% and milled for 20 h. Consolidation by HIP was carried out at 150 MPa for 2 h at 1250 °C. For comparative purposes the unreinforced Ni₃Al–8Cr alloy was processed following the same route. After consolidation by HIP both materials show a bimodal microstructure consisting of coarse and fine grain regions in which fine particles are heterogeneously distributed. Besides Cr reinforcement, the difference between the two materials is the presence of β phase and higher volume fractions of γ+γ′ regions and α-phase precipitates in the reinforced material. The reinforced material presents the highest hardness, yield stress and the ultimate tensile strength values. The yield stress and ultimate tensile strength of the reinforced material at room temperature is 1286 and 1335 MPa, respectively. The strength of the composite is determined by the strength of the Cr particles and the good bonding between the matrix and Cr reinforcement. Although the ductility loss as the temperature increases is not suppressed, an improvement in ductility is obtained at temperatures above 500 °C compared with the unreinforced material.     

Processing of ultra-high strength SiCp/Al–Zn–Mg–Cu composites

The ultra-high strength SiC_p/Al–10%Zn–3.6%Mg–1.8%Cu–0.36%Zr–0.15%Ni composite was prepared by spray co-deposition followed by extrusion process. The heat treatment processing, microstructures and mechanical properties of the as-processed composite were investigated. The well-bonded SiC/Al interfaces and fine grains of matrix alloy were obtained in the as-extruded composite. The precipitated phase MgZn₂ dissolved during solid solution treatment at 490 °C for 1 h, but the Cu-rich phase was residual in the matrix. Comparatively, the Cu-rich phase dissolved into the matrix alloy exposed at 470 °C for 1 h and then at 490 °C for 1 h. The composite heat-treated with 470 °C/1 h + 490 °C/1 h + 120 °C/28 h exhibited high modulus above 100 GPa and ultra-high strength about 785 MPa, which was 30 MPa higher than that of the same composite treated with 490 °C/1 h + 120 °C/28 h processing. The low elongation of the composite can be attributed to the breakage of SiC particulates and interfacial debonding of SiC/Al.     

Thermomechanical properties of TiC particle-reinforced tungsten composites for high temperature applications

Tungsten and tungsten alloys are widely used in high temperature environments where arc ablation or mechanical deformation and damage are the main sources of materials failure. For high temperature critical applications in thermomechanical environments, however, the low strength limits the use of tungsten and tungsten alloys. Hence, new tungsten based materials with good high temperature thermomechanical properties need to be developed in order to extend the use of tungsten. TiC particle-reinforced tungsten based composites (TiC_p/W) were fabricated by hot pressing at 2000 °C, 20 MPa in a vacuum of 1.3×10⁻³ Pa. The composites were examined with respect to their thermophysical and mechanical properties at room temperature and at elevated temperature. Vickers hardness and elastic modulus increased with increasing TiC content from 0 to 40 vol.%. The highest flexural strength, 843 MPa, and the highest toughness, 10.1 MPa m^1/2, of the composites at room temperature were all obtained when 20 vol.% TiC particle were added. As the test temperature rose, the flexural strength of the TiC_p/W composites firstly increased and then decreased, except in the monolithic tungsten. The highest strength of 1155 MPa was measured at 1000 °C in the composite containing 30 vol.% TiC particles. The strengthening effect of TiC particles on the tungsten matrix is more significant at high temperatures. With the addition of TiC particles, the thermal conduction of tungsten composites was drastically decreased from 153 W m⁻¹ K⁻¹ for monolithic W to 27.9 W m⁻¹ K⁻¹ for 40 vol.% TiC_p/W composites, and the thermal expansion was also increased. The new composites are successfully used to make high temperature grips and moulds.     

Mechanical behavior of diamond matrix composites with ceramic Ti3(Si,Ge)C2 bonding phase

Polycrystalline diamond, PCD, compacts are usually produced by high pressure–high temperature (HP–HT) sintering. This technique always introduces strong internal stresses into the compacts, which may result in self-fragmentation or graphitization of diamond. This may be prevented by a bonding phase and Ti₃(Si,Ge)C₂ was so investigated. This layered ceramic was produced by Self Propagating High Temperature Synthesis and the product milled. The Ti₃(Si,Ge)C₂ milled powder was mechanically mixed, in the range 10 to 30 wt.%, with 3–6 μm diamond powder (MDA, De Beers) and compacted into disks 15 mm in diameter and 5 mm high. These were sintered at a pressure of 8.0 GPa and temperature of 2235 K in a Bridgman-type high pressure apparatus. The amount of the bonding phase affected the mechanical properties: Vickers hardness from 20.0 to 60.0 GPa and Young's modulus from 200 to 500 GPa, with their highest values recorded for 10 wt.% Ti₃(Si,Ge)C₂. For this composite fracture toughness was 7.0 MPa m^1/2, tensile strength 402 MPa and friction coefficient 0.08. Scanning and transmission electron microscopy, X-ray and electron diffraction phase analysis were used to examine the composites.     

Correlation of precipitate stability to increased creep resistance of Cr–Mo steel welds

An order of magnitude decrease (from 16.0 × 10^?4 to 4.1 × 10^?4% h^?1) in steady-state creep rate was observed in the fine-grained heat-affected zone (HAZ) of a Cr–Mo steel weld by the reduction of the pre-weld tempering temperature from 760 °C (HTT) to 650 °C (LTT). The microstructure during each stage of the manufacturing path, including pre-weld temper, thermal cycling and post-weld heat treatment, was characterized using a suite of characterization techniques. The techniques included simulated thermal cycling, dilatometry and electron microscopy, as well as time-resolved X-ray diffraction using Synchrotron radiation. Both LTT and HTT steels before welding contain M₂₃C₆ (M = Cr, Fe) and MX (M = Nb, V; X = C, N) precipitates in a tempered martensite matrix. During simulated HAZ thermal cycling with different peak temperatures, changes in M₂₃C₆ carbide characteristics were observed between the HTT and LLT conditions, while MX precipitates remained stable in both conditions. Simulated post-weld heat treatment samples show larger M₂₃C₆ in the HTT condition than in the LTT condition. The results provide a solution to extending the life of Cr–Mo steel welded structures used in power plants.     

In situ synthesis,microstructure, mechanical properties and thermal shock resistance of (ZrB2 + SiC)/Zr2[Al(Si)]4C5 composites

Dense (ZrB₂ + SiC)/Zr₂[Al(Si)]₄C₅ composites with adjustable content of (ZrB₂ + SiC) reinforcements (0–30 vol.%) were prepared by in situ hot-pressing. The microstructure, room and high temperature mechanical and thermal physical properties, as well as thermal shock resistance of the composites were investigated and compared with monolithic Zr₂[Al(Si)]₄C₅ ceramic. ZrB₂ and SiC incorporated by in situ reaction significantly improve the mechanical properties of Z₂[Al(Si)]₄C₅ by the synergistic action of many mechanisms including particulate reinforcement, crack deflection, branching, bridging, “self-reinforced” microstructure and grain-refinement. With (ZrB₂ + SiC) content increasing, the flexural strength, toughness and Vickers hardness show a nearly linear increase from 353 to 621 MPa, 3.88 to 7.85 MPa·m^1/2, and 11.7 to 16.7 GPa, respectively. Especially, the 30 vol.% (ZrB₂ + SiC)/Zr₂[Al(Si)]₄C₅ composite retains a high modulus up to 1511 °C (357 GPa, 86% of that at 25 °C) and superior strength (404 MPa) at 1300 °C in air. The composite shows higher thermal conductivity (25–1200 °C) and excellent thermal shock resistance at ΔT up to 550 °C. Superior properties render the composites a promising prospect as ultra-high-temperature ceramics.     

Development of intergranular thermal residual stresses in beryllium during cooling from processing temperatures

The intergranular thermal residual stresses in texture-free solid polycrystalline beryllium were determined by comparison of crystallographic lattice parameters in solid and powder samples measured by neutron diffraction during cooling from 800 °C. The internal stresses are not significantly different from zero >575 °C and increase nearly linearly <525 °C. At room temperature, the c axis of an average grain is under ～200 MPa of compressive internal stress, and the a axis is under 100 MPa of tensile stress. For comparison, the stresses have also been calculated using an Eshelby-type polycrystalline model. The measurements and calculations agree very well when temperature dependence of elastic constants is accounted for, and no plastic relaxation is allowed in the model.     

Microstructure and some properties of TiAl-Ti2AlC composites produced by reactive processing

The TiAl–Ti₂AlC composites with and without impurities, Ni, Cl and P, were prepared by combustion reaction from the elemental powders and cast after arc melting. The resulting composites had about 18 vol% Ti₂AlC in the lamellar matrix consisting of γ-TiAl and Ti₃Al (α₂). In the homogenized specimens, the α₂ phase decomposed to γ-TiAl and Ti₂AlC. The composite material had a high strength both at ambient and elevated (1173 K) temperatures; about 800 and 400 MPa, respectively, with an ambient temperature ductility of 0.7% at bending test. The fracture toughness test also proved that the homogenized composite has higher toughness than the as cast one. The toughness value reached to 17.8 MPa m^1/2. The zigzag cracks propagated in the homogenized composite and the reinforcement Ti₂AlC particles and the finely precipitated Ti₂AlC particles were main obstacles to the crack propagation. The composite with impurities showed a marginal improvement in the oxidation resistance over the composites without impurities.     

Nanostructured Al–Al2O3 composite formed in situ during consolidation of ultrafine Al particles by back pressure equal channel angular pressing

Ultrafine pure Al particles were consolidated into fully dense bulk material using back pressure equal channel angular pressing (BP-ECAP). The consolidation was carried out at 400 °C with a back pressure of 200 MPa. A fully dense Al–Al₂O₃ composite consisting of mostly nanocrystalline Al and γ-Al₂O₃, a small fraction of ultrafine Al grains and amorphous alumina was produced after four passes from the freshly formed particles. In contrast, no consolidation was achieved from the aged particles which had been kept for between 18 and 24 months. The formation of the nanostructure was attributed to the interaction between severe shear deformation and in situ oxidation during ECAP. The ultimate strength of the nanostructured material reached ～740 MPa in compression with a plastic strain to fracture of the order of ～1%. It is demonstrated that ultrafine particles can be well consolidated by ECAP when they are sheared to change shape rather than to slide over each other.     

Creep behaviour of a new air-hardenable intermetallic Ti–46Al–8Ta alloy

Creep behaviour of a new cast air-hardenable intermetallic Ti–46Al–8Ta (at.%) alloy was investigated. Constant load tensile creep tests were performed at initial applied stresses ranging from 200 to 400 MPa in the temperature range from 973 to 1073 K. The minimum creep rate is found to depend strongly on the applied stress and temperature. The power law stress exponent of the minimum creep rate is n = 5.8 and the apparent activation energy for creep is calculated to be Q_a = (382.9 ± 14.5) kJ/mol. The kinetics of creep deformation of the specimens tested to a minimum creep rate (creep deformation about 2%) is suggested to be controlled by non-conservative motion of dislocations in the γ(TiAl) matrix. Besides dislocation mechanisms, deformation twinning contributes significantly to overall measured strains in the specimens tested to fracture. The initial γ(TiAl) + α₂(Ti₃Al) microstructure of the creep specimens is unstable and transforms to the γ + α₂ + τ type during creep. The particles of the τ phase are preferentially formed along the grain and lamellar colony boundaries.     

On the presence of work-hardened zones around fibers in a short-fiber-reinforced Al metal matrix composite

Dislocation densities are investigated in a short-fiber-reinforced Al–11 wt.% Zn–0.2 wt.% Mg metal matrix composite (MMC) with a special focus on regions near the fiber–matrix interfaces. Clear microstructural evidence is provided for the formation of work-hardened zones (WHZs) around fibers during creep using transmission electron microscopy (TEM). The dislocation densities in the WHZs are higher after creep than after squeeze casting, where the plastic strains associated with the thermal stresses that build up during solidification also result in an increased dislocation density close to fibers. The effect of heating and cooling on the dislocation substructure is also considered. The results are discussed in light of previous findings and provide microstructural evidence for the presence of WHZs as predicted by the Dlouhy model of MMC creep.     

Twinned dendrite growth in binary aluminum alloys

The formation of twinned dendrites (feathery grains) in binary Al–Zn, Al–Mg, Al–Cu and Al–Ni alloys has been studied in specimens directionally solidified under identical thermal conditions, i.e. G ≈ 100 K cm⁻¹, v ≈ 1 mm s⁻¹, and with slight natural convection in the melt. The influence of the solute element nature and content has been found to be of less importance than previously reported since feathery grains were formed in all four alloys, regardless whether the alloying elements are hexagonal close packed (Zn and Mg) or face-centered cubic with a high (Ni) or low (Cu) stacking fault energy. A detailed analysis confirmed that twinned dendrites grow along 〈1 1 0〉 directions in all four cases, with a complex branch morphology made of up to six to nine arms. Surprisingly, at high Zn or Mg compositions for which regular dendrites grow along 〈1 1 0〉 instead of 〈1 0 0〉, [Gonzales F, Rappaz M. Metall Trans A 2006; 37: 2797. [1]] no twinned dendrites could be formed. In terms of both the growth kinetics advantage of twinned dendrites over regular ones and the associated tip shape, some experimental evidence seems to contradict the doublon conjecture suggested by Henry [Henry S. PhD thesis, Ecole Polytechnique Fédéral de Lausanne, 1999. [21]], at least for the solute compositions studied in the present work.     

Solid-state foaming of Ti–6Al–4V by creep or superplastic expansion of argon-filled pores

Ti–6Al–4V foams are produced by the expansion of pressurized argon pores trapped in billets created by powder metallurgy. Pore expansion during thermal cycling (840–1030 °C, which induces transformation superplasticity in Ti–6Al–4V) improves both the foaming rate (by reducing the flow stress) and the final porosity (by delaying fracture of the pores and subsequent escape of the gas), as compared to isothermal pore expansion at 1030 °C, where Ti–6Al–4V creep is the controlling mechanism. Raising the argon content in the billet increases the foaming rates for both creep and superplastic conditions, in general agreement with an analytical model taking into account the non-ideal behavior of high-pressure Ar and the pore size dependence of surface tension. Superplastically foamed Ti–6Al–4V with 52% open porosity exhibits a combination of high strength (170 MPa) and low stiffness (18 GPa), which is useful for bone implant applications.     

Fabrication of Al6061 composite with high SiC particle loading by semi-solid powder processing

Aluminum alloys reinforced with silicon carbide (SiC) particles have been studied extensively for their favorable properties in structural and thermal applications. However, there has been only limited research into investigating the loading limit of a reinforcement phase of a metal matrix composite. In this paper, semi-solid powder processing (SPP), a fabrication method that exploits the unique behavior of a solid–liquid mixture, was used to synthesize SiC particle-reinforced Al6061. A high volume loading (>45 vol.%) of SiC in Al6061 matrix was investigated by varying the SiC loading volume fraction, forming pressure, SiC particle size and Al6061 particle size. The compaction and synthesis mechanism of the composite by SPP was discussed based on reinforcement phase compaction behavior and processing parameters. Microstructure, hardness, fracture surface and X-ray diffraction results were also analyzed. Results showed that SPP can achieve over 50 vol.% loading of SiC in Al6061 matrix with near theoretical density.