Functionally graded materials produced by laser cladding

AlSi40 functionally graded materials (FGMs) were produced by a one-step laser cladding process on cast Al-alloy substrate as a possible solution for interfacial problems often present in laser coatings. The microstructure of the FGMs consists of a large amount of silicon primary particles surrounded by α-Al dendritic halos and by Al/Si eutectic. The Si particles exhibit a continuous increase in both size and volume fraction, from 8.5 μm and 22.7% at the bottom to 52 μm and 31.4% at the top of the FGM layer, respectively. The morphology of the Si particles changes accordingly from a small polygonal shape to a coarsely branched equi-axial shape. The α-Al halos and eutectic areas show less change over the same distance. From an analysis of the temperature field of the laser pool, Si particles heterogeneously nucleate on incompletely melted Si particles. The number density of Si particles is most likely being controlled by the non-homogeneous temperature field of the pool that determines the decomposition of the original Si phase in the AlSi40 powder. The growth rate and time available at different depths of the laser pool mainly affect the final size of Si particles.     

Functionally graded Mg2Si/Al composite produced by an electric arc remelting process

A graded composite of Mg₂Si/Al has successfully been fabricated by an electric arc remelting process. The results show that the graded microstructure of the composite consists of a large amount of Mg₂Si primary particles surrounded by clouds of -Al particles. The primary Mg₂Si particles gradually increase in size, while there is a decrease in length of the dendrites with distance from the bottom. In addition, the primary Mg₂Si dendritic crystals have certain orientations tending to be identical to the direction from top to bottom, and the dendritic crystals in the same array are almost parallel. The morphology of eutectic Mg₂Si is identified as fine and short fibrous like. The microhardness of graded material along the graded microstructure gradual increased with increasing distance from the top part.     

TiAl/Al的连接及Ti/TiA/Al系梯度材料的制备

1473K,30MPa,1h的热压条件下烧结了Ti／Ti TiAl／TiAl粉体叠层材料,在烧结过程中,混合层Ti＋TiAl内部发生了剧烈的化学反应（Ti＋TiAl→AlTi2）,该反应波及到相邻的Ti层及TiAl层,因而形成了物相组成渐变的精细梯度结构：Ti／Ti＋AlTi2／AlTi2／AlTi2＋TiAl／TiAl．使用A176Si10Zn10Cu4质量分数,％）合金钎料在853K,20min的钎焊条件下将该材料的TiAl例与Al进行了连接界面的测试表明,钎焊过程中钎料中的元素Si向TiAl表面扩散,并有Ti-Si化合物生成对反应机理进行了探讨．最终获得的Ti／TiAl／Al系密度梯度材料不仅整体致密,而且其密度治厚度准连续变化     

In Situ SEM Observations of Fracture Behavior of Laser Welded–Brazed Al/Steel Dissimilar Joint

Laser welding–brazing of 6061-T6 aluminum alloy to DP590 dual-phase steel with Al-Si12 flux-cored filler wire was performed. The microstructure at the brazing interface was characterized. Fracture behavior was observed and analyzed by in situ scanning electron microscope. The microstructure of the brazing interface showed that inhomogeneous intermetallic compounds formed along the thickness direction, which had a great influence on the crack initiation and propagation. In the top region, the reaction layer at the interface consisted of scattered needle-like Fe(Al,Si)₃ and serration-shaped Fe_1.8Al_7.2Si. In the middle region, the compound at the interface was only serration-shaped Fe_1.8Al_7.2Si. In the bottom region, the interface was composed of lamellar-shaped Fe_1.8Al_7.2Si. The cracks were first detected in the bottom region and propagated from bottom to top along the interface. At the bottom region, the crack initiated and propagated along the Fe_1.8Al_7.2Si/weld seam interface during the in situ tensile test. When the crack propagated into the middle region, a deflection of crack propagation appeared. The crack first propagated along the steel/Fe_1.8Al_7.2Si interface and then moved along the weld seam until the failure of the joint. The tensile strength of the joint was 146.5 MPa. Some micro-cracks were detected at Fe(Al,Si)₃ and the interface between the steel substrate and Fe(Al,Si)₃ in the top region while the interface was still connected.     

强流脉冲电子束处理对Al-20Si合金微观组织和显微硬度的影响

研究了强流脉冲电子束处理对过共晶铝硅合金Al-20Si组织结构和显微硬度的影响.通过扫描电镜和X射线衍射对改性表面的组织特征进行了分析.扫描电镜结果表明,在电子束所诱导的顶部熔化层中,初生硅溶解在铝基体中形成了铝硅过饱和固溶体.相邻初生硅颗粒由于硅元素的扩散融合成大的初生硅颗粒.X射线衍射分析表明电子束处理后铝的晶格常数下降,晶格畸变增加.显微硬度测试结果指出初生硅的表面硬度在电子束处理后从中心向边缘呈现梯度分布,并且初生硅的中心硬度随脉冲次数的增加而减小.这表明强流脉冲电子束技术在处理过共晶铝硅合金初生硅组织中有着良好的应用前景.     

Al-10％Fe合金梯度材料的组织与性能

采用离心铸造技术成功地制得了过共晶Ａｌ－１０％Ｆｅ梯度材料,离心机转速每分钟１４００转,金属模具预热温４５０℃,浇注温度１０００℃,采用金相及扫描电子显微镜、ＨＶ－５小负荷维氏硬度计及销盘式ＭＬ－１００型磨粒磨损试验研究了梯度材料组织、硬度及耐磨性的分布规律,结果表明由于初晶Ａｌ３Ｆｅ密度比Ａｌ液密度高,在离心力场初中晶Ａｌ３Ｆｅ向试样外侧移动。Ａｌ－１０％Ｆｅ合金梯度材料的组织分布为最外层初晶Ａ     

Design and fabrication of compositionally graded inorganic oxide thin films: Mechanical,optical and permeation characteristics

Different types of inorganic oxide films composed of a chemical composition gradient single layer were designed, fabricated and characterized. Compositionally graded thin films were created by power-controlled co-sputtering of alumina (Al₂O₃) and silica (SiO₂) at room temperature, allowing the structural design of the film to be tailored at the nanometer scale. Two distinct graded thin films were fabricated: one with a compositionally asymmetric structure consisting of a SiO₂-rich bottom interface and a Al₂O₃-rich top surface, and the other with a compositionally balanced sandwich structure consisting of both the top surface and bottom interface rich in SiO₂ and a core rich in Al₂O₃ (referred to as SGS for ‘sandwich graded structure’). Smoothly graded thin films without interfacial boundaries were verified by Auger electron spectroscopy profiles. X-ray photoelectron spectroscopy demonstrated that the Al₂O₃/SiO₂ graded structures consisted of Si–O and Al–O bonds, as well as Al–O–Si bonds in the transition layer. Neat Al₂O₃ or SiO₂ and their graded ones were all investigated for their mechanical, optical and permeation properties. A SGS thin film presented the best mechanical stability (i.e., about three times improved film toughness of a neat Al₂O₃ single layer), demonstrating that balanced internal stresses and alternating bonding structures, achieved via a graded structure without interfaces, are crucial for enhancing mechanical stability. Furthermore, neat and graded thin films exhibited the similar level of optical transmittance and the permeation properties for the graded films were well matched with the behaviors of mechanical stability.     

Influence of heat treatment on microstructure and mechanical properties of Al/Al-Cu graded materials

Five-layered Al/Al-Cu functionally graded material (FGM) was prepared by powder metallurgy technology, and the subsequent heat treatment was carried out for the graded material. The microstructures and distribution of Cu element under pressure sintering (F), solution treatment (T4) and artificial aging treatment (T6) were investigated, and the Vickers hardness and flexural properties of different states were tested. The results showed that sintered compact with dense structure and compositional continuous c...     

Centrifugal casting of functionally graded aluminium matrix composite components

Abstract

Centrifugal casting is one of the potential manufacturing techniques used for producing near net shaped components with improved properties. The emergence of new class of functionally graded materials has made it an important technique for the fabrication of engineering components and structures with graded property. The present paper describes the studies carried out on processing and characterisation of functionally graded Al matrix composites components based on Al–SiC ex situ and Al–Si in situ composites. The microstructural and mechanical characteristics of the composites are evaluated. In the case of Al–SiC functionally graded metal matrix composites discs, the particles are segregated gradiently towards the outer periphery of the casting exhibiting high strength and hardness towards the outer periphery. The Al–Si in situ composite cylinder shows the dispersion of primary Si particles towards the inner periphery of the casting which can lead to higher hardness and wear resistance.     

Optimization of Mechanical and Wear Properties of Functionally Graded Al6061/SiC Nanocomposites Produced by Friction Stir Processing(FSP)

The objective of present work is to apply the friction stir processing(FSP) to fabricate functionally graded Si C particulate reinforced Al6061 composite and investigate the effect of Si C particle mass fraction distribution on the mechanical properties and wear behavior of Al6061/Si C composite. Regarding the obtained results in this work, with increasing Si C mass fraction, elongation decreased, but hardness enhanced. However, the optimized functionally graded composite with the highest tensile strength and wear resistance was achieved for composite with 10 wt% surface Si C. Also,the results showed that wear resistance and tensile strength decreased for composite with 13 wt% surface Si C, due to reinforcement particle clustering depending on high Si C mass fraction.     

超高压梯度烧结法制备W／Cu功能梯度材料

提出了一种制备具有递变电阻及高熔点差功能梯度材料的新方法－超高压梯度烧结法,并成功制备出了相对密度达到96％的W／Cu梯度功能材料。推导了通电烧结过程中梯度材料内部的温度分布,表明温度场与电流密度及材料的厚度大致成平方的梯度分布模式;考察了不同的烧结助剂对W／Cu梯度材料致密化的影响,发现Ni比V和Zr有更好的致密化效果;观察了W／Cu梯度材料显微结构并对梯度烧结的过程机理进行了初步探讨。     

过共晶铝硅合金Al-17.5Si强流脉冲电子束表面改性

研究了强流脉冲电子束表面改性处理对过共晶铝硅合金(Al-17.5Si)组织和性能的影响.利用扫描电镜和X射线衍射分析了改性机理.扫描电镜结果表明,在电子束处理后的合金表面上,硅元素扩散到铝基体中形成单相α固溶体.X射线衍射分析指出,电子束处理后合金表面没有新的物相生成,并在15脉冲处理后铝的晶格参数显着降低.硬度结果表明,在铝硅扩散区域,初生硅的硬度从中心向边缘呈现梯度分布趋势,而且初生硅中心处的硬度随脉冲次数的增加逐渐减小.耐磨性随脉冲次数的增加先提高后降低,磨损量在15次脉冲后降低了84.6%.因此该技术在改善过共晶铝硅合金表面耐磨性方面展现了良好的应用前景.     

离心铸造Al—Fe—Si自生梯度功能材料韧脆变化的分形度量

用离心铸造法制备了一定意义下的Al-Fe-Si自生梯度功能材料。用分形方法测算所获梯度功能断口的分形参数H，用以度量材料截面上韧脆特性的变化。     

Characterization of aluminum based functionally graded composites developed via friction stir processing

Al/SiC functionally graded material (FGM) was developed through a novel multi-step friction stir processing (FSP) method. SiC particles with a mean size of 27.5 μm were embedded in the groove on the 6082-Al plate. To create a graded structure over a predefined value, FSP was carried out with three tools with different pin lengths and with varying volume fractions of SiC particles. The structure was formed by passing tools with 1−3 passes with a constant rotational and traveling speeds of 900 r/min and 20 mm/min, respectively. The experiments were conducted at room temperature. Microstructural features of functionally graded (FG) samples were examined by using scanning electron microscopy (SEM) and 3D light microscopy. Mechanical properties in terms of wear resistance and microhardness were thoroughly assessed. The results indicate that the increase in FSP pass number causes more uniform SiC particle dispersion. The microhardness values were impacted by the number of passes and improved by 51.54% for Pass 3 when compared to as-received 6082-Al. Wear resistance of Al/SiC FG samples was found to increase as a result of the addition of SiC particles.     

Study of the potential effect of spark plasma sintering on the preparation of complex FGM/laminated WC-based cermet

In the present work, the capability of SPS process for the production of a complex composite possessing different forms of materials based on WC-Ni-Ti-CNT FGM/laminated composite is investigated. With regard to the unique properties of SPS in producing and densifying a large number of materials, a complex material was prepared as a sandwich structure based on the reaction among Ti, CNT, Ni and WC in various forms consisting of powders, sheets and nano-tubes. The starting materials were initially placed in the graphite mold in the order of Ni powders, WC-10Ni, CNTs coated Ti sheet, WC-15Ni and Ti sheet from bottom to top. The microstructure study showed that the layer of Ni powders was adequately densified as an integrated layer, the second layer, WC-Ni, was attached to the Ni layer from the bottom and, at the top, it was connected to the highly concentrated WC layer formed as a consequence of Ni consumed by Ti to form NiTi and Ni₃Ti compounds. Moreover, the Ti sheets were changed into TiC particles as a result of reaction with WC and CNTs, and the WC-15Ni was placed at the top of this layer by bonding the structure properly; and eventually, the Ti sheet remained at the top of the specimen. The micro-hardness examination of the sample revealed the highest hardness related to the position of Ti-based layer due to the formation of intermetallic compounds and carbides.     

颗粒增强铝基梯度复合材料的摩擦磨损性能

摘要采用新型喷射沉积技术制备SiC体积分数呈连续分布(0～30%)的Al-Si基梯度复合材料,利用MG-2000型销-盘磨擦磨损试验机,研究不同滑动转速和载荷对该梯度复合材料摩擦磨损性能的影响.采用SEM和MHV-2000型维氏硬度计研究该梯度复合材料的显微组织、硬度及其耐磨性的梯度分布规律.结果表明随着滑动转速和载荷的增大,梯度材料的摩擦因数逐渐降低;材料的磨损率随载荷的增加而增大,随滑动转速的提高先增大后减小,在转速500 r/min时达到最大;对比研究沉积态与热压态材料的摩擦磨损行为,喷射沉积态由于孔隙等缺陷的存在,其磨损形式主要是磨粒磨损和剥层磨损;热压后,梯度材料的磨损形式以磨粒磨损和粘着磨损为主;随基体中SiC含量的逐渐增加,锭坯各部分硬度和耐磨性也随之提高.     

熔渗-焊接法制备W/Cu功能梯度材料的研究

采用熔渗－焊接法经过工Ｗ骨架制备,渗Ｃｕ及热压焊接三个步骤制备出Ｗ／Ｃｕ功能梯度材料,并对Ｗ／Ｃｕ梯度过渡层的显微结构进行了观察,对Ｗ／Ｃｕ功能梯度材料的热震性进行了测试。     

Optimization of ceramic strength using elastic gradients

We present a new concept for strengthening ceramics by utilizing a graded structure with a low elastic modulus at both top and bottom surfaces sandwiching a high-modulus interior. Closed-form equations have been developed for stress analysis of simply supported graded sandwich beams subject to transverse center loads. Theory predicts that suitable modulus gradients at the ceramic surface can effectively reduce and spread the maximum bending stress from the surface into the interior. The magnitude of such stress dissipation is governed by the thickness ratio of the beam to the graded layers. We test our concept by infiltrating both top and bottom surfaces of a strong class of zirconia ceramic with an in-house prepared glass of similar coefficient of thermal expansion and Poisson’s ratio to zirconia, producing a controlled modulus gradient at the surface without significant long-range residual stresses. The resultant graded glass/zirconia/glass composite exhibits significantly higher load-bearing capacity than homogeneous zirconia.     

粉末冶金制备SiC_P/2009Al复合材料的相组成和元素分布

采用粉末冶金法制备SiCp/2009AI复合材料热压锭,并对热压锭进行了热挤压,分析了热压态和挤压态复合材料的相组成和元素分布.结果表明:热压锭存在轻微的元素偏析,下部Cu和Mg含量略高于上部.热压态复合材料组成相主要为Al,SiC,Al2Cu和Mg2Si,另外还含有少量的Al7Cu2Fe和Mg的氧化物.经固溶处理后,Al₂Cu和Mg₂Si溶解,Cu在基体中均匀分布,但Mg仍偏聚于原始铝颗粒边界和SiC团聚处.挤压变形不改变复合材料的相组成,但使SiC分布更均匀并破碎了铝颗粒表面的氧化膜.挤压态复合材料经固溶处理后,Cu和Mg均在基体中均实现了均匀分布.     

Laser cladding of Ni/Cu/Al functionally graded coating on magnesium substrate

Laser cladding of graded multi-layer Ni/Cu/Al coatings on magnesium substrates was performed with the aim of improving the inherently low corrosion and wear resistance of magnesium. The quality of the coating was found to be good: the interfaces between the different layers are generally free from any major solidification defects such as porosity and cracks. Despite the fact that considerable mixing had occurred in the Al layer, the top Ni layer was free from Al and Mg. The top Ni layer comprises a single solid solution (Ni) phase; its corrosion and wear resistance was found to be excellent. The wear properties of the coating were explained in terms of stacking fault energy and the ratio of hardness to elastic modulus.