An experimental study on the in situ strength of SiC fibre in unidirectional SiC/Al composites

In order to investigate the effect of strain rate and high temperature exposure on the mechanical properties of the fibre in the unidirectional fibre reinforced metal-matrix composite, in situ SiC fibre bundles are extracted from two kinds of SiC/Al composite wires, which are heat-treated at two different temperatures (exposed in the air at 400 and 600 °C for 40 min after composition). Tensile tests for these two fibre bundles are performed at different strain rates (quasi-static test: 0.001 s⁻¹, dynamic test: 200, 700, and 1200 s⁻¹) and the stress–strain curves are obtained. The experimental results show that their mechanical properties are rate-dependent, the modulus E, strength σ_b and unstable strain _b (the strain corresponding to σ_b) all increase with increasing strain rate. Compared with the mechanical properties of the original SiC fibre, those of the two in situ fibres degrade to some extent, the degradation of the in situ fibre extracted from the composite wire exposed at 600 °C (hereafter referred to as in situ fibre 2) is more serious than that of the in situ fibre extracted from the composite wire exposed at 400 °C (hereafter referred to as in situ fibre 1). The mechanism of the degradation is investigated. A bi-modal Weibull statistical constitutive equation is established to describe the stress–strain relationship of the two in situ fibre bundles. The simulated stress–strain curves agree well with the experimental results.     

Micromechanism of fracture in Al/SiC composites

An SEM study was made of the micromechanism of fracture in SiC particle-reinforced 6061 aluminium composites. The fracture toughness tests on the composites with SiC volume fractions of 0%, 10% and 20% were conducted on single-edge notched sheet specimens. Both qualitative observations of void nucleation at the notch root of the composite samples and quantitative measurements of crack profiles are made to assess the special role of the particle effects in these composites. The results are discussed with respect to the micromechanism of particle breakage and interface debonding and their effect on the nucleation and propagation of microcracks. Two kinds of void are defined to explain the facts that Al/SiC is brittle macroscopically and ductile microscopically. The direction of crack propagation in Al/SiC and the microstructure in the tip region of the crack are also studied with these results.     

Influence of microstructure of fibre/matrix interface on mechanical properties of Al/SiC composites

Abstract

The relationship between microstructure and mechanical properties of composites of squeeze cast Al–Cu and Al–Cu–Mg reinforced with 25 vol.-%SiC whiskers was investigated. Tensile test results were compared with values calculated using a modified rule of mixtures (ROM). The results were found to be in good agreement for the Al–Cu matrix composite, whereas a relatively large discrepancy was observed for the Al–Cu–Mg matrix composite. It was concluded from microstructural observations that this difference resulted from a reduction of the whisker strength due to more pronounced decoration of the interfaces by oxides and spinels. For the Al–Cu–Mg composite, the effect of interfacial phases on the composite strength must betaken into account when the modified ROM is applied.

MST/1242     

Fracture characteristics of Al/zircon particulate composites

A study has been made of the effects of volume fraction and size of zircon particulates on fracture toughness and micromechanisms of fracture in Al/zircon particulate composites. The composites are prepared by a liquid metallurgy technique using volume fractions of zircon in the range 0·06–0·18 and particulate sizes between 75 and 250 μm. The study was conducted on composites in the cast and the forged conditions. The experimental programme included a particle size distribution study, tensile tests, fracture mechanics tests leading to J_1c and crack tip opening displacement evaluation, fractographic investigations, etc. The process zone size at the crack tip was evaluated from crack tip stresses and strains, and compared with the interparticle spacing and particle diameter in order to understand the micromechanics of cracking. The Al/zircon composites were compared with Al/graphite composites in terms of strength and fracture toughness as a function of volume fraction of the filler phase, and regions of optimum performance were identified.     

Study of machinable SiC/Gr/Al composites

The effect of flaky graphite particles [with volume fraction (vf) 3–7%] on machinability and mechanical properties of SiC/Al composites were investigated. Results showed that the machinability was improved greatly with the increasing vf of graphite particles. When the vf of graphite particles was 7%, the tool life was prolonged by 130%, and the tensile strength and elastic modulus of SiC/Gr/Al composite were 365 MPa and 144 GPa, respectively. The presence of flake graphite particle acted as solid lubrication and promoted chip formation during cutting, resulting in an improved machinability.     

Production of rapidly solidified Al/SiC composites

Rapidly solidified metal matrix composites have been produced on a laboratory scale either by (1) melt spinning a composite after introduction of the ceramic phase and extrusion of the flakes obtained, or (2) blending melt-spun powder (basic alloy) with the ceramic phase and subsequent extrusion. AlMg(Si) alloys were used as matrix material while SiC particles with diameters of 3 or 20 m were used as the ceramic phase. For the composites prepared by route 1 it was found that the basic alloy was reinforced by the addition of 3 m particles whereas for the 20m particles reinforcement was observed only for very ductile matrices. The bond between SiC particles and matrix was good. A diffusion and wetting bond was formed. For the composites prepared by route 2 it was found that reinforcement did not occur and that the bond between particles and matrix was weak. Debonding of the particles took place in the case of tensile fracture. The advantage of a rapidly solidified matrix for these composites is that relatively high ductilities are combined with good reinforcement effects. Prior contact of the ceramic phase and the aluminium melt is needed for a good bond between SiC and the matrix material. It is concluded that route 1 should be preferred for the production of rapidly solidified aluminium matrix composites.     

Degradation of Al2O3–SiC–Al composites prepared by the oxidative growth of Al-alloys into SiC particulate

Composites of Al₂O₃–SiC–Al have been prepared by the oxidative infiltration of Si-free aluminium alloys into SiC particulate that were coated with spray-pyrolysed alumina. Moisture degradation studies were carried out to evaluate the extent of formation of aluminium carbide, the formation of which was also inferred by the determination of the residual silicon content in the composite. The efficiency of the coating technique in protecting the SiC from attack by the melt was evaluated at 1000 and 1200 °C. This revised version was published online in November 2006 with corrections to the Cover Date.     

Processing of advanced Al/SiC particulate metal matrix composites under intensive shearing – A novel Rheo-process

Particulate metal matrix composites (PMMCs) have attracted interest for application in numerous fields. The current processing methods often produce agglomerated particles in the ductile matrix and as a result these composites exhibit extremely low ductility. The key idea to solve the current problem is to adopt a novel Rheo-process allowing the application of sufficient shear stress (τ) on particulate clusters embedded in liquid metal to overcome the average cohesive force or the tensile strength of the cluster. In this study, cast A356/SiC_p composites were produced using a conventional stir casting technique and a novel Rheo-process. The microstructure and properties were evaluated. The adopted Rheo-process significantly improved the distribution of the reinforcement in the matrix. A good combination of improved ultimate tensile strength (UTS) and tensile elongation (ε) is obtained.     

Microstructure and microchemistry of the Al/SiC interface

The characteristics of the Al/SiC interface play a critical role in controlling the properties of SiC-reinforced aluminium composites and aluminium-brazed SiC ceramic joints. Recently, a detailed investigation on the wettability of SiC single crystals by aluminium and several of its alloys was conducted. In order to understand further the nature of the Al/SiC interface, high resolution and conventional transmission electron microscope techniques have now been used to investigate its microchemistry and microstructure. The results revealed the coexistence of two polytype structures, rhombohedral and hexagonal, in the SiC single crystal structure. Aluminium carbide (Al₄C₃) and silicon were the reaction products found at the Al/SiC interface. From diffraction patterns, epitaxial orientation relationships between the SiC substrate and Al₄C₃, Si were determined.     

Effect of SiC particles on fatigue crack propagation in SiC/Al composites

Fatigue crack propagation has been studied in two SiC particulate-reinforced aluminium-matrix composites with differing matrix alloys and composite heat treatments. Results indicate that the fatigue crack propagation rate (FCPR) of aged SiC/LY12 Al composites decreases with increasing volume fraction (V_f) of SiC particles; for composites containing 15 volume % SiC particles in an LY12 Al matrix the FCPR is independent of heat treatment (ageing or annealing). Annealed SiC/5083 Al composite has a higher FCPR than annealed SiC/LY12 AI. The influence of SiC particles on crack path is briefly discussed.     

平纹编织SiC/SiC复合材料多尺度建模及强度预测

连续SiC纤维增强SiC基体复合材料（SiC/SiC）具有优异的高温力学性能、辐照稳定性及较低的氚渗透率,在核工程结构领域具有良好的应用前景,掌握其承载状态下的损伤演化和强度性能,对SiC/SiC复合材料的应用具有重要指导意义。本文基于平纹编织SiC/SiC复合材料的制备过程和组分材料分布的多尺度特性,考虑复合材料微观结构的局部近似周期性,建立了纤维丝尺度和纤维束尺度单胞模型。使用有限元分析软件对纤维丝尺度模型的弹性性能和强度性能进行预测,将这些性能参数代入纤维束尺度模型,引入Tsai-Wu失效准则,根据材料的不同失效模式并对失效单元进行方向性刚度折减,模拟了平纹编织SiC/SiC复合材料在单轴拉伸载荷下的渐进损伤过程。数值模拟曲线与试验曲线吻合较好,实现了对平纹编织SiC/SiC复合材料强度的有效预测。      

Thermal treatment effects in SiC/Al metal matrix composites

A short-fibre-reinforced SiC/Al-7% Si-0.6% Mg composite has been subjected to thermal cycling and elevated temperature isothermal exposure treatments. The microstructure and residual mechanical properties have been determined as a function of these treatments. It was found that isothermal or cycling treatment at 350 °C caused severe room-temperature strength degradation while treatment at 525 °C caused little change. Strength changes are attributed principally to precipitation and dissolution effects and to transfer of magnesium from the matrix into the fibre/matrix interfacial reaction layer. There was no evidence of mechanical damage resulting from the cycling treatments.     

Investigation on diffusion bonding characteristics of SiC particulate reinforced aluminium metal matrix composites (Al/SiCp-MMC)

Joining characteristics of SiC particulate reinforced aluminium metal matrix composites (Al/SiC_p-MMC) were investigated by vacuum diffusion bonding process. The joining performances of the similar and dissimilar composites were studied, and the influences of SiC_p volume percentage and the insert alloy layer on bonding quality and properties of the bonded joints were also estimated. The experimental results indicate that the strength of vacuum diffusion bonded joints decreases with increasing SiC_p volume percentage, and obtaining satisfactory bonding quality in the diffusion bonded joints of the dissimilar Al/SiC_p-MMC is much more difficult than that of the similar Al/SiC_p-MMC. Moreover, the results still manifest that the diffusion bonding either for the similar or for the dissimilar Al/SiC_p-MMC, the suitable insert alloy layer can improve evidently the joining quality of joints, and the strength of diffusion bonded joints corresponding to using the insert alloy layer is apparently higher than that of no insert layer.     

Reactions at the Al/SiO2/SiC layered interface

Electron spectroscopy and thermodynamic modelling have been used to examine reactions at the Al/SiO₂/SiC layered interfaces at 800 °C. The reactions have been examined as a function of oxide thickness. Three regimes have been isolated: (i) where there is no oxide present aluminium and SiC react to produce Al₄C₃ and free silicon; (ii) where there is a thin oxide present the initial products are aluminosilicates and amorphous alumina; however, once the SiO₂ is consumed, Al₄C₃ emerges as a product; (iii) where a thick oxide is present only aluminosilicate and alumina are formed.     

Polytypism of SiC and interfacial structure in SiCp/Al composites

In the present work, the polytypism of SiC and the interfacial structure between SiC and Al were investigated using X-ray diffraction (XRD) and high resolution transmission electron microscopy (HREM). It was approved that 15R could be juxtaposed with 6H stacking sequences in the same SiC reinforcement and a structural transformation zone was also observed. The Al₄C₃ compound can nucleate on SiC at the SiC/Al interface with the growth orientation parallel to the C axis of SiC. Mechanisms for the observed phenomena were also discussed in detail.     

不连续界面相Al4C3对SiC/Al复合材料界面结合影响的第一性原理及实验

采用密度泛函理论的第一性原理及实验相结合的方法,探讨了不连续界面相Al₄C₃对SiC/Al复合材料界面结合的影响,并与无界面新相生成时进行对比。研究表明,当Al(111)表面吸附C原子时,在Bridge位置上吸附C原子最为稳定;随着C覆盖率的增加,C原子吸附能逐渐减小;当界面相呈不连续分布时,界面由原来的SiC/Al转变为(SiC+Al₄C₃)/Al,界面黏着功由原来的0.851 J/m2增加至1.231 J/m2,这主要由于当C原子在Al表面吸附时,C原子和Al原子间形成共价键和离子键,且与界面处的Si原子也形成共价键,从而促进界面结合。利用第一性原理计算的SiC/Al和(SiC+Al₄C₃)/Al体系黏着功与实验值较为接近,且变化规律相同,具有较高的参考价值。