Fabrication of laminated metal–intermetallic composites by interlayer in-situ reaction

A simple and cost-effective method, interlayer in-situ reaction process, has been developed to produce laminated metal-intermetallic materials. Layered NiAl₃ and Ni₂Al₃/Ni composites have been fabricated successfully by using the process. It is shown that volume friction of the intermetallic layers can be well controlled by the thickness of the metals. It is difficult to produce high strength composites if the original metals are directly exposed at high temperature. This is rectified by a pre-treating processing in which a prefect interface is formed to prevent the metals from oxidation at high temperature. The pre-treated composites have an improvement in tensile strength and thermal stability. SEM observations show that the composites exhibit a mixing fracture mode suggesting that the composites would have high toughness.     

Fabrication of Al–TiC master composites and their dispersion in Al,Cu and Mg melts

Abstract

TiCpowders have been spontaneously infiltrated by molten Al with the aid of a K-Al-Fflux. The fluxdissolves the oxide film on the surface of molten Al, facilitating wetting between 'clean' Al and TiC particle surfaces, enabling liquid to be rapidly drawn into the network of TiC particles by capillary forces. The resulting master alloy was readily incorporated and dispersedinto molten Al, Cu, and Mg, indicative that the additive was readily wetted by all three molten metals and that the particles in the additive were not joined together by strong bonds. The use of a flux to facilitate cleaning of TiC, dissolution of Al in the meltand the avoidance of direct contactbetween TiC and melt surface oxides, all contribute to improved wetting. The slightly poorer quality of the particle distribution and the lowest yield in the Cu based alloy, suggest that wetting is worst in this system.     

Preparation of Cu–Al–Ni shape memory alloy strips by spray deposition-hot rolling route

The present work describes the preparation of near-full density Cu–Al–Ni shape memory alloy (SMA) strips via a novel processing route consisting of ‘spray deposition’ of atomised liquid Cu–Al–Ni alloy with a jet of argon gas followed by hot-rolling densification of the deposited preform. The subsequent homogenisation of the hot rolled Cu–Al–Ni strips resulted in complete martensitic structure in the finished strip, consisting of self-accommodated plates of β₁′ and γ₁′ martensites. The characteristic transformation temperatures and shape memory effects of Cu–Al–Ni strips were studied. It has been demonstrated that the Cu–Al–Ni SMA strips, prepared in the present work, resulted in relatively finer grain size with better combination of strength and ductility compared to other techniques based on conventional casting method.     

Fabrication of Al2O3 continuous fibre reinforced Al–Cu alloys by axial infiltration process

Abstract

This paper describes the fabrication of Al₂O₃ continuous fibre reinforced Al-Cu alloys by an axial infiltration process which is expected to be used in the production of stick, bar, or platelike composites. A discussion on the infiltrating process gave equations for the critical infiltration pressure and the size of composite defects. Microscopic observations and microprobe analyses on Al-4.43Cu, Al-6.48Cu, Al-10.11Cu, and Al-4.45Cu-1.54Mg (wt-%) matrix composites identified the solidification process of matrix alloys in the presence of Al₂O₃ fibres. The approximate relationships between microstructure, interspace size, and the matrix composition are described schematically. Microsegregation of Cu and Mg in the composites are also analysed quantitatively.     

Entrance analysis of 7075 Al/Mg–Gd–Y–Zr/7075 Al laminated composite prepared by hot rolling and its mechanical properties

Entrance of 7075 Al/Mg–12Gd–3Y–0.5Zr/7075 Al laminated composites produced by a hot rolling bonding method was investigated. The results showed that using a wedge-end and multi-step process ensured that the assembly of multi-layered plates could enter the rollers area at the beginning of the process. The conventional entrance prerequisite for a single plate during rolling, i.e. having an entrance angle smaller than the friction angle, was not sufficient for multi-layered plates. In addition, a condition for preventing the tail end of the aluminum alloy plates lifting up when these plates come in contact with the rollers must be taken into account. The bonding strength and the ultimate tensile strength of the laminated composite were also studied and it was shown that the mechanical bond played a major role in the bonding strength of the samples produced. The ultimate tensile strength of the laminated composite was lower than that of 7075 Al alloy and higher than that of Mg–12Gd–3Y–0.5Zr Mg alloy. This result could be explained by calculating the stress distribution in the laminated composite under tensile loading.     

Fabrication and properties of novel composites in the system Al–Zr–C

Composite bodies in the system Al–Zr–C, with about 95% relative density, were obtained by heating the compact body of powder mixture consisting of Al and ZrC (5 : 1 mol %) in Ar at 1100–1500°C for various lengths of time. Components of the material heated at more than 1200°C were Al, Al3Zr, ZrC and AlZrC2. The Al3Zr exhibited plate-like aggregation, and its size increased with increasing temperature. In the material heated at 1500°C for 1 h, the largest plate-like Al3Zr aggregation was 2000 m long and 133 m thick. Then the AlZrC2 was present as well-proportioned hexagonal platelet particles with a 8–9 m diameter and a 1–2 m thickness in the interior of the plate-like Al3Zr aggregation and Al matrix phase. The average three-point bending strength of the bodies was 140–190 MPa, and the maximum strength was 203 MPa in the body heated at 1300°C for 1 h. The body heated at 1500°C for 1 h showed high oxidation resistivity to air up to 1000°C.     

Grain refinement of Cu–Zn–Al and Cu–Al–Ni by Ti addition

Abstract

To obtain fine grained Cu based shape memory alloys after thermomechanical processing, Ti is added to β-Cu–Zn–Al or β-Cu–Al–Ni as a particle forming element. This work consists of a study of the mechanism that controls the grain growth limiting effect during the final annealing treatment. A critical evaluation of the grain growth models in particle containing materials and comparison with the experimental results lead to the conclusion that the grain growth inhibition is mainly attributable to the effect of the second phase particles but also to the influence of Ti atoms in solid solution.

MST/678     

Infiltrated Cu8Al–Ti alumina composites

The effect of titanium additions on the interface and mechanical properties of infiltrated Cu8 wt%Al–Al₂O₃ composites containing 57 ± 2 vol% ceramic are investigated, exploring two different Al₂O₃ particle types and four different Ti concentrations (0, 0.2, 1, 2 wt%Ti). Addition of 0.2 wt%Ti leads to the development of a thin (5–10 nm) layer enriched in Ti at the interface between Cu alloy and Al₂O₃ particles; this Ti concentration produces the best mechanical properties. With higher Ti-contents Ti₃(Cu, Al)₃O appears; this decreases both the interface and composite strength. Composites reinforced with vapor-grown polygonal alumina particles show superior mechanical properties compared to those reinforced by angular comminuted alumina particles, as has been previously documented for aluminum-based matrices. Micromechanical analysis shows that damage accumulation is more extensive, as is matrix hardening by dislocation emission during composite cooldown, in the present Cu8 wt%Al matrix composites compared with similarly reinforced and processed Al-matrix composites.     

Microstructure evolution and elemental diffusion of SiCp/Al–Cu–Mg composites prepared from elemental powder during hot pressing

15vol%SiCp/Al–Cu–Mg composites were fabricated by hot pressing method using pure elemental powders. Microstructure evolution and elemental diffusion of Cu and Mg were studied. The microstructure of as-hot pressed composites and the elemental distribution of the composites before and after solution treatment were also investigated. The results showed that there were two types of eutectic liquid phases with different compositions after the compact was heated to 580 °C. After the compact was held at 580 °C for 60 min, the eutectic liquid was absorbed into the Al matrix and some equilibrium liquid phases formed in the boundaries of the initial Al particles. Meanwhile, Cu was homogeneously distributed in the Al particles while Mg tended to be distributed near the boundaries of the initial Al particles and in the SiC clusters. The presence of Al₂Cu, Mg₂Si, and some oxides of Mg was identified in the as-hot pressed composite. After solution treatment, Al₂Cu dissolved into the Al matrix, however, some Mg-rich compounds (silicide and oxide of Mg) did not dissolve into the matrix completely.     

Fabrication of bioglass infiltrated Al2O3–(m-ZrO2) composites

Using 80 vol.% of poly methyl methacrylate (PMMA) as a pore-forming agent to obtain interconnected porous bodies, porous Al₂O₃–(m-ZrO₂) bodies were successfully fabricated. The pores were about 200 μm in diameter and were homogeneously dispersed in the Al₂O₃–25 vol.% (m-ZrO₂) matrix. To obtain Al₂O₃–(m-ZrO₂)/bioglass composites, the molten bioglass was infiltrated into porous Al₂O₃–(m-ZrO₂) bodies at 1400°C. The material properties of the Al₂O₃–(m-ZrO₂)/bioglass composites, such as relative density, hardness, compressive strength, fracture toughness and elastic modulus were investigated.     

The effect of rolling direction on the creep process of Al–Cu bimetallic sheet

The study of the mechanical properties of aluminium–copper (Al–Cu) metal layered composite, formed by joining aluminium and copper sheets in the process of rolling have been presented in this paper. The influence of the rolling direction on the basic strength parameters and rheological properties of the composite was analysed. All tests were carried out on flat specimens cut from a sheet in the direction compatible with the rolling direction (RD) and transverse direction (TD). Preliminary tests of monotonic uniaxial tension at a temperature of 293 K were carried out and the basic mechanical properties of Al–Cu bimetal were determined. The hardening process of the material was described by the three-parameter Swift’s equation. The essential creep tests were carried out at a temperature of 523 K in the range of stress 88.5–137.9 MPa. The relation between minimum creep rate and applied stress for the specimens cut from the RD and TD directions were determined. The relationships between the time to fracture, stress, and rupture elongation, obtained from the creep tests, were determined as well. Variations of the steady creep rate with time to fracture by using the Monkman–Grant’s model and its modifications were analysed. It was found that the rolling process strongly affected the short-time monotonic deformation at 293 K and the creep process at 523 K temperature.     

Wear behavior of Al–Cu and Al–Cu/SiC components produced by powder metallurgy

In the present study, the dry sliding wear behavior of some powder metallurgy (P/M) Al–Mg–Cu alloys with different weight percentage of Cu (0, 1, 2, 3, 4, and 5 wt%) and corresponding metal matrix composites reinforced with 5 or 10 vol% silicon carbide particles (SiC) have been carried using pin-on-disk apparatus. The tested specimens were tested against hardened steel disk as a counter face at room conditions (∼20 °C and ∼50% relative humidity). The normal load was 40 N and sliding velocity of counter face disk was 150 rpm (0.393 m/s) and total testing time of 60 min, which corresponds to a distance of 1414 m. Generally, both hardness and wear resistance were enhanced by the addition of Cu and/or SiC to the Al-4 wt% Mg alloy. The formations of mechanically mixed layer (MML) as a result of material transfer from counter face disk to the samples and vice versa were observed in all tested specimens.     

Fabrication of Al–Si coating on Ti–6Al–4V substrate by mechanical alloying

Al–Si coatings were synthesized on Ti–6Al–4V alloy substrate by mechanical alloying with Al–Si powder mixture. The as-prepared coatings had composite structures. The effects of Al–Si ratio, milling duration and rotational speed on the microstructure and oxidation behavior of coating were investigated. The results showed that the continuity and the anti-oxidation properties of the coating were enhanced with the increase of Al–Si weight ratio. The thickness of the coating largely increased in the initial 5-hour milling process and decreased with further milling. A rather long-time ball milling could result in the generation of microdefects in coating, which had an adverse effect on the oxidation resistance of coating. Both the thickness and the roughness of the coating increased with the raise of rotational speed. The low rotational speed would lead to the formation of discontinuous coating. The rotational speed had a limited effect on the coating oxidation behavior. Dense, continuous and high-temperature protective Al–Si coatings could be obtained by mechanical alloying with Al–33.3?wt.%Si powder at the rotational speed ranging from 250 to 350?rpm for 5?h.     

Assessment of diffusion barriers for Ti–SiC composites

Abstract

The application of chemical vapour deposition and physical vapour deposition coatings, either singly or in combination, onto SiC fibres is discussed in terms of their ability to enhance the high temperature stability of Ti–SiC composites. The thermal stability and success of potential barrier layers was assessed by studying the fibre-matrix interdiffusion and measurement of the mechanical properties of individual fibres following coating and thermal exposure. Measurements of the level of strength retention have proved to be a reliable method of assessing the effectiveness of potential diffusion barriers. Failures may result from one of three sources. For high strength fibres failures are SiC–core reaction zone initiated, for intermediate strength fibres failures are surface defect (SiC) initiated and for low strength fibres, failures are fibre–matrix reaction zone or coating initiated. To ensure high strength (i.e. core failures) it is essential that a carbon layer is retained at the SiC surface. The most successful barriers have been shown to be TiB₂ and PtAl₂ coatings preventing outward diffusion of carbon and minimising the interaction with the titanium matrix. From these results a life prediction model has been developed based on the fibre–coating interaction, which will predict fibre strength as a function of time at a given temperature.

MST/3001     

Effect of rolling temperature on the evolution of defects and properties of an Al–Cu alloy

The defects and properties of a precipitation hardening Al–Cu alloy 2017 were studied after rolling at room temperature (RT) and cryogenic (liquid N₂) temperature (CT). It is found that CT rolling produced practically the same hardness as RT rolling for a wide range of rolling strains. However, electrical resistivity measurement revealed a clear difference indicating different defect structures in the CT- and RT-rolled samples. This difference led to higher hardness, after subsequent ageing, for samples processed by CT rolling. It is deduced that precipitation occurred during RT rolling, which compensated for the effect of lower dislocation density (evaluated from X-ray diffraction) in RT-rolled sample, and consequently resulted in similar hardness in both RT- and CT-rolled samples. It is noted that after ageing, CT-rolled sample has higher strength (~35%) than the standard T4 treatment.     

Tensile behaviour of powder metallurgy processed (Al–Cu–Mg)/SiCp composites

Abstract

The tensile behaviour of Al–Cu–Mg alloy matrix composites produced by a powder metallurgy process was investigated as a function of particle size in the as extruded, homogenised, and peak aged conditions. The tensile behaviour of the corresponding matrix alloy which was produced in a similar manner, designated as Control, was also studied. There was a significant increase in the 0.2% yield strength of Control and all the metal matrix composites (MMCs) after homogenisation treatment (53–68%) and peak aging (93–109%), as compared to their values in the as extruded condition. The ultimate tensile strength (UTS) of Control as well as the MMCs also increases considerably after homogenisation treatment (39–70%), however, subsequent peak aging did not result in any further increase in UTS in case of any of the MMCs. It was found that the finer the reinforcement size, the higher the 0.2% yield strength and UTS in all the conditions. On the other hand, ductility decreased considerably after homogenisation treatment and subsequent peak aging. The results are discussed in the light of dislocation strengthening as well as reinforcement damage.     

Fabrication of porous glasses by water vapor corrosion of Y–Al–Si–O–N glass

The effects of exposure conditions on the microstructural changes of the oxynitride Y–Al–Si–O–N glass system were investigated. The oxynitride glass was exposed to dry O₂ gas, or water vapor containing either O₂ or Ar, at temperatures between 1133 and 1183 K. A porous scale layer was formed by exposure to water vapor, while a non-porous deteriorated scale was obtained only by exposure to dry O₂. Formation of the porous layer was promoted by the presence of oxygen in the water vapor. The corrosion rate of the oxynitride glass in humidified O₂ near the glass transition temperature followed a linear rate law. The morphology of the porous layer was strongly dependent on the exposure temperature, which may be due to the significant decrease in the viscosity of the glass with increasing temperature. The permeability of the porous layer cut from the exposed glass behaved according to Darcy’s law; therefore, this layer was considered to be composed of three-dimensional continuous pores. The microstructure of the porous layer could be controlled by the exposure temperature, so that a graded porous glass with different morphological characteristics within the layer could be obtained by exposure to humidified gases at different temperatures.     

Development of rolling textures in Cu–Ni alloys

Abstract

The development of texture during the cold rolling of Cu–12·5Ni and Cu–27Ni (wt-%) alloys has been studied using X-ray analysis and transmission electron microscopy (TEM). Pole figures and diffractometer intensity measurements from rolling sections confirm that the texture is of the ‘copper’ type, although the preferred orientation develops more slowly and is consequently less sharp than in the pure metal at equivalent strains. The microstructures were consistent with deformation by slip, no evidence of mechanical twinning being found despite the greater hardness of the alloys compared with copper. However, the presence of nickel in solid solution was found to alter the deformation sequence observed by TEM. Beyond 80% reduction (ε=2·0), the cell structure characteristic of deformed copper, both at low and high strains, was almost entirely replaced by an assembly of small, slightly elongated crystallites whose boundaries often lay at ~±35° to the rolling direction. Long microbands, associated with fine scale rippling in the optical microstructure, appeared after only ~90% reduction (ε=2·5), there being a much reduced tendency for such lamellae to group into transition bands than in copper. Compared with the pure metal, the macroscopic deformation of cupronickels thus proceeds more homogeneously, although larger orientation differences, e.g. of ~10;°, as measured by a precision convergent beam technique, existed between adjacent crystallites, adjacent microbands, and across crystallite/microband boundaries. Possible causes of these differences of behaviour in the alloys are discussed and related to the higher hardness and work hardening rates of Cu–Ni alloys.

MST/499     

Effects of Al–8.5Si–25Cu–xY filler metal foils on vacuum brazing of SiCp/Al composites

Rapidly solidified Al–8.5Si–25Cu–xY (wt-%, x?=?0, 0.05, 0.1, 0.2, 0.3, 0.4, and 0.5) foils were used as filler metal to braze Al matrix composites with high SiC particle content (SiCp/Al-MMCs), and the filler presented fine microstructure and good wettability on the composites. The joint shear strength first increased, then decreased and a sound joint with a maximum shear strength of 135.32?MPa was achieved using Al–8.5Si–25Cu–0.3Y as the filler metal. After Y exceeded 0.3%, a needle-like intermetallic compound, Al3Y, was found in the brazing seam, resulting in a dramatic decline in the shear strength of the brazed joints. In this research, the Al–8.5Si–25Cu–0.3Y filler metal foil was found to be suitable for the brazing of SiCp/Al-MMCs with high SiC particle content.     

Effect of heat treatment on the tribological properties of Al–Cu–Mg/nanoSiC composites

In this study, the effect of heat treatment on the tribological properties of Al–Cu–Mg alloy reinforced with 4 wt.% SiC particles with 650 nm average particle size has been investigated. The age hardening process consists of solution treatment at 540 °C for 6 h, followed by water quenching and ageing at different temperatures of 175, 200 and 225 °C with soaking times of 3, 6 and 9 h. Hardness measurements were applied to monitor the precipitation effect and the aged samples were then subjected to wear tests under dry sliding conditions against steel and alumina counterfaces. The results showed that the reinforced material exhibits an enhanced ageing response compared to the unreinforced material in the same heat treatment conditions. The rate of ageing increases with increasing temperature; however, ageing at 200 and 225 °C for more than 6 h resulted in over-ageing. The best combinations for the enhanced tribological properties for the composite material were selected as 6 h ageing at 225 °C. The precipitation effect for this alloy can be enhanced by the small addition of SiC nanoparticles. Having a small amount of nanoSiC particles with fine precipitates inside the matrix further increases the hardness and wear properties.