Fabrication of particulate aluminium-matrix composites by liquid metal infiltration

Aluminium-matrix composites were fabricated by liquid metal infiltration of porous particulate reinforcement preforms, using AlN, SiC and Al₂O₃ as the particles. The quality of the composites depended on the preform fabrication technology. In this work, this technology was developed for high-volume fraction (up to 75%) particulate preforms, which are more sensitive to the preform fabrication process than lower volume fraction whisker/fibre preforms as their porosity and pore size are much lower. The technology developed used an acid phosphate binder (with P/Al molar ratio=23) in the amount of 0.1 wt% of the preform, in contrast to the much larger binder amount used for whisker preforms. The preforms were made by filtration of a slurry consisting of the reinforcement particles, the binder and carrier (preferably acetone), and subsequent baking (preferably at 200 °C) for the purpose of drying. Baking in air at 500 °C instead of 200 °C caused the AlN preforms to oxidize, thereby decreasing the thermal conductivity of the resulting Al/AlN composites. The reinforcement-binder reactivity was larger for AlN than SiC, but this reactivity did not affect the composite properties due to the small binder amount used. The Al/AlN composites were superior to the Al/SiC composites in the thermal conductivity and tensile ductility. The Al/Al₂O₃ composites were the poorest due to Al₂O₃ particle clustering.     

High-strength and highly-uniform composites produced by compocasting and cold rolling processes

Silicon carbide reinforced aluminum alloy composite materials produced by casting methods are increasingly used in many engineering fields. However, these materials suffer from poor distribution of the reinforcement particles in the matrix and high content of porosity. The effect of subsequent cold rolling process with different reductions on the porosity, microstructure and mechanical properties of cast Al6061/10 vol.% SiC_p composite was investigated in this study. Composites fabricated by compocasting method were rolled at five different reductions of 30, 60, 75, 85 and 95%. The rolled specimens exhibited reduced porosity as well as a more uniform particle distribution when compared with the as-cast samples. Microscopic investigations of the composites after 95% reduction showed an excellent uniform distribution of silicon carbide particles in the matrix. During cold rolling process it was observed that the tensile strength and ductility of the samples increased by increasing the reduction content. After 95% reduction, the tensile strength and elongation values reached 306.7 MPa and 7.9%, which were 4.6 and 3.3 times greater than those of the as-cast composite, respectively.     

Interface reactions during preparation of aluminium-matrix composites by the sodium process

A process has been developed in which aluminium matrix composites, reinforced by either graphite or polycrystalline alumina (FP) fibres, are prepared by immersing the fibres sequentially in molten baths of sodium, tin, and aluminium. The experimental details of this process are presented, and the theory behind the process is explained. In essence, sodium wets the fibres, and is then reacted to form stable intermetallic compounds at the fibre-matrix interface; these compounds are then wetted by the aluminium. Composites with full theoretical strength can be prepared by means of this process if rayon-base graphite. Pan I graphite, or FP fibres are used. Composites containing an intimate mixture of two or more types of fibres are also possible.This research was Company funded.     

Corrosion protection of aluminium-matrix aluminium nitride and silicon carbide composites by anodization

Anodization is an effective surface treatment for improving the corrosion resistance of aluminium-matrix composites. For SiC particle-filled aluminium, anodization was performed successfully in an acid electrolyte, as usual. However, for AlN particle-filled aluminium, anodization needed to be performed in an akaline (0.7 N NaOH) electrolyte instead of an acid electrolyte, because NaOH reduced the reaction between AlN and water, whereas an acid enhanced this reaction. The concentration of NaOH in the electrolyte was critical; too high a concentration of NaOH caused the dissolution of the anodizing product (Al2O3) by the NaOH, whereas too low a concentration of NaOH did not provide sufficient ions for the electrochemical process. The corrosion properties and anodization characteristic of pure aluminium, Al/AlN and Al/SiC were compared. Without anodization, pure aluminium had better corrosion resistance than the composites and Al/SiC had better corrosion resistance than Al/AlN. After anodization, the corrosion resistance of Al/AlN was better than Al/SiC and both composites were better than pure aluminium without anodization, but still not as good as the anodized pure aluminium.     

Process,microstructure and properties of squeeze-cast short-carbon-fibre-reinforced aluminium-matrix composites

Two types of high-modulus short-carbon-fibre-reinforced commercially pure aluminium-matrix composites were fabricated in-house using a home-made squeeze caster. The type-I composites were fabricated from short-fibre preforms in which fibres exist as dispersed bundles. The type-II composites were fabricated from preforms in which individual fibres were uniformly dispersed. The detailed processes are described in the text. A three-point-bending strength of higher than 200 M Pa was obtained for the type-1 composite with 17 vol% of fibre. When more fibre was incorporated, both the strength and the ductility decreased due to inadequate infiltration. However, a bending strength of greater than 240 MPa was recorded on a hot-rolled type-I composite with a fibre content as high as 28 vol%. This significant improvement in the mechanical properties is explained by a hot-rolling-inducedvoid-healing effect. The type-II composites, with lower fibre volume fractions than those of the type-I due to their different preforms, exhibited bending strengths up to 166 MPa. Scanning electron microscopy fractography shows that the two types of composites fracture in distinctive manners. Transmission electron microscopy results featured thermal-stress-induced dislocations at carbon-aluminium interfaces as well as submicrometre-sized aluminium carbide, the reaction product, which nucleated from the interface and grew into the matrix interior.     

Factors affecting the damping capacity of cast aluminium-matrix composites

The damping capacity of stir-cast aluminium-matrix composites containing graphite and silicon carbide particles, were studied using a cantilever beam specimen and an HP 5423A Structural Dynamics Analyser. Damping data were determined in the first mode of vibration. Aluminium-matrix composites containing 5–10 vol % graphite particles and 10 vol % silicon carbide particles were prepared by the stir-casting technique and die cast to obtain standard samples (6 mm×25 mm100 mm). Graphite particles were found to be more effective in enhancing the damping capacity of composites compared to silicon carbide particles. The damping capacity of composites increased with the volume percentage of graphite within the range studied. However, no notable improvements in damping capacity were observed by dispersion of silicon carbide in aluminium alloy. The results have been analysed in terms of the effect of size, shape, nature and volume fraction of particles on the damping capacity of the aluminium matrix particulate composites and compared with the damping capacity data available in the literature. The effects of frequency, strain amplitude, temperature and processing on damping capacity of the aluminium matrix composites are reviewed.     

Graphite and boron carbide composites made by hot-pressing

Composites consisting of graphite and boron carbide were made by hot-pressing mixed powders of coke carbon and boron carbide. The change of relative density, mechanical strength and electrical resistivity of the composites and the X-ray parameters of coke carbon were investigated with increase of boron carbide content and hot-pressing temperature. From these experiments, it was found that boron carbide powder has a remarkable effect on sintering and graphitization of coke carbon powder above the hot-pressing temperature of 2000° C. At 2200° C, electrical resistivity of the composite and d(002) spacing of coke carbon once showed minimum values at about 5 to 10 wt% boron carbide and then increased. The strength of the composite increased with increase of boron carbide content. It was considered that some boron from boron carbide began to diffuse substitutionally into the graphite structure above 2000° C and densification and graphitization were promoted with the diffusion of boron. Improvements could be made to the mechanical strength, density, oxidation resistance and manufacturing methods by comparing with the properties and processes of conventional graphites.     

Microstructure and some mechanical properties of fly ash particulate reinforced AA6061 aluminum alloy composites prepared by compocasting

Fly ash has gathered widespread attention as a potential reinforcement for aluminum matrix composites (AMCs) to enhance the properties and reduce the cost of production. Aluminum alloy AA6061 reinforced with various amounts (0, 4, 8 and 12 wt.%) of fly ash particles were prepared by compocasting method. Fly ash particles were incorporated into the semi solid aluminum melt. X-ray diffraction patterns of the prepared AMCs revealed the presence of fly ash particles without the formation of any other intermetallic compounds. The microstructures of the AMCs were analyzed using scanning electron microscopy. The AMCs were characterized with the homogeneous dispersion of fly ash particles having clear interface and good bonding to the aluminum matrix. The incorporation of fly ash particles improved the microhardness and ultimate tensile strength (UTS) of the AMCs.     

Improvement of the temperature resistance of aluminium-matrix composites using an acid phosphate binder

The use of phosphate binders instead of the widely used silica binder resulted in improved temperature resistance, increased tensile strength and decreased coefficient of thermal expansion. The effects were largest for the phosphate binder which contained the largest amount of phosphoric acid (P/Al atom ratio = 24 in the liquid binder). These effects were probably due to the protection of the SiC whiskers by the binder phases (aluminium metaphosphate or aluminium orthophosphate), the binder-SiC reaction product (SiP₂O₇) and the binder-aluminium reaction product (AIP) from further reaction between the SiC and aluminium. The tensile strength of the composite containing the SiC whisker preform made with the phosphate binder (P/Al atom ratio = 6 or 24 in the liquid binder) was increased after heating at up to 600 °C for 240 h. The silicon phosphate (SiP₂O₇) acted as an in situ binder and was primarily responsible for increasing the compressive strength of the preform and increasing the temperature resistance of the composite. The carbon fibre composite containing the preform made by using the phosphate binder (P/Al atom ratio = 24 in the liquid binder) with either water or acetone as the liquid carrier during wet forming of the preform had a higher tensile strength than the carbon fibre composite made by using the silica binder. After composite heat exposure to 600 °C for 14 h, the carbon fibre composite made by using this phosphate binder with acetone as the liquid carrier during wet forming of the preform showed the best temperature resistance, while the carbon fibre composites made by using this phosphate binder with water as the carrier showed the second best temperature resistance, and that made by using silica binder was the worst. The reason for the better effect of the phosphate binder than the silica binder is probably due to the ability of the phosphate binder and the binder-aluminium reaction product (AIP) to protect the carbon fibres from the undesirable reaction between the carbon fibres and aluminium. The lack of a binder-fibre reaction contributed to making the carbon fibre composites less temperature resistant than the SiC whisker composites. The use of a higher binder concentration is attractive for increasing the temperature resistance of the composites. The binder concentration in the preform can be increased by increasing the binder concentration in the slurry used in the wet forming of the preform.     

The effect of Al2O3 particulates on the precipitation behaviour of 6061 aluminium-matrix composites

The effect of angular and spherical shaped Al₂O₃ particulates on the precipitation behaviour of 6061 aluminium-matrix composites has been studied using microhardness testing, differential scanning calorimetry (DSC) and transmission electron microscopy (TEM). The evolution of precipitates at each stage of precipitation corresponding to the DSC-peak was monitored through careful TEM observations. Both the formation and dissolution behaviour of the precipitates in the ageing process in the composites were compared with the unreinforced 6061 matrix alloy. Although an overall accelerated ageing response in the composites was reported, not all stages in the ageing process were influenced by the addition of particulates. However, the precipitation sequence was not altered by the presence of the particulates. The degree of acceleration and the relative proportion of the phase/phases was found to depend on reinforcement parameters such as size, shape and volume fraction. In the composites, higher dislocation densities were observed in the immediate vicinity of the ceramic particles which may have formed due to the large difference in the coefficients of thermal expansion (CTE) between the ceramic particles and the matrix. These CTE-dislocation effects influence the kinetics of precipitation.     

Characterization of thermoplastic natural fibre composites made from woven hybrid yarn prepregs with different weave pattern

This paper focuses on the effect of weave structure on mechanical behaviour and moisture absorption of the PLA/hemp woven fabric composites made by compression moulding. The unidirectional woven fabric prepregs were made from PLA (warp) and PLA/hemp wrapped-spun hybrid yarn (weft) with two different weave patterns; 8-harness satin and basket. Unidirectional composites with 30 mass% hemp content were fabricated from these prepregs, and compared to winded PLA/hemp hybrid yarn laminates with same composition. The composite from the satin fabric had significantly lowest porosities and best mechanical properties compared to the composite made from the winded hybrid yarn and basket fabric. The tensile, flexural, and impact strength were 88 MPa, 113.64 MPa, and 24.24 kJ/m², respectively. The effect of weave pattern on water absorption is significant. Although the composite from hybrid yarn laminate has larger water absorption than that of the pure PLA, it exhibits lower moisture absorption than both weaves.     

Microstructure and composition of Al-Al2O3 composites made by reactive metal penetration

The microstructure of Al-Al₂O₃ composites made by reactive penetration of Al (or Al alloy) into ceramic (mullite or kaolin) preforms has been investigated using transmission electron microscopy (TEM). The Al-Al₂O₃ composites were found to contain a mutuallyinterconnected network of Al and Al₂O₃. No crystallographic orientation was observed between the Al and Al₂O₃ phase. Impurities and pores in the ceramic preforms were found to have a strong effect on the microstructure of the composites. The impurities resulted in formation of small particles in the Al₂O₃ grains of Al-Al₂O₃ composites, whereas the porosity yielded a varied ratio of Al to Al₂O₃ in the composites. The growth rate of the Al-Al₂O₃ composites was found to depend on the microstructure and composition of the ceramic preforms as well as the composition of the reactive metals. Pure aluminium penetrated into a dense mullite faster than into a porous mullite at temperatures below 1200 °C. Addition of Mg to Al reduced the growth rate, whereas a continuous phase of amorphous SiO₂ in the ceramic preforms increased the growth rate.     

Toughened carbon/epoxy composites made by using core/shell particles

Toughened epoxy resin composites have been prepared by resin-transfer moulding by using a range of toughening agents. Two types of epoxy-functional preformed toughening particles were investigated and have a three-layer morphology in which the inner core is crosslinked poly(methyl methacrylate), the intermediate layer is crosslinked poly(butyl acrylate) rubber and the outer layer is a poly[(methyl methacrylate)-co-(ethyl acrylate)-co-(glycidyl methacrylate)]. The presence of glycidyl groups in the outer layer facilitates chemical reaction with the matrix epoxy resin during curing. Comparisons were made with acrylic toughening particles that have a similar structure, but which do not have the epoxy functionality in the outer shell, and with a conventional carboxy-terminated butadiene acrylonitrile (CTBN) liquid rubber toughening agent. The composites were characterised by using tensile, compression and impact testing. The fracture surfaces and sections through the moulded composites were examined by means of optical and scanning electron microscopy. Short-beam shear tests and fragmentation tests were used to investigate the interfacial properties of the composites. In general, use of the epoxy-functionalised toughening particles gave rise to superior properties compared with both the non-functionalised acrylic toughening particles and CTBN.     

Mechanical properties and corrosion behavior of lead-silicon carbide fiber and lead-carbon fiber composites made by electrodeposition

Multifilament silicon carbide fibers (Nippon Carbon, Nicalon type) and carbon fibers (Thornel, Pan T 300 and Pitch type) were used to produce lead-matrix composite materials for battery plate grid applications. Lead was impregnated into the fibers by electrodeposition from fluoborate baths. The electrical conductivity of carbon fibers was sufficient for direct electroplating; silicon carbide fibers were electroless plated with copper beforehand. The experimental conditions for good penetration of lead into the fiber tows were determined.Unidirectional composite samples with a fiber volume fraction of 5 to 25% were prepared from both lead impregnated fiber sheets and rods by hot-pressing (280°C, 50 MPa, 5–30 mm). The flexural strength and modulus of these samples were measured as a function of the infiltration current density and of the fiber volume fraction. Ultimate strengths in the range 300–400 MPa were attained for both lead-silicon carbide and lead-carbon composites, at a fiber volume fraction of about 25%. These latter composites exhibited a good corrosion resistance towards 38.5 wt-% sulfuric acid under non-anodic conditions.     

Experimental composites made of electron beam irradiated reinforced fillers

This study investigated the influence of electron beam irradiated reinforced fillers on the three body wear and flexural strength of experimental composite blends. Three formulations of reinforced fillers were investigated: (A) high loaded inorganic filler composite with 60 wt.% SiO₂, (B) low loaded inorganic filler composite with 40 wt.% SiO₂, (C) organic filler composite (precipitated Bis-phenol-A-di-methacrylate). The fillers were assigned to two subgroups of unswollen (A, B, C) and monomer swollen (A_s, B_s, C_s) fillers. The experimental blends (matrix: Urethane-dimethacrylate) were mixed using un-treated, annealed (90 °C), or electron beam irradiated fillers with 30 and 90 kGy, respectively. All specimens were heat-cured for 20 min at 140 °C. Three-body abrasion and flexural strength tests were performed. The highest flexural strength was evaluated for composites made of the 30 kGy irradiated type B_s filler. The comparison with annealed fillers showed that the effect was independent of increasing temperatures during the radiation process. Blends with a SiO₂ content of 60 wt.% (type A, A_s) had significantly less wear than blends with 40 wt.% (type B, B_s) or blends with organic fillers (type C, C_s). The flexural strength of the composite could be improved by using pre-irradiated reinforced fillers. However, wear was not affected using this procedure.     

Characterization and testing of fibre-modified bitumen composites

The binding of cellulose fibres to bitumen compared to polyester, mineral and glass fibres is presented. The surface characteristics of fibres were analysed using scanning electron micrographs and BET techniques. The results of elongation tests, softness, hardening and elasticity of the fibre-bitumen composites are shown. The influence of fibres in asphalt paving materials and mixtures used on roads is evaluated.     

Mechanical properties of ABOw+MWNTs/Al hybrid composites made by squeeze cast technique

Multi-wall carbon nanotubes (MWNTs) have been considered a realistic kind of reinforcement for composite materials. In this paper, microstructure and mechanical properties of the aluminum borate whisker (ABOw) and MWNTs hybrid composites were investigated. The results show that MWNTs decrease the compressive deformation of the hybrid preforms and are kept intact in the matrix during squeeze cast processing. A small amount of MWNTs may effectively improve the modulus, strength and elongation of the hybrid composite. Decreasing micropores and strengthening the matrix, high strength MWNTs make the mechanical properties of the hybrid composite superior to the singularly reinforced ones. This makes MWNTs a promising material for novel micro/nanohybrid composite.