Aluminum matrix composites: Fabrication and properties

Aluminum alloy matrix composites containing 1 to 30 wt pct of fibrous and particulate nonmetals varying in size from 0.06 μm to 840 μm were fabricated. The composites were cast into cylindrical molds for friction and wear tests, hot extrusion and tensile tests. The distribution of the nonmetals in the cast ingots was homogeneous. Friction and wear tests were done on a pin (52100 bearing steel) and dish type machine without lubrication. It was found that composites containing ∼10 wt pct or more of SiC, TiC, Si₃N₄, Al₂O₃, glass, solid waste slag, and silica sand wear less than the pure matrix alloy, but have slightly higher average coefficients of friction. Wear in composites containing soft particles, especially MgO and boron nitride was higher than the pure matrix alloy. The average coefficient of friction of all the composites was in the range of 0.35 to 0.58. Increasing the sliding velocity reduced this range to ∼ 0.4 to 0.45. The longitudinal tensile properties of the extruded composites (with the exception of loss of ductility in some cases) are comparable to that of the matrix alloys. Improvements in strength or ductility were noted. For example, addition of 15 wt pct of 3 μm size Al₂O₃ particles raised the yield and ultimate strength of the Al-4 pct Cu-0.75 pct Mg alloy matrix from 227 to 302 MPa, and 356 to 403 MPa, respectively. The corresponding percent elongation decreased from 25.8 to 12.5. The fact that the various composites can be readily cast and hot formed suggests a variety of engineering applications. AKIRA SATO, formerly Visiting Scientist at Massachusetts Institute of Technology, Cambridge.     

Effects of SiCp reinforcement by electroless copper plating on properties of Cu/SiCp composites

Abstract

Silicon carbide reinforced copper matrix composites containing 50–80 vol.-%SiC_p were fabricated by hot pressing copper coated SiC_p powder. The results show that the densification, thermal expansion coefficients, flexural strength, and thermal conductivity of Cu/SiC_p composites reinforced by electroless copper plating and their corrosion resistance in 5%NaCl solution are better than those without electroless plating. Physical properties and flexural strength of the composites decrease with an increase in SiC_p content, whereas the corrosion resistance increases with an increase in SiC_p volume fraction. By observing the fracture surface after a flexural test, it can be seen there are two types of fracture model: the cracking of Cu/SiC_p interface and the pulling out of SiC_p particles. The experiment also proved that the bonding strength of the Cu/SiC_p interface and the pressure of the hot pressing operation are the two main factors which influence the fracture of these composites.     

Effects of Ni60WC25 powder content on the microstructure and wear properties of WC<Subscript>p</Subscript> reinforced surface metal matrix composites

The vacuum evaporative pattern casting technique was used to fabricate WC_p reinforced surface metal matrix composites in order to study the effects of Ni60WC25 powder content on the microstructure and wear properties of it. The results showed that the Ni60WC25 powders weakened the stability of WC particles and reacted with metal matrix at the interfacial regions in the composite. Diffusion kinetics and Gibbs free energy were calculated from the interactions between WC particles and matrix. It was found that adding 35 vol% Ni60WC25 alloy powder to composites led to the formation of Fe₃W₃C phases and complete dissolution of WC particles. The wear properties of composites with different Ni60WC25 alloy powder content were tested by the MLD-10 type tester. WC particles and Fe₃W₃C phases could protect the matrix and the matrix could support WC particles and Fe₃W₃C phases during wear processing.     

Sliding Wear Behavior Solid Lubricant Based Ni–Al–Bronze Surface Composite Developed by Friction Stir Processing

In this study, a nickel aluminium bronze (NAB) metal matrix composite reinforced with solid lubricants i.e. graphite and molybdenum disulphide (MoS₂) was prepared by friction stir processing. Friction stir processing (FSP) refined the grain structure as compared to the as-cast NAB. The micrographs of graphite reinforced matrix revealed fine globular α phase with some elongated morphology α phases, whereas MoS₂ reinforced surface composite mainly exhibited fine α phase particles. FSP also resulted in the distribution of solid lubricant particles in the NAB matrix. The hardness of the composites decreased with the addition of the solid lubricants in NAB matrix. SEM–EDS analysis of the reinforced NAB matrix confirmed the presence of solid lubricants. The influence of solid lubricants on the sliding wear behavior of NAB metal matrix was investigated by using the design of experimental approach. The experimental results revealed better wear resistance of the NAB–MoS₂ surface composite as compared to graphite reinforced and FSPed NAB surface. SEM–EDS analysis of worn out surfaces and wear debris were carried out for understanding the wear mechanism.     

Study of 6061-Al2O3p composites produced by reciprocating extrusion

A reciprocating extrusion process was developed to consolidate 6061-Al₂O_3p composites from mixed powders. The 6061 alloy powder was first dehydrated in a vacuum chamber at 450 °C and then mixed with 12.5 μm Al₂O₃ powder in various volume fractions: 0, 5, 10, 20, and 30 pct. The mixed powders were hot pressed at 300 °C under a pressure of 300 MPa and finally extruded reciprocatingly 14 times at 460 °C. The results show that the composites were fully densified, with no sign of pores or oxide layers observable in the optical microscope. The Al₂O₃ particles were distributed uniformly in the matrix. As compared with 6061 alloys, the composites demonstrated a smaller precipitation hardening and elongation, but exhibited a higher Young’s modulus and a larger work hardening capacity. The degradation of precipitation hardening was due to the loss of Mg, which reacts with Al₂O₃ to form MgAl₂O₄. The large work-hardening capacity is attributable to the incompatibility between Al₂O₃ and the matrix, which possibly generates more dislocations to harden the matrix. The composites had much higher friction coefficients and greater wear resistances than the 6061 alloy against steel disc surface. The friction coefficient of the 6061-30 vol pct Al₂O_3p composite was double that of the 6061 alloy and the wear resistance was 100-fold. As compared with similar composites reported previously, these composites possessed much higher elongation at the same strength level. A 30 vol pct Al₂O_3p still displayed an elongation of 9.8 pct in the T6 condition. All of these improvements are attributed to the merits, including full densification of the bulk, uniform dispersion of the Al₂O₃ particles in the matrix, and strong binding between the Al₂O₃ particles and the matrix resulting from reciprocating extrusion.     

Structural heterogeneity and its effects on the properties of an in situ TiB2–TiC/Cu composite synthesised by hot pressing

ABSTRACT

In situ TiB₂ and TiC reinforced copper matrix composites with tailored heterogeneous structure were fabricated via high-energy ball milling of Cu, TiH₂ and B₄C powders followed by hot pressing. The microstructures of both ball-milled powders and hot-pressed composites were compared. Although the dislocation density of Cu matrix was changed after hot pressing, the mode of distribution of ceramic phases in the Cu matrix was noted to transmit from the ball-milled powders to hot-pressed composites in case of the TiH₂ particles synthesised by the in situ reactions. The structural inheritance between the ball-milled powders and hot-pressed composites could be used to control microstructural features and thus to tune properties. The hot-pressed TiB₂–TiC/Cu composites with tailored heterogeneous structure exhibited better performance than those of homogeneous counterparts.     

Wear behaviour of Fe3 Al intermetallic particle reinforced PM based iron metal matrix composites

Abstract

The wear behaviour of unreinforced and reinforced PM based iron metal matrix composite, the latter containing 10 and 20 vol.-% nano sized Fe₃Al intermetallic particles, was studied as a function of sliding distance under two different loads and dry lubricated conditions. The intermetallic Fe₃Al nanoparticles were prepared by mechanical alloying and used as particle reinforcement with 10 and 20 vol.-% in the matrix. The processing of the composites included mixing and cold compaction followed by sintering at 1120°C. The influence of Fe₃Al additions on the dry sliding wear behaviour was studied at loads 20 and 40 N over sliding distances 2160, 3240, 4320 and 6480 m. The study showed that the composite exhibited a lower wear rate than that of the unreinforced matrix and the wear rate was influenced by the volume percentage of Fe₃Al particles. It is understood that iron aluminide reinforcement has a beneficial effect on the wear properties. Delamination and microcutting were the chief mechanisms of wear for the composites.     

Effect of Speed on the Tribological Behavior of Fe–Cu–C Based Self Lubricating Composite

In this work, the effect of different speeds on the tribological properties of sintered iron–copper–graphite (Fe–Cu–C) based self lubricating composites have been studied. Fe–Cu–C based self-lubricating composites were prepared by powder metallurgical compaction and sintering method. CaF₂, a solid lubricant in weight percentages of 0, 3, 6, 9 and 12 was added to the base matrix consisting of Fe-2Cu-0.8C. The fabricated samples were tested for friction and wear at a constant load of 10 N and three different speeds of 0.5, 5 and 10 m/s. The surface properties of unworn and worn surfaces were analyzed using optical and scanning electron microscope. The friction and wear test of the composites exhibited decrease in coefficient of friction and increase in wear loss with the increase in speed. The results also revealed different trends in the friction behavior of the developed composites at low (0.5 m/s) and high speeds(5 and 10 m/s). However, at all test speeds, COF of samples with 3, 6 and 9 wt.% was less than the base matrix, and wear loss of 3 wt.% CaF₂ sample was the lowest at all speeds. Ploughing, adhesive and delamination wear were the dominant wear mechanism as revealed by SEM. Based upon the findings, the developed material could be used for low and high speed antifriction applications.     

High Temperature Friction and Wear Characteristics of Fe–Cu–C Based Self-Lubricating Material

The objective of this paper is to investigate the tribological properties of a novel iron-copper-graphite (Fe–Cu–C) based self lubricating material at high temperature. The effect of Calcium fluoride (CaF₂) as a solid lubricant on friction and wear behavior of sintered Fe–Cu–C materials has been studied. Fe–Cu–C based self-lubricating materials were prepared by single stage compaction and sintering process. CaF₂ was added to Fe–2Cu–0.8C based materials in different weight percentages of 0, 3, 6, 9, and 12 wt%. The developed materials were tested for mechanical and tribological properties at high temperature (500 °C). The worn out surfaces were analyzed using a scanning electron microscope. The material with 3 wt% CaF₂ exhibited high hardness value where as compression strength of the materials decreased with the addition of CaF₂. Samples with 3, 6, and 9 wt% exhibited low value of coefficient of friction (COF) than base matrix. The material with 3 wt% CaF₂ addition exhibited better wear resistance as compared to other developed materials. The worn surfaces were mostly characterized by delaminating and abrasive wear. A high temperature solid lubricant CaF₂ was used in Fe–Cu–C based matrix and, the developed composites were tested for tribological properties at high temperature. The results showed that addition of CaF₂ in Fe–Cu–C improved the friction and wear properties. Based upon the findings, the developed material could be used for antifriction applications.     

Magnetic and structural properties of hot pressed Cu–SmCo5 composites obtained by mechanical alloying

Abstract

Cu–8 wt-%SmCo₅ alloys were obtained through mechanical milling for novel industrial applications. Copper and SmCo₅ powder mixtures were mechanically alloyed in a planetary ball mill to disperse SmCo₅ fine particles in the copper matrix with the aim to modify the structural, mechanical, electrical and magnetic properties. The resulting alloyed powders were characterised as a function of milling time. Under the magnetic field, SmCo₅ particles achieved M_s to improve the soft magnetic properties of copper–8 wt-%SmCo₅ to be used in dielectromagnetic components. The magnetic properties of Cu–8 wt-%SmCo₅ powders reached their optimum values after milling time ranging from 10 to 15 h. The consolidation of milled alloy powders was performed by uniaxial hot pressing at 923 K for 2 h under argon atmosphere to obtain dense compacts. The consolidation process resulted in good dense metal matrix composite materials with adequate properties of compression strength >900 MPa, 95 HRB in hardness, electrical conductivity up to 43% of that of the International Annealed Copper Standard (IACS) and magnetic properties such as coercive field, saturation and remanent magnetisation obtained at 218 Oe, 70·23 emu g^?1 and 6·09 emu g^?1 respectively at 300 K. The existence of a coercive field and a little magnetic memory of the consolidated system is a typical behaviour of magnetically soft materials. The variation of electric and magnetic properties and its dependence on structure strength change with milling time were discussed.     

Mechanical and Wear Properties of Al–Al<Subscript>2</Subscript>O<Subscript>3</Subscript> Metal Matrix Composites Fabricated by the Combined Effect of Stir and Squeeze Casting Method

The effects of nano particles on double shear strength and tribological properties of A356 alloy reinforced with Al₂O₃ nano particles of size 30 nm were investigated. The percentage inclusions of Al₂O₃ were varied from 0.5 to 1.5 wt%. The particles were added with stirring at 400 rpm and squeeze casting at 750 °C and pressure of 600 MPa in a squeeze casting machine. Comparison of the performance of as cast samples of A356/Al₂O₃ nano composite was conducted. The tribological properties of the samples were also investigated by pin-on-disk tests at 10, 30 and 50 N load, sliding speed 0.534 m/s and sliding distance 1100 m in dry condition. SEM images of microstructure analysis of the composite, Al₂O₃ (0.5 and 1 %) particles were well dispersed in the A356 alloy matrix. Partial agglomeration was observed in metal matrix composite with higher (1.5 %) Al₂O₃ particle contents. The nano dispersed composites containing 0.5 and 1 wt% of Al₂O₃ nano particles exhibited the highest double shear strength, lesser wear loss and coefficient of friction.     

Current PM literature for engineers and users

Abstract

Transmission electron microscopy (TEM) as well as corresponding analytical techniques, such as high resolution TEM (HRTEM), energy dispersive X-ray (EDX) analysis, electron energy loss spectroscopy (EELS) and elemental mapping via a Gatan imaging filter (GIF), have been used to study the complex precipitation morphology of the commercial Fe–Cr–Al based oxide dispersion strengthened (ODS) alloy PM 2000. Formation of homogeneously distributed Y–Al–O ODS particles from Y₂O₃ added to the metal powder is shown. Besides these ODS particles, a large amount of complex Y–Al–O/Al₂O₃ and Y–Al–O/TiC as well as pure Al₂O₃ inclusions with sizes significantly larger than ODS particles have been identified. A typical feature is the growth of Al₂O₃ and Y–Al–O particles on the surface of small Ti(C,N) nuclei. Some implications of the results obtained from the mechanical properties of PM 2000 steel are discussed.     

Tribological behaviour of silver based self-lubricating composite

Abstract

Silver based composites with varying concentration of graphite and/or MoS₂ were prepared by powder metallurgy method. Impacts of composition on the tribological performance of the composites in ambient air and vacuum were investigated. The lowest friction in air was achieved by Ag–20G (vol.-%) composite, while Ag–20MoS₂ exhibited the best lubricity in vacuum. XPS evaluation revealed the oxidation of MoS₂ in air and a decrease concentration of graphite on the surface of the wear tracks under vacuum. As the proportion of graphite to MoS₂ increased, the friction coefficient and the wear rates ascended gradually in air while decreased sharply under vacuum. As compared with other compositions, Ag–15MoS₂–5G exhibited a comparable stable and good tribological performance as the environmental condition changed for its friction coefficient and wear rate remained around 0·14 and 5×10^?6 mm³ N^?1 m^?1.     

Tribological Properties of TiO<Subscript>2</Subscript> Reinforced Nickel Based MMCs Produced by Pulse Electrodeposition Technique

Nickel–TiO₂ composite coatings were prepared under pulse current conditions by co-deposition of TiO₂ particles and nickel from a Watts type bath. The effect of TiO₂ particle concentration was studied on microhardness, friction coefficient and wear resistance. The morphological features and the structures were studied by scanning electron microscope, X-ray diffraction analysis and 3D profilometry facilities. A wide particle size range (between 95 and 140 nm) was chosen to provide a high dispersion and load bearing ability for the co-deposited layers. It was determined that increasing the particle concentration in the electrolyte dramatically increased the co-deposited TiO₂ particles in the coating. The results showed that the high concentration of TiO₂ particles in the electrolyte yielded the highest amount of particles co-deposited in the plating layer. The influence of the co-deposited TiO₂ volume on microstructure and tribological properties in the coating were investigated. The wear tests were carried out using a constant load by a reciprocating ball-on disk configuration. Wear loss and friction coefficients of Ni/TiO₂ composites were decreased by increasing TiO₂ content in the electrolyte because of the increasing content of TiO₂ in the deposited layer. The change in wear mechanisms by changing TiO₂ content was also determined.     

Microstructural evolution and hardness property of in situ Al–Mg2Si composites using one-step gravity casting method

In the present investigation, Al–X?wt-% Mg₂Si (X?=?0, 5, 10, 15 and 20) in situ composites are successfully synthesised by one-step gravity casting technique. Commercially pure Al, Mg and Si are used as raw materials. Microstructural evaluation and correlation of micro- and bulk hardness properties have been studied on developing composites. The composites consist of mainly three phases: matrix (α-Al), reinforcing (primary Mg₂Si) and binary eutectic (Al–Mg₂Si) phase. Primary Mg₂Si particles are formed by pseudo-eutectic transformation during solidification and surrounded by matrix and binary eutectic phase. It is found that Mg₂Si concentration has a significant impact on morphology and volume per cent of the above-mentioned phases. Primary Mg₂Si particles’ size and volume per cent increase with increasing wt-% of Mg₂Si. Volume per cent of individual phases and Mg₂Si concentration have great impact on hardness properties of composites. Bulk hardness increases with increasing wt-% of Mg₂Si concentration, but micro-hardness of primary Mg₂Si particle decreases slightly. Mg₂Si concentration also has significant impact on micro-hardness of individual phases.     

Tribological properties of metal-matrix composite materials reinforced by superelastic hard carbon particles

Metal-matrix composite materials (CMs) are synthesized from a mixture of a metal powder (Ti, Fe, Co, Ni, Cu, Al-based alloy) and fullerenes (10 wt %). The thermobaric synthesis conditions (700–1000°C, 5–8 GPa) ensure the collapse of fullerene molecules and their transformation into superelastic carbon phase particles with an indentation hardness H_IT = 10–37 GPa, an elastic modulus E_IT = 60–260 GPa, and an elastic recovery of >80% upon indentation. After reinforcing by superelastic hard carbon, the friction coefficient of CM decreases by a factor of 2–4 as compared to the friction coefficient of the matrix metal, and the abrasive wear resistance increases by a factor of 4–200. Superelastic hard carbon particles are a unique reinforcing material for an increase in the wear resistance and a simultaneous decrease in the friction coefficient of CM.     

Extrusion and Properties of 7075 Ingot and Particulate

Abstract

A vacuum infiltration process has been developed to fabricate copper matrix composites reinforced with 50 vol.-%Si powers and 0–10 wt-%Fe additive. In this study, the powder compacts were prepared using well mixed Si and Fe powders and were then packed in quartz tubes. Then pure copper was used to infiltrate these compacts. The results show that the wettability, the infiltration rate, the thermal conductivity, and the density are all promoted when the Cu/Si_p composites are added to 5–10 wt-%Fe. In addition, the coefficient of thermal expansion (CTE) of the Fe containing composite is lower than that of the composites without Fe additive. From the X-ray diffraction analysis and the differential thermal analysis, it can be seen that Fe additive also can generate the FeSi₂ compound and reduce the Cu₃Si brittle compound formation in the Cu/Si interface.     

The Wear Behavior of In-Situ Al–AlN Metal Matrix Composites

Al–AlN composites are synthesized using NH₄Cl + CaO powder as a nitrogenation precursor in the melt of pure aluminum. In-situ formation of AlN to varying volume fraction is attempted using different proportion of NH₄Cl + CaO precursor into the aluminum melt held at 700 °C. Mechanical properties of synthesized metal matrix composites are evaluated for different volume fraction and distribution of AlN particles in aluminum matrix. Agglomeration of AlN is noticed with increasing precursor addition and synthesis time into the aluminum matrix. Due to heterogeneous distribution of AlN particles in aluminum matrix, marginal changes in hardness are observed. Pin on disc, dry sliding wear of metal matrix composites is carried to study wear behavior of synthesized composites. Composite with good dispersion of AlN particulates has shown higher hardness and wear resistance. Present paper discusses wear behavior of composites with different weight fraction of AlN tested under load and sliding distance as wear parameters. The shearing mechanism of agglomerate due to friction and its correlation with the wear loss is also highlighted in the present paper.     

液态反应合成Mg—Li—MgO／Mg2Si复合材料的组织与性能

用ＤＴＡ对ＳｉＯ２与Ｍｇ－Ｌｉ合金反应合成复合材料的热力学进行了研究,证明反应能够进行。检测结果表明反应生成的粒子尺寸细小且分布均匀。复合材料的强度,硬度,弹性模量明显提高;该复合材料的延伸率低于基体合金,但仍可达到较高水平（〉４％）,高于Ａｌ２Ｏ３及ＳｉＣ纤维增强复合材料。     

Tribological Behavior of A356/Al2O3 Surface Nanocomposite Prepared by Friction Stir Processing

Surface A356 aluminum alloy matrix composites containing micro and nanosized Al₂O₃ are prepared by a new approach utilizing high-velocity oxy-fuel spraying and friction stir processing (FSP). Optical and scanning electron microscopy, microhardness, and wear tests were used to characterize the surface composites. Results indicated that, the presence of Al₂O₃ in matrix can improve the mechanical properties of specimens. The microhardness of surface composites containing micro and nanosized Al₂O₃ were 89.8 ± 2.6 HV and 109.7 ± 2.5 HV, respectively, which were higher than those for the as-received (79.6 ± 1.1 HV) and the FSPed A356-T6 with no alumina powder (66.8 ± 0.9 HV). Surface composites revealed low friction coefficients and wear rates, which were significantly lower than those obtained for substrate. The wear mass losses of the as-received, the FSPed, and surface micro and nanocomposite specimens after 500-m sliding distance were 50.5, 55.6, 31, and 17.2 mg, respectively. Scanning electron microscopy tests revealed different wear mechanisms on the surface of the wear test specimens.