Effect of Matrix Constitution on Microstructure and Mechanical Properties of Rheocast Metal Matrix Composites

In this study, aluminum-based metallic matrices with varying amounts of copper (I wt.% Cu, 3 wt.% Cu and 4.5 wt.% Cu) were reinforced with SiC particulates using a partial liquid phase casting technique. Microstructural characterization studies conducted on the composite samples revealed an increase in uniformity of distribution of SiC particulates and SiC/Al interfacial integrity and a decrease: in porosity in the metallic matrix with decreasing weight percent of copper. The results of the ageing studies revealed an accelerated ageing kinetics for the Al-1% Cu/SiC composite when compared to Al-3% Cu/SiC and Al-4.5% Cu/SiC samples. Results of ambient temperature mechanical tests demonstrate an increase in 0.2% yield strength and ultimate tensile strength of the composites and a decrease in ductility and strain hardening rate with an increasing weight percent of copper in the metallic matrix. Fracture studies revealed the presence of interfacial debonding, particulate breakage and cracks in the matrix of tensile specimens. The results of microstructural characterization, mechanical testing and fractography were finally rationalized in terms of the effect of variation in weight percent of copper in the metallic matrix.     

Effect of variation in physical properties of the metallic matrix on the microstructural characteristics and the ageing behaviour of Al-Cu/SiC metal matrix composites

In this study, aluminium-based metallic matrices with varying amount of copper (1 wt% Cu and 4.5 wt% Cu) were reinforced with SiC particulates using a partial liquid phase casting technique. The results of the present investigation showed smaller sized and higher weight percent of SiC particulates being successfully incorporated with a decrease in the weight percent of copper in the matrix. Microstructural characterisation studies conducted on the composite samples revealed an increase in uniformity of distribution of SiC particulates, improved SiC/Al interfacial integrity and smaller grain size of the metallic matrices with decreasing weight percent of copper. Results of the microstructural characterisation studies also exhibited the presence of solute rich zone in the near vicinity of SiC particulates and the nucleation of secondary phases both at and in near vicinity of SiC particulates. The result of the ageing studies revealed an accelerated ageing kinetics for the Al-1%Cu/SiC composite when compared to the Al-4.5%Cu/SiC composite samples. The results of accelerated ageing kinetics were rationalised in terms of the effect of variation in the physical properties of the metallic matrix and the ensuing microstructural characteristics due to variation in the amount of copper in the matrix.     

Effect of type of processing on the microstructural features and mechanical properties of Al-Cu/SiC metal matrix composites

In this study, an aluminum based metallic matrix (Al-2wt.% Cu) was reinforced with SiC particulates using a conventional casting technique and a new disintegrated melt deposition technique. Microstructural characterization studies conducted on the samples taken from disintegrated melt deposition technique revealed a more uniform distribution of SiC particulates and good interfacial integrity between SiC particulates and metallic matrix when compared to the conventionally cast composite samples. Results of ambient temperature mechanical tests demonstrate an increase in 0.2% YS and ultimate tensile strength of samples taken from disintegrated melt deposition technique when compared with the unreinforced and conventionally cast composite samples. The results of microstructural characterization and mechanical testing were finally rationalized in terms of the nature of processing technique employed to reinforce Al-2wt.% Cu metallic matrix with SiC particulates.     

Properties of Dispersion Casting of Y2O3 Particles in Hypo, Hyper and Eutectic Binary Al-Cu Alloys

In the present work,the dispersion casting of Y-2O-3 particles in aluminum-copper alloy was investigated in terms of microstructural changes with respect to Cu contents of 20 （hypo）,33 （eutectic） and 40 （hyper） wt pct by scanning electron microscopy （SEM） and energy dispersive spectroscopy （EDS）.For the fabrication of Al-Cu alloy dispersed Y-2O-3 ceramic particles,stir casting method was employed.In case of Al-20 wt pct Cu alloy （hypoeutectic）,SEM images revealed that primary Al was grown up in the beginning.After that,eutectic phase with well dispersed ceramic particles was formed.In case of eutectic composition,Y-2O-3 particles were uniformly dispersed in the matrix.When the Cu is added into Al up to 40 wt pct （hypereutectic）,primary phase was grown up without any Y-2O-3 ceramic particles in the early stage of solidification.Thereafter, eutectic phase was formed with well dispersed ceramic particles.It can be concluded that Y-2O-3 ceramic particles is mostly dispersed in case of eutectic composition in Al-Cu alloy.     

Effect of temperature in single phase regime on aging response of (Al-2Cu)/SiC metal matrix composite synthesised using disintegrated melt deposition technique

Abstract

In the present study, an aluminium based metal matrix composite ((Al-2 wt-%Cu)/SiC) was synthesised using an innovative disintegrated melt deposition technique and investigated to determine its microstructural characteristics and the effect of temperature in the single phase regime on the peak aging characteristics. Microstructural characterisation carried out on the as processed composite revealed the presence of a dendritic–equiaxed microstructure, non-interconnected porosity, uniform distribution of SiC particles, and good interfacial integrity. The results of solutionising studies indicated that the peak hardness during solutionising can only be realised if the composite is soaked at a critical solutionising temperature. Further, the results also indicated that the time required to attain peak solutionising hardness at various temperatures in the single phase regime is independent of the solutionising temperatures investigated in this study. The results of the aging studies revealed that the maximum hardness following aging is achieved for the composite solutionised at a critical solutionising temperature and time. The results of heat treatment characterisation were finally rationalised in terms of the changes in the constitutional and microstructural features during the various stages of the heat treatment procedure used in the present study.     

Processing-microstructure-mechanical properties of an Al-Cu/SiC metal matrix composite synthesized using disintegrated melt deposition technique

In the present study, an aluminum based metallic matrix (Al-2wt. % Cu) was reinforced with SiC particulates using a new disintegrated melt deposition technique. Microstructural characterization studies conducted on the samples taken from disintegrated melt deposition technique revealed a columnar-equiaxed matrix microstructure, finite amount of porosity and uniform distribution of SiC particulates. Results of ambient temperature mechanical tests demonstrate an increase in 0.2% Y.S and UTS and decrease in ductility of samples taken from disintegrated melt deposition technique when compared to the unreinforced samples. The results of microstructural characterization and mechanical testing were finally rationalized in terms of the processing steps involved in the disintegrated melt deposition technique.     

Strengthening mechanisms of aluminum matrix composite containing Cu-coated SiC particles produced by friction stir processing

ABSTRACT

A friction stir processing (FSP) method has been developed to fabricate a locally reinforced aluminum matrix composite (AMC) by stirring electroless-copper-coated SiC particles into AA6061 matrix. The interfacial bonding between particulate reinforcement and the matrix was enhanced by the copper coating. Effective improvement in hardness and in tensile strengths has been proved. Microstructural investigation and analyses were conducted to correlate the microstructural evidences with the possible strengthening mechanisms. The effect of copper coating on the bonding between SiC particles and Al-matrix; the role of the dispersed Cu debris and the increased Cu content in solid solution on the strengthening; and the effect of friction stir on dislocation density and on the recrystallization behavior were analyzed. Multiple strengthening mechanisms due to diffusion between copper film and matrix; dispersion of fine copper debris and Al-Cu intermetallic compounds (IMCs) in the matrix; solid solution due to increased copper content and dislocation punching were four major mechanisms in interpreting the strengthening phenomena in AMC containing copper coated SiC reinforcements.     

In situ alloying of elemental Al-Cu12 feedstock using selective laser melting

ABSTRACT

This investigation developed selective laser melting (SLM) processing parameters for the in situ fabrication of an Al-Cu12 alloy from pure elemental blends of aluminium and copper powders. Use of elevated pre-heat temperatures (400°C) created a coarser dendritic cell microstructure consisting of supersaturated Al-rich with a uniform Al₂Cu phase granular microstructure compared to non-pre-heated samples. Al-Cu12 in situ samples achieved maximum tensile strength values comparable to that of sand cast pre-alloyed Al-Cu12. Processing at elevated pre-heat temperatures created components with higher ultimate tensile strength and ductility compared to standard room temperature-built samples due to it assisting a more complete melting of Al and Cu particles. Additionally pre-heating enabled an artificial age hardening, producing an equilibrium α?+?θ microstructure. The creation of an alloy in situ through the use of elemental powder blends represents a low-cost and flexible methodology for exploration of new SLM material compositions and potential candidate materials for semi-solid processing using SLM.     

原位自生TiB2/Al-4.5Cu复合材料微观组织和力学性能

采用混合盐反应法制备TiB2含量分别为0%,2%,5%,8%(质量分数,下同)的TiB2/Al-4.5Cu复合材料,T6热处理后,采用XRD,ICP,OM,SEM,EDS等测试手段和室温拉伸实验进行微观组织观察和力学性能测试。XRD和ICP测试证实,合金体系中仅含α-Al,Al2Cu及TiB2,无Al3Ti,Al2B等反应中间产物。OM和SEM发现,基体材料中α-Al平均晶粒尺寸为167.5μm,而在2%,5%,8%的TiB2/Al-4.5Cu中,其平均晶粒尺寸依次为110.4,87.2,75.2μm,晶粒细化效果显著。TEM观察发现,TiB2颗粒主要分布在晶界处,呈四方和六方结构。室温拉伸实验表明,随着TiB2含量的增加,强度、显微硬度值均呈增加趋势,但伸长率不断下降。当加入8%TiB2时,屈服强度、抗拉强度、弹性模量和显微硬度分别达到356 MPa,416 MPa,92.5GPa和96.5HV,但其伸长率从10.3%降低到4.3%。载荷传递强化、细晶强化、位错增殖强化是TiB2/Al-4.5Cu复合材料力学性能得以大幅提升的影响因素,尤其是在位错增殖强化作用下,TiB2颗粒周边致密分布的位错胞、位错环对强度的提升起到了决定性作用。     

Investigation of microstructure and mechanical properties of steel fibre–cast iron composites

Abstract

The aim of the present experimental study was to investigate improvement of the toughness and strength of grey cast iron by reinforcing with steel fibres. The carbon content of the steel fibres was chosen to be sufficiently low that graphite flakes behaving as cracks were removed by carbon diffusion from the cast iron to the steel fibres during the solidification and cooling stages. To produce a graphite free matrix, steel fibres with optimum carbon content were used and the reinforced composite structure was cast under controlled casting conditions and fibre orientation. Three point bend test specimens were manufactured from steel fibre reinforced and unreinforced flake graphite cast iron and then normalising heat treatments were applied to the specimens at temperatures of 800 and 850°C. The fracture toughness and strength properties of the steel fibre reinforced material were found to be much better than those of unreinforced cast iron. The microstructures of the composite at the fibre–matrix transition zone were examined.     

Synthesis and recyclability of a magnesium based composite using an innovative disintegrated melt deposition technique

Abstract

This study has addressed the feasibility of synthesising and recycling a silicon carbide reinforced magnesium composite using an innovative disintegrated melt deposition technique with the aim of improving the mechanical properties. Microstructural characterisation studies revealed a marginal decrease in porosity and reinforcement content, and no change in grain morphology, reinforcement distribution pattern, and interfacial integrity between matrix and reinforcement following recycling. Results of physical and mechanical property characterisation revealed increases in 0.2% yield strength, ultimate tensile strength, ductility, and coefficient of thermal expansion of the recycled specimens when compared with the parent composite. These properties have been rationalised in terms of the microstructural characteristics associated with the disintegrated melt deposited composite specimens. Particular emphasis was placed on studying the effect of recycling on the microstructure and properties of the composite.     

Stress-strain rate relations for high-temperature deformation of two-phase Al-Cu alloys

Al-Cu alloys containing 6, 11, 17, 24 and 33 wt% Cu, annealed for 0.5–100 h, were deformed by the differential strain-rate test technique over a strain-rate range of 4×10^–6 to 3×10^–2s^–1 at temperatures ranging from 460–540°C. Superplastic behaviour, with strain-rate sensitivity, m0.5, and activation energy, Q=171.5 kJ mol^–1, is shown by the Al-24Cu and Al-33Cu alloys at lower strain rates and higher temperatures. All the alloys show m0.20 at higher strain rates, but the average activation energy for deformation of the Al-6Cu, Al-11Cu, and Al-17Cu alloys is evaluated to be 480.7 kJ mol^–1, in contrast to a lower value of 211 kJ mol^–1 for the Al-24Cu and Al-33Cu alloys. Instead of grain size, the mean free path between particles is suggested to be a more appropriate microstructural parameter for the constitutive relationship for deformation of the Al-Cu alloys.     

Preparation of Al-20Si-4.5Cu alloy and its composite from elemental powders

Hypereutectic Al-Si-Cu alloys with a low thermal expansion coefficient and good wear resistance are commonly prepared from pre-alloyed powders using atomization. In the present work, an attempt was made to explore the possibility of fabricating the materials from cheaper elemental powders through sintering the compacts of the mixture of a silicon powder and an Al-4.5Cu elemental powder in the liquid state. Another advantage of taking this fabrication route is that it gives an additional flexibility to incorporate Al₂O₃ particles into the alloys to form aluminium matrix composites with a further improved Young's modulus, dimensional stability and wear resistance. Due to the change in the phase constitution brought about by the silicon addition, the sintering scheme for the Al-Cu elemental powder must be modified. The results show that it is well possible to take advantage of the good sinterability of the Al-4.5Cu elemental powder, to maintain the dimensions of the Al-20Si-4.5Cu compacts and to hold their shape during liquid-phase sintering. After consolidation with hot extrusion and heat treatment, the materials show an improved Young's modulus and a lowered thermal expansion coefficient at the sacrifice of strength and ductility. The success in using the elemental powders to produce the hypereutectic Al-Si-Cu alloys and their composites opens up a new flexible and economic way to tailor the properties of the materials.     

Mg对原位自生TiB2/Al-4.5Cu复合材料微观组织及力学性能的影响

采用Al-K₂TiF₆-KBF₄混合盐原位自生反应法,制备了不同Mg质量分数的3wt% TiB₂/Al-4.5Cu复合材料。采用SEM、TEM、HM硬度测试和室温拉伸等方法研究了Mg含量和多级热处理对3wt% TiB₂/Al-4.5Cu复合材料微观组织和力学性能的影响。微观组织观察发现:Mg质量分数为3wt%时,经过多级热处理后,TiB₂颗粒的团聚现象明显改善,反应生成的TiB₂颗粒平均尺寸约为130 nm,基体内伴随有大量弥散分布的纳米级颗粒,且α-Al的晶粒尺寸也明显减小。力学测试结果表明:多级热处理后,3wt% TiB₂/Al-4.5Cu复合材料的硬度和抗拉强度随Mg含量的增加而提高,但过量的Mg (≥4wt%)会造成TiB₂颗粒细化效果下降。分析表明:Mg的加入能够降低TiB₂/α-Al界面能,减少脆性相Al₃Ti、Al₂B的生成,并通过反应生成的MgAl₂O₄使界面结构变成TiB₂/MgAl₂O₄/α-Al,从而有效抑制了TiB₂的团聚,改善了TiB₂颗粒与Al液界面的润湿性,提高了形核率,进一步细化了α-Al晶粒尺寸。      

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.     

Microstructural investigation on antifriction characteristics of self-lubricating copper hybrid composite

Abstract

Owing to good antifriction properties and high wear resistance, copper hybrid composites reinforced with hard ceramic particles and solid lubricant components are regarded as promising materials for applications in sliding electrical contacts. The present work investigates the antifriction mechanism of a (SiC+Gr)/Cu composite from a microstructural viewpoint, so as to assist the development and application of this material. A graphite rich tribolayer formed on the worn surface was responsible for good tribological properties of the composites. Testing results showed that nanoparticles of graphite were involved in a mechanically mixing process by adhering to both the other wear debris and the two contacting surfaces, thereby developing a solid lubricant tribolayer. The nanographite to nanographite contacting mode, formed between the composite and the counterface, significantly improved wear resistance and friction stability. The forming and failure process of the graphite rich tribolayer was studied. A mechanism has been developed based on the experimental results.     

Effect of Cu addition on microstructures and tensile properties of high-pressure die-casting Al-5.5Mg-0.7Mn alloy

In this study, Cu was added into the high-pressure die-casting Al-5.5Mg-0.7Mn (wt%) alloy to improve the tensile properties. The effects of Cu addition on the microstructures, mechanical properties of the Al-5.5Mg-0.7Mn alloys under both as-cast and T5 treatment conditions have been investigated. Additions of 0.5 wt%, 0.8 wt% and 1.5 wt% Cu can lead to the formation of irregular-shaped Al₂CuMg particles distributed along the grain boundaries in the as-cast alloys. Furthermore, the rest of Cu can dissolve into the matrixes. The lath-shaped Al₂CuMg precipitates with a size of 15–20 nm × 2–4 nm were generated in the T5-treated Al-5.5Mg-0.7Mn-xCu (x = 0.5, 0.8, 1.5 wt%) alloys. The room temperature tensile and yield strengths of alloys increase with increasing the content of Cu. Increasing Cu content results in more Al₂CuMg phase formation along the grain boundaries, which causes more cracks during tensile deformation and lower ductility. Al-5.5Mg-0.7Mn-0.8Cu alloy exhibits excellent comprehensive tensile properties under both as-cast and T5-treated conditions. The yield strength of 179 MPa, the ultimate tensile strength of 303 MPa and the elongation of 8.7% were achieved in the as-cast Al-5.5Mg-0.7Mn-0.8Cu alloy, while the yield strength significantly was improved to 198 MPa after T5 treatment.     

Unidirectionally cooled eutectic and eutectoidal composites of Al-Cu alloy

Al-Cu alloys having eutectic (Al-17·3 at.% Cu) or eutectoid (Cu-24 at.% Al) compositions were allowed to solidify unidirectionally. These two alloys were cooled from an elevated temperature in order to observe the microstructural characteristics. The freezing rate for obtaining a parallel and ordered structure is naturally much faster in eutectic than in eutectoid alloys although both the reaction temperatures are about the same (eutectic temperature =548, eutectoid temperature =565° C). The difference in the solidification rate is due to the diffusion rates of each atomic species in the liquid and the solid states. Similar defects were observed in both the specimens and their mechanisms of formation will be considered.     

Forging of the AA2618/20 vol.% Al2O3p composite: Effects on microstructure and tensile properties

The use of aluminium-based particulate reinforced MMCs for automotive components and aircraft structures have been shown to be highly advantageous over their unreinforced alloys, due to their high specific strength and stiffness and superior wear resistance in a wide temperature range. The aim of this paper was to evaluate the effect of the hot forging process on the microstructure and tensile properties (at room and high temperature) of a MMC based on the aluminium alloys AA2618 reinforced with 20 vol.% of alumina particles (Al₂O_3p). Microstructural analyses of the as-cast and heat-treated composite showed large grain size of the aluminium alloy matrix and a quite non-homogeneous distribution of the reinforcing particles. The forging process led to an evident grain refinement, while it did not lead to significant variations in the size and distribution of the reinforcement particles. Regarding the effect of the forging process on the mechanical properties, it induced a slight increase in hardness, tensile strength, elastic modulus and an evident increase in tensile elongation. SEM analyses of the fracture surfaces of the tensile specimens showed substantially similar morphologies for the as-cast and forged composites, both at room and high temperature. The mechanism of damage was mainly decohesion at the matrix–particle interface.     

Effect of melt treatment on microstructure and impact properties of Al-7Si and Al-7Si-2.5Cu cast alloys

The microstructures and impact toughness of Al-7Si and Al-7Si-2.5Cu cast alloys were studied after various melt treatments like grain refinement and modification. The results indicate that combined grain refined and modified Al-7Si-2.5Cu alloys have microstructures consisting of uniformly distributed α-Al grains, interdendritic network of fine eutectic silicon and fine CuAl₂ particles in the interdendritic region. These alloys exhibited improved impact toughness in as cast condition when compared to those treated by individual addition of grain refiner or modifier. The improved impact toughness of Al-7Si-2.5Cu alloys are related to breakage of the large aluminum grains and uniform distribution of eutectic silicon and fine CuAl₂ particles in the interdendritic region resulting from combined refinement and modification. This paper attempts to investigate the influence of microstructural changes in the Al-7Si and Al-7Si-2.5Cu cast alloys by grain refinement, modification and combined action of both on the impact toughness.