Effect of heat treatment on strength and abrasive wear behaviour of Al6061-SiC<Subscript>p</Subscript> composites

In recent years, aluminum alloy based metal matrix composites (MMC) are gaining importance in several aerospace and automobile applications. Aluminum 6061 has been used as matrix material owing to its excellent mechanical properties coupled with good formability and its wide applications in industrial sector. Addition of SiC_p as reinforcement in Al6061 alloy system improves its hardness, tensile strength and wear resistance. In the present investigation Al6061-SiC_p composites was fabricated by liquid metallurgy route with percentages of SiC_p varying from 4 wt% to 10 wt% in steps of 2 wt%. The cast matrix alloy and its composites have been subjected to solutionizing treatment at a temperature of 530°C for 1 h followed by quenching in different media such as air, water and ice. The quenched samples are then subjected to both natural and artificial ageing. Microstructural studies have been carried out to understand the nature of structure. Mechanical properties such as microhardness, tensile strength, and abrasive wear tests have been conducted both on matrix Al6061 and Al6061-SiC_p composites before and after heat treatment. However, under identical heat treatment conditions, adopted Al6061-SiC_p composites exhibited better microhardness and tensile strength reduced wear loss when compared with Al matrix alloy.     

Effect of the SiC particle size on the dry sliding wear behavior of SiC and SiC–Gr-reinforced Al6061 composites

The effect of size of silicon carbide particles on the dry sliding wear properties of composites with three different sized SiC particles (19, 93, and 146 μm) has been studied. Wear behavior of Al6061/10 vol% SiC and Al6061/10 vol% SiC/5 vol% graphite composites processed by in situ powder metallurgy technique has been investigated using a pin-on-disk wear tester. The debris and wear surfaces of samples were identified using SEM. It was found that the porosity content and hardness of Al/10SiC composites decreased by 5 vol% graphite addition. The increased SiC particle size reduced the porosity, hardness, volume loss, and coefficient of friction of both types of composites. Moreover, the hybrid composites exhibited lower coefficient of friction and wear rates. The wear mechanism changed from mostly adhesive and micro-cutting in the Al/10SiC composite containing fine SiC particles to the prominently abrasive and delamination wear by increasing of SiC particle size. While the main wear mechanism for the unreinforced alloy was adhesive wear, all the hybrid composites were worn mainly by abrasion and delamination mechanisms.     

Different reinforcement strategies of hybrid surface composite AA6061/(B4C+MoS2) produced by friction stir processing

Aluminum surface composites have gained huge importance in material processing due to their noble tribological characteristics. The reinforcement of solid lubricant particles with hard ceramics further enriches the tribological characteristics of surface composites. In the current study, friction stir processing was chosen to synthesize hybrid surface composites of aluminum containing B₄C and MoS₂ particles with anticipated improved tribological behavior. B₄C and MoS₂ powder particles in 87.5: 12.5 ratio were reinforced into the AA6061 by hole and groove method. Microstructural observations indicated that reinforcement particles are well distributed in the matrix. The hardness and wear resistance of hybrid surface composites improved as compared to the base material, due to well distributed abrasive B₄C and solid lubricant MoS₂ particles in AA6061. The hybrid surface composites achieved ∼32 % increased average hardness as compared to the base material. Hole method revealed ∼13 % better wear resistance compared to the groove method for friction stir processed hybrid surface composite, attributing to an improved homogeneity of particle distribution shown by zigzag hole pattern. Moreover, friction stir processed AA6061 without reinforcement particles exhibited reduced hardness and wear resistance due to loss of strengthening precipitates during multi-pass friction stir processing.     

Influence of B4C on the tribological and mechanical properties of Al 7075–B4C composites

In the present investigation, the influence of B₄C on the mechanical and Tribological behavior of Al 7075 composites is identified. Al 7075 particle reinforced composites were produced through casting, K₂TiF₆ added as the flux, to overcome the wetting problem between B₄C and liquid aluminium metal. The aluminium B₄C composites thus produced were subsequently subjected to T6 heat treatment. The samples of Al 7075 composites were tested for hardness, tensile, compression, flexural strengths and wear behavior. The test results showed increasing hardness of composites compared with the base alloy because of the presence of the increased ceramic phase. The wear resistance of the composites increased with increasing content of B₄C particles, and the wear rate was significantly less for the composite material compared to the matrix alloy. A mechanically mixed layer containing oxygen and iron was observed on the surface, and this acted as an effective insulation layer preventing metal to metal contact. The coefficient of friction decreased with increased B₄C content and reached its minimum at 10 vol% B₄C.     

Effects of particulate reinforcement and heat treatment on the hardness and wear properties of AA 2024-MoSi2 nanocomposites

In this study, nanocomposites of AA 2024 aluminum alloy matrix reinforced with different volume fractions of nanometric MoSi₂ intermetallic particles ranging from 0 to 5%, were produced using mechanical alloying technique. For comparison, samples without reinforcing particles and mechanical alloying and a sample with micrometric MoSi₂ particles were also synthesized. The prepared composite powders were consolidated by cold and hot pressing and then heat treated to solution and aged condition (T6). The effects of MoSi₂ particle size, volume fraction and also heat treatment on the hardness and wear properties of the composites were investigated using Brinell hardness and pin-on-disc wear tests. The results indicated that although T6 heat treatment increases the hardness of all samples compared to as hot-pressed (HP) condition, the age-hardenability (aging induced hardness improvement) decreases after mechanical alloying and with increasing MoSi₂ volume fraction due to the high dislocation density produced during mechanical alloying. With increasing the volume fraction of nano-sized MoSi₂ particles up to 3–4%, the hardness of the composites continuously increases and then declines most probably due to the particle agglomeration. The wear sliding test disclosed that the wear resistance of all specimens in T6 condition is higher than that of HP condition and increases with increasing MoSi₂ content. Scanning electron microscopic observation of the worn surfaces was conducted and the dominant wear mechanism was recognized as abrasive wear accompanied by some adhesive wear mechanism.     

Role of zirconia filler on friction and dry sliding wear behaviour of bismaleimide nanocomposites

This paper discusses the friction and dry sliding wear behaviour of nano-zirconia (nano-ZrO₂) filled bismleimide (BMI) composites. Nano-ZrO₂ filled BMI composites, containing 0.5, 1, 5 and 10 wt.% were prepared using high shear mixer. The influence of these particles on the microhardness, friction and dry sliding wear behaviour were measured with microhardness tester and pin-on-disc wear apparatus. The experimental results indicated that the frictional coefficient and specific wear rate of BMI can be reduced at rather low concentration of nano-ZrO₂. The lowest specific wear rate of 4 × 10⁻⁶ mm³/Nm was observed for 5 wt.% nano-ZrO₂ filled composite which is decreased by 78% as compared to the neat BMI. The incorporation of nano-ZrO₂ particles leads to an increased hardness of BMI and wear performance of the composites shows good correlation with the hardness up to 5 wt.% of filler loading. The results have been supplemented with scanning electron micrographs to help understand the possible wear mechanisms.     

Mg_2B_2O_(5W),SiC和Gr颗粒增强6061Al基复合材料的摩擦磨损行为

采用粉末热挤压法制备2%Mg2B2O5w/6061Al,2%Gr/6061Al,2%SiCp/6061Al,2%Mg2B2O5w+2%Gr/6061A,2%Mg2B2O5w+2%SiCp/6061Al,2%Mg2B2O5w+2%Gr+2%SiCp/6061Al单一及混杂增强的铝基复合材料,并对其耐磨性和摩擦行为进行研究。结果表明:随着载荷的增大,各种复合材料的磨损率均增大,石墨的添加增大了铝基复合材料的磨损率;复合材料的摩擦因数随载荷的增大而降低并趋于稳定,摩擦因数均介于0.22~0.32之间。未加入石墨的复合材料的磨损机制以磨料磨损和轻微的黏着磨损为主,加入石墨后复合材料的磨损机制转变为剧烈的黏着磨损。     

A physical model for the aging of an aluminum-base alloy reinforced with nitride particles

6061/X (X = AlN, Si₃N₄, TiN) aluminum-matrix composites have been prepared by a powder metallurgy process: by mixing aluminum alloy 6061 powder with nitride particles and extruding the mixture at high temperatures. After sintering and aging, the Vickers hardness of the composites has been measured. The results indicate that the Vickers hardness of the composites increases significantly with nitride particle content both before and after aging. The aging behavior of the composites can be interpreted in terms of a simple kinetic model, which was used earlier to predict changes in the yield strength of age-hardened unreinforced aluminum alloys. The model is shown to adequately describe the changes in the hardness of the composites. It is concluded that reinforcing nitride particles increase the precipitation rate, without influencing the nature of the precipitation process in the supersaturated solid solution.     

Microstructure and properties of Sip/Al–Si surface composites prepared by ultrasonic method

Primary Si particles reinforced Al–Si surface composites (Si_p/Al–Si surface composites) were prepared by means of ultrasonic equipment with a special horn crucible. The microstructure and properties of the surface composites were investigated using optical microscope, scanning electron microscopy (SEM), hardness meter and friction and wear tester. The results show that when Al–12%Si alloy was treated by ultrasonic, Si element was easy to move up because of the decrease of the viscosity of the melt, and the alloy composition at the top of the melt became hypereutectic. So, a mass of primary Si particles formed in this place. The thickness of the surface composite layer in the surface composites decreased with increasing the ultrasonic input power. The average size of the primary Si particles in the surface composite layer was larger than that of Al–Si alloy untreated by the ultrasonic and increased with increasing ultrasonic input power. The top layer hardness of Si_p/Al–Si surface composites is higher than that of Al–Si alloy without ultrasonic treatment and increased with increasing ultrasonic input power. The friction coefficients of the top layers of the surface composites are lower than that untreated by ultrasonic. The friction coefficient decreased with increasing ultrasonic input power. With the increase of the applied load, the friction coefficient of the top layer of the surface composites increased. The wear mass loss of Si_p/Al–Si surface composites is lower than that Al–Si alloy without ultrasonic treatment. The wear resistance of the surface composites was improved with increasing ultrasonic input power.     

Microstructural characteristics and mechanical behavior of B4Cp/6061Al composites synthesized at different hot-pressing temperatures

B₄Cp/6061Al composites have become important structural and functional materials and can be fabricated by powder metallurgy and subsequent hot rolling. In this work, the effects of the hot-pressing temperature on microstructures and mechanical behaviors of the B₄Cp/6061Al composites were investigated. The results showed that compared with the T4 heat treated B₄Cp/6061Al composite hot pressed at 560 °C, the yield strength and failure strain of the composites hot pressed at 580 °C were increased to 235 MPa and 18.4%, respectively. This was associated with the interface bonding strength between the B₄C particles and the matrix. However, the reaction products, identified to be MgAl₂O₄ phases, were detected in the composites hot pressed at 600 °C. The formation of the MgAl₂O₄ phases resulted in the Mg depletion, thus reducing the yield strength to 203.5 MPa after the T4 heat treatment due to the effect of the solid solution strengthening being weakened. In addition, the variation of hardness and electrical conductivity was mainly related to the Mg content in the matrix. Based on the as-rolled microstructures observed by SEM, SR-μCT and fracture surfaces, the deformation schematic diagram was depicted to reflect the tensile deformation process of the composites.     

Strategical parametric investigation on manufacturing of Al–Mg–Zn–Cu alloy surface composites using FSP

Friction stir processing (FSP) is a unique approach being presently researched for composite fabrication. In the present investigation, Al-B₄C surface composite was fabricated through FSP by incorporating B₄C powder particles into Al–Mg–Zn–Cu alloy (AA 7075) matrix. The influence of varying powder particle reinforcement strategies on the microstructure, powder distribution, microhardness, and wear resistance of the surface composite is reported. In addition, AA 6061/B₄C composites were prepared using the same parameter set and the powder distribution in the composite was compared to that in the AA 7075/B₄C composite. More homogeneous dispersion of B₄C powder was observed in AA 6061 as compared to AA 7075 substrate. Among the prepared AA 7075/B₄C composites, the best B₄C powder distribution was detected in samples processed using fine powder and incorporating the change in stirring direction between passes. The hardness and wear resistance of the prepared composites were almost doubled attributing to several strengthening mechanisms and B₄C powder distribution in the AA 7075 matrix.     

Development of Al3Ti and Al3Zr intermetallic particulate reinforced aluminum alloy AA6061 in situ composites using friction stir processing

Aluminum rich intermetallic particles are potential reinforcements for discontinuously reinforced aluminum matrix composites (DRAMCs). The objective of the present work is to produce AA6061/Al₃Ti and AA6061/Al₃Zr composites using in situ casting technique and applying friction stir processing (FSP) to enhance the distribution and morphology of Al₃Ti and Al₃Zr particles. AA6061/Al₃Ti and AA6061/Al₃Zr DRAMCs were produced by the in situ reaction of inorganic salts K₂TiF₆ and K₂ZrF₆ with molten aluminum. The microstructure was observed using optical and scanning electron microscopy. AA6061/Al₃Ti DRAMC exhibited clusters of Al₃Ti particles while the segregation of needle shape Al₃Zr particles was observed in AA6061/Al₃Zr DRAMC. The prepared composites were subjected to FSP. Significant changes in the distribution and morphology of Al₃Ti and Al₃Zr particles were observed after FSP. The changes in microhardness and sliding wear behavior of AA6061/Al₃Ti and AA6061/Al₃Zr DRAMCs before and after FSP is detailed in this paper.     

Tribological characterization of Al6061/alumina/graphite/redmud hybrid composite for brake rotor application

Dry sliding tribological characterization of redmud particle-reinforced Al6061/alumina/graphite hybrid metal matrix composite (RM-AlHMMC) was investigated as per ASTM G99-05 using pin on disc experimental setup. Initially, hybrid composites were fabricated through stir casting process by varying the wt.% of redmud particle as 3, 7, and 11, and then the wear tests were carried out based on L₂₇ orthogonal array. The experimental results revealed that 11?wt.% RM-AlHMMC showed maximum of 90% improved wear resistance than AlHMMC. For all the composites, the coefficient of friction (CoF) increases and saturates with the applied load and sliding distance, in which 11?wt.% RM-AlHMMC showed maximum of 48% increased CoF than AlHMMC. Metallographic investigation of worn-out AlHMMC composite showed that at maximum applied load, sliding velocity, and sliding distance, the wear mechanism changes from abrasive to adhesive, but adding of redmud particle showed combined adhesive and abrasive wear mechanisms. The optimized tribological parameters were obtained using grey relational analysis which revealed that 11?wt.% RM-AlHMMC has improved tribological properties.     

基体各类对混杂复合材料摩擦磨损性能的影响

研究了基体种类对SiC和石墨（Gr)颗粒混杂增强铝基复合材料的摩擦磨损性能的影响。各种铝基体的混杂复合材料的耐磨性有明显差异,纯铝基混杂复合材料具有最好的耐磨性,其次是A356,2024和6061为基体的混杂复合材料。     

Abrasive wear of FeCr (M7C3–M23C6) reinforced iron based metal matrix composites

Abstract

The effects of volume fraction, particle size, and sintered porosity of FeCr (M₇C₃–M₂₃C₆) particulates on the abrasive wear resistance of powder metallurgy (PM) Fe alloy metal matrix composites have been studied under different abrasive conditions. It was seen that the abrasive wear rate of the composites increased with an increase in the FeCr volume fraction in tests performed with 80 grade SiC abrasive paper, but it decreased for tests conducted with 220 grade SiC abrasive paper. Furthermore, the wear rates decreased with an increase in FeCr size for composites containing the same amount of FeCr. Hence it is deduced that Fe alloy composites reinforced with larger size FeCr particles are more effective against abrasive wear than those reinforced with smaller ones. At the same time the results show that the beneficial effects of hard FeCr particulates on wear resistance far outweighed the detrimental effects of sintered porosity in the PM metal matrix composites. In addition, the fabrication of composites containing soft particles such as graphite or copper favours a reduction in the coefficient of friction, and increases the matrix hardness of the composite. For this reason graphite and copper were used in the matrix in different amounts to test their effect on the wear resistance. Increase in graphite and copper volume fraction allowed the formation of additional phases, which had high hardness and wear resistance. It was also found that the wear rate of the composites decreased considerably with graphite and copper addition.     

Evaluation of the effects of plasma nitriding temperature and time on the characterisation of Ti 6Al 4V alloy

The effects of plasma nitriding (PN) temperature and time on the structural and tribological characterisation of Ti 6Al 4V alloy were investigated. PN processes under gas mixture of N₂/H₂ = 4 were performed at temperatures of 700, 750, 800 and 850 °C for duration of 2, 5 and 10 h. Cross section and surface characterisation were evaluated by means of SEM, AFM, XRD and microhardness test techniques. Dry wear tests were performed using a pin on disc machine. Mass loss and coefficient of friction were measured during the wear tests. Three distinguished structures including of a compound layer (constituted of δ-TiN and ɛ-Ti₂N), an aluminium-rich region and a diffusion zone (interstitial solid solution of nitrogen in titanium) were detected at the surface of plasma nitrided Ti 6Al 4V alloy. These structures increased surface hardness of Ti 6Al 4V alloy significantly and gradually distributed the hardness from the surface to the substrate. The "surface hardness", "surface roughness", "wear resistance" and "coefficient of friction" of the alloy were increased due to plasma nitriding process. Moreover, rising both process temperature and time led to increasing of "layers thicknesses", "surface hardness", "surface roughness", "dynamic load-ability" and "wear resistance" of Ti 6Al 4V alloy.     

SiCp/Al复合材料微弧氧化膜的组织结构及性能

采用微弧氧化技术对SiC体积分数分别为17vol%和55vol%的两种SiCp/Al复合材料进行处理。分析了两种材料微弧氧化膜的组织、形貌、相组成,测定了膜层的粗糙度、显微硬度、结合力,考察了膜层的耐磨和耐蚀性。结果表明:SiC的含量对SiCp/Al复合材料微弧氧化膜的表面形貌、粗糙度、相组成、结合力及摩擦磨损性能均有影响。17vol%SiCp/2009Al复合材料的微弧氧化膜较55vol%SiCp/6061Al复合材料更平整,微孔大小更均匀。55vol%SiCp/6061Al复合材料的微弧氧化膜的粗糙度(3.308 μm)比17vol%SiCp/2009Al复合材料(2.140 μm)大,表面熔融物堆积更多。两种材料的微弧氧化膜中均含有Al、Si、O、C、W等元素。55vol%SiCp/6061Al复合材料的微弧氧化膜中Mullite(SiO₂-Al₂O₃)相、α-Al₂O₃相、β-Al₂O₃相较多。17vol%SiCp/2009Al复合材料的微弧氧化膜的结合(38.55 N)较55vol%SiCp/6061Al(11.5 N)复合材料好。55vol%SiCp/6061Al复合材料的微弧氧化膜摩擦系数较大,磨损较严重。微弧氧化处理能有效改善两种SiCp/Al复合材料的耐蚀性。      

Effect of SiC content on the processing, compaction behavior, and properties of Al6061/SiC/Gr hybrid composites

Aluminum matrix composites reinforced with SiC and graphite (Gr) particles are a unique class of advanced engineered materials that have been developed to use in tribological applications. The conventional techniques for producing these composites have some drawbacks. In this study, a new method, namely In situ Powder Metallurgy (IPM), is applied for the preparation of Al6061/SiC/Gr hybrid composites. In this method, the stir casting and the powder metallurgy synthesizing processes are combined into an integrated net shape forming process. 0?C40 vol.% of SiC particles with an average size of 19 ??m, along with 9 vol.% of uncoated Gr particles, were introduced to the molten 6061 aluminum alloy. Then, the slurries were stirred in a specified time?Ctemperature regime resulting in mixtures of the SiC, Gr, and aluminum powder particles. The powder mixtures were cold pressed in six different pressures (between 250 and 750 MPa) and sintered. Finally, the produced composites were heat treated and their hardness and wear properties were investigated. Homogenous distribution of the SiC and Gr particles within the powder mixtures and the hybrid composites is clear from the SEM images. The results also show that the SiC particles decrease the compressibility of the hybrid powders and improve the hardness of composites. The best wear resistance is achieved in the hybrid composite containing 20 vol.% SiC particles.     

Processing of heat-treated silicon carbide-reinforced aluminum alloy composites

The present study investigates the processing of heat-treated silicon carbide (SiC) particle-reinforced 6061 aluminum alloy (AA) composites. As-received SiC powders were heat treated at 1300ºC, 1400ºC, and 1500ºC in nitrogen atmosphere for 2 h, and the 6061 AA–SiC composites were developed by spark plasma sintering at 560ºC and 60 MPa for 5 min in argon atmosphere. The amorphous silicon nitride is found to form in SiC particles as a result of heating at 1400ºC. The microstructure of the composites exhibited uniform distribution of SiC or SiC/Si₃N₄ particles in 6061 AA matrix. Further, the heat-treated SiC-reinforced 6061AA composites exhibited improved mechanical properties. A typical combination of UTS of 240 MPa and elongation of 21% is obtained for the 6061 AA composites prepared using SiC powders heated at 1400ºC.     

Slurry erosive wear behavior of Ni–P coated Si3N4 reinforced Al6061 composites

Ni–P coated Si₃N₄ reinforced Al6061 composites were fabricated by liquid metallurgy route. Percentage of reinforcement was varied from 4 wt% to 10 wt% in steps of 2. The developed composites were subjected to microstructure and sand slurry erosive wear studies. The influence of experimental parameters such as slurry concentration, rotational speed of slurry, size of impinging particles and the test duration on slurry erosive wear behavior of developed composites have been studied. Results reveals that, Al6061–Si₃N₄ composites exhibited improved wear resistance when compared with the matrix alloy under identical test conditions. With increase in slurry concentration, rotational speed of slurry, test duration, size of impinging particles, the slurry erosive wear rates of both matrix alloy and developed composites increases. However, under all the tests conditions studied, the developed composites possess higher wear resistance when compared with that of matrix alloy. Energy dispersive spectroscopy (EDS), X-ray diffraction analysis (XRD) and X-ray photoelectron spectroscopy (XPS) techniques were used to identify the oxides/passive layer formed on the worn surfaces. Scanning Electron Microscopy (SEM) examinations were also carried out on worn surfaces to observe the possible mechanisms of material removal in the matrix alloy and developed composites.