Production and characterization of AA6061–B4C stir cast composite

This work focuses on the fabrication of aluminum (6061-T6) matrix composites (AMCs) reinforced with various weight percentage of B₄C particulates by modified stir casting route. The wettability of B₄C particles in the matrix has been improved by adding K₂TiF₆ flux into the melt. The microstructure and mechanical properties of the fabricated AMCs are analyzed. The optical microstructure and scanning electron microscope (SEM) images reveal the homogeneous dispersion of B₄C particles in the matrix. The reinforcement dispersion has also been identified with X-ray diffraction (XRD). The mechanical properties like hardness and tensile strength have improved with the increase in weight percentage of B₄C particulates in the aluminum matrix.     

Influence of the hard coated B4C particulates on wear resistance of Al–Cu alloys

In the present study, sliding wear tests were carried out on different sizes and volume fractions of coated B₄C particles reinforced 2024 aluminum alloy composites fabricated by a squeeze casting method. Microstructural examination showed that the B₄C distributions were generally homogeneous in the matrix while some particle clusterings were observed at relatively high particle containing composites. As compared to the 2024 Al matrix alloy, the hardness of the composites was found to be greater. It is observed that the wear resistance of the composites was significantly higher than that of the unreinforced aluminum alloy, and increased with increasing B₄C particles content and size. The hard B₄C particles act as a protrusion over the matrix, carries a major portion of the applied load and protect the abrasives from penetration into the specimen surface. Combination of rough and smooth regions is distinguished on the worn surface of the composites. The depth and number of grooves in composites decreased with increasing volume fraction of B₄C particles, and the worn surfaces of composites were relatively smooth.     

Microstructure and abrasive wear behaviour of B<Subscript>4</Subscript>C particle reinforced 2014 Al matrix composites

In this study, the microstructure and abrasive wear properties of varying volume fraction of particles up to 12% B₄C particle reinforced 2014 aluminium alloy metal matrix composites produced by stircasting method was investigated. The density, porosity and hardness of composites were also examined. Wear behaviour of B₄C particle reinforced aluminium alloy composites was investigated by a block-on-disc abrasion test apparatus where the samples slid against the abrasive suspension mixture (contained 10 vol.% SiC particles and 90 vol.% oil) at room conditions. Wear tests performed under 92 N against the abrasive suspension mixture with a novel three body abrasive. For wear behaviour, the volume loss and specific rate of the samples have been measured and the effects of sliding time and the content of B₄C particles on the abrasive wear properties of the composites have been evaluated. The dominant wear mechanisms were identified using SEM. Microscopic observation of the microstructures revealed that dispersion of B₄C particles was generally uniform while increasing volume fraction led to agglomeration of the particles and porosity. The density of the composite decreased with increasing reinforcement volume fraction but the porosity and hardness increased with increasing particle content. Moreover, the specific wear rate of composite decreased with increasing particle volume fraction. The wear resistance of the composite was found to be considerably higher than that of the matrix alloy and increased with increasing particle content.     

Effect of Bi<Subscript>2</Subscript>O<Subscript>3</Subscript> coating on interfacial wettability and tensile properties of Al<Subscript>18</Subscript>B<Subscript>4</Subscript>O<Subscript>33</Subscript>w/Al composite

A pure aluminum matrix composite reinforced by Bi₂O₃-coated Al₁₈B₄O₃₃ whisker was fabricated by squeeze casting method. The effects of Bi₂O₃ coating on the whisker/matrix wettability and the ultimate tensile strength and elongation to fracture of the composite are investigated. The results show that Bi₂O₃ coating can react with aluminum matrix during casting process, which improves the whisker/matrix wettability. Moreover, the ultimate tensile strength and elongation to fracture of the composite attain the maximum values at the mass ratio of 40:1 between whisker and Bi₂O₃ coating.     

Particle distribution and interfacial reactions of Al–7%Si–10%B<Subscript>4</Subscript>C die casting composite

Aluminum–boron carbide particle reinforced composite is an advanced material which can be used in applications such as neutron-shielding components, aircraft, and aerospace structures. In the microstructural characterization of an Al–7%Si–10%B₄C die casting, attention is particularly focused on particle distribution and interface reaction products between B₄C particles and the aluminum matrix. The quantitative analysis results show that, in a cross-section of the cast part, more particles concentrate in the center and fewer particles are present in the wall regions. Moreover, some particle segregation bands have been observed. The mechanisms of the particle migration are proposed to describe the phenomenon. However, the average particle fraction in any cross-section of the cast part is almost the same. A barrier layer consisting of several sublayers was detected on the surface of B₄C particles. Using electron diffraction in selected areas, it is found that these sublayers are composed of Al₃BC crystals, TiB₂ crystals, Si crystals, and coarse stick-shaped TiB₂ particles. In addition, it is observed that Si plays an important role in the formation of a dense barrier layer. The barrier layer can limit B₄C decomposition and improve B₄C stability in the aluminum melt.     

On the impact toughness of Al-15 vol.% B4C metal matrix composites

The present work was performed on ten metal matrix composites (MMCs) produced using the new powder injection technique. These MMCs were divided into two series in which pure aluminum was the matrix for one series, while an experimental 6063 alloy was the matrix for the second series. Small amounts of Ti, Zr and Sc were added to those composites, either individually or combined. In all cases the volume fraction of the reinforced B₄C particles was in the range 12–15 vol. %. The molten metal was cast in an L-shaped metallic mold preheated at 350°C. Unnotched rectangular impact samples (1 cm × 1 cm × 5 cm) were prepared from these castings and heat treated. Samples were tested using instrumental impact testing machine. Microstructure and fracture surface were examined using Hitachi SU-8000 FESEM. The results show that the presence of Ti improves the wettability of the B₄C particles and their adherence to the matrix. Repeated remelting at 730 °C applying vigorous mechanical stirring could lead to fragmentation of some of the B₄C particles. Aluminum based composites exhibited better toughness compared to those obtained from 6063 based composites in all the studied conditions. The composite impact toughness was controlled by the precipitation and coarsening of hardening phase particles namely Mg₂Si, Al₃Zr and/or Al₃Sc. Cracks in the fracture surface were observed to be initiated at the particle/matrix interfaces and propagate either through the B₄C particles or through the protective layers. No complete debonding was reported due the presence of Zr/Ti/Sc rich layers which improved the particle/matrix adhesion.     

Microstructure and mechanical behavior of AA6082-T6/SiC/B4C-based aluminum hybrid composites

The microstructural and mechanical behavior of hybrid metal matrix composite based on aluminum alloy 6082-T6 reinforced with silicon carbide (SiC) and boron carbide (B₄C) particles was investigated. For this purpose, the hybrid composites were fabricated using conventional stir casting process by varying weight percentages of 5, 10, 15, and 20?wt% of (SiC?+?B₄C) mixture. Dispersion of the reinforced particles was studied with x-ray diffraction and scanning electron microscopy analyses. Mechanical properties such as micro-hardness, impact strength, ultimate tensile strength, percentage elongation, density, and porosity were investigated on hybrid composites at room temperature. The results revealed that the increase in weight percentage of (SiC?+?B₄C) mixture gives superior hardness and tensile strength with slight decrease in percentage elongation. However, some reduction in both hardness and tensile strength was observed in hybrid composites with 20?wt% of (SiC?+?B₄C) mixture. As compared to the un-reinforced alloy, the improvement in hardness and tensile strength for hybrid composites was found to be 10% and 21%, respectively. Reduction in impact strength and density with increase in porosity was also reported with the addition of reinforcement.     

Statistical analysis of the fracture strengths of aluminum alloy–alumina (Al<Subscript>2</Subscript>O<Subscript>3</Subscript>) particulate composites

The mechanics of composite materials and their “fracture behaviors” are relatively complex phenomena to analyze and establish due to their inconsistent process stability and reliability, combined with production and related processing problems. In this work, an attempt has been made to statistically analyze the tensile behavior of metal matrix composites. Composites of aluminum alloy containing 5–20% volume fraction of Al₂O₃ particles of 15 μm size were prepared by adding alumina particles to a vigorously agitated semi-solid aluminum alloy. Prior to this, alumina particles were subjected to preheating at 800 °C for 5 h. Particles were then added to the aluminum alloy and further heated to 850 °C by using a mixer in a nitrogen medium. A total of 20 tension tests were performed for each volume fraction according to ASTM Standards B557 and using these test data, the initial estimators for an empirical model were obtained. Using this empirical model, the reliability of the composite characteristics in terms of its tensile strength was assessed. Another significant implication of the present study is proving the ability and utility of the Weibull statistical distribution for describing the experimentally measured data on the tensile strength of metal matrix composites, in a more appropriate manner.     

Effects of Manufacturing Processes on Microstructure and Properties of Al/A356–B4C Composites

Liquid and semi-solid stir casting processes were applied to fabricate B₄C particles-reinforced aluminum–matrix composites. The effects of manufacturing processes on particle distribution, particle/matrix interface, and mechanical properties of the prepared composites were studied. The results show that particle distribution can be significantly improved by using K₂TiF₆–flux and Ti powders in the liquid stir casting process, whereas in the semi-solid stir casting process it could be improved by decreasing the temperature of the slurry. With additions of Ti, the decomposition of B₄C was prevented, and the interfacial bonding strength was significantly improved due to the fact that a TiB₂ layer formed at the particle/matrix interface. Compared to the matrix, the hardness and tensile strength of the Al–B₄C composite fabricated by the liquid stir casting process were increased by 89.6% and 128.8%, respectively; those of the A356–B₄C composite fabricated by the semi-solid stir casting process had no significant improvement due to the weak particle/matrix interface and the presence of particle porosity clusters.     

Preparation and investigation of Al–4 wt % B<Subscript>4</Subscript>C nanocomposite powders using mechanical milling

Boron carbide nanoparticles were produced using commercially available boron carbide powder (0·8 μm). Mechanical milling was used to synthesize Al nanostructured powder in a planetary ball-mill under argon atmosphere up to 20 h. The same process was applied for Al–4 wt % B₄C nanocomposite powders to explore the role of nanosize reinforcements on mechanical milling stages. Scanning electron microscopy (SEM) analysis as well as apparent density measurements were used to optimize the milling time needed for completion of the mechanical milling process. The results show that the addition of boron carbide particles accelerate the milling process, leading to a faster work hardening rate and fracture of aluminum matrix. FE-SEM images show that distribution of boron carbide particles in aluminum matrix reaches a full homogeneity when steady state takes place. The better distribution of reinforcement throughout the matrix would increase hardness of the powder. To study the compressibility of milled powder, modified heckel equation was used to consider the pressure effect on yield strength as well as reinforcing role of B₄C particles. For better distribution of reinforcement throughout the matrix, r, modified heckel equation was used to consider the pressure effect on yield strength as well as reinforcing role of B₄C particles.     

Effect of titanium on microstructure and fluidity of Al–B<Subscript>4</Subscript>C composites

The effect of Ti on the interfacial reactions, microstructural characteristics, and the related fluidity of Al–12%B₄C composites has been investigated. Without Ti addition, B₄C decomposed heavily during holding, and a large quantity of reaction-induced compounds, Al₃BC and AlB₂, was generated. When Ti was added, a TiB₂ layer was built surrounding B₄C particle surfaces, which acted as a diffusion barrier to separate B₄C from liquid aluminum. Thus, the decomposition of B₄C slowed down remarkably. The fluidity of the composite without Ti was the shortest of all composites and deteriorated quickly during the holding time. The fluidity of the composite melt was improved significantly with increased Ti levels. The optimum Ti level for the best fluidity results lied between 1.0 and 1.5%. The solid particle volume and the particle agglomeration are the two main factors influencing the fluidity.     

Fabrication of TiC and TiB<Subscript>2</Subscript> locally reinforced steel matrix composites using a Fe–Ti–B<Subscript>4</Subscript>C–C system by an SHS-casting route

Steel matrix composites locally reinforced by in situ TiC and TiB₂ particulates were successfully fabricated using self-propagating high-temperature synthesis (SHS) in a Fe–Ti–B₄C–C system during casting. The locally reinforced steel matrix composites consist of three distinct regions: (i) a TiC and TiB₂ particulate-reinforced region, (ii) a transition region, and (iii) a steel matrix region. The TiC and TiB₂ particulates in the locally reinforced regions display a relatively uniform distribution, and their sizes decrease with the increase in Fe content from 10 wt.% to 40 wt.%. The wear resistance of the locally reinforced region of the steel matrix composites is much higher than that of the unreinforced steel matrix.     

Nacre-inspired lightweight and high-strength AZ91D/Mg<Subscript>2</Subscript>B<Subscript>2</Subscript>O<Subscript>5</Subscript>w composites prepared by ice templating and pressureless infiltration

We developed a facile and low-cost approach to prepare lightweight and high-strength magnesium–matrix composites with a nacre-inspired laminated structure. First, lamellar Mg₂B₂O₅ whisker (Mg₂B₂O₅w) scaffolds with initial solid loadings of 10, 15 and 20 vol% were prepared by ice templating. The wettability between a molten AZ91D alloy and the Mg₂B₂O₅w scaffold was greatly improved by the incorporation of nano-SiO₂ sol in the aqueous slurry, making the preparation of nacre-mimetic AZ91D/Mg₂B₂O₅w composite by way of pressureless infiltration feasible. The SiO₂ content in the Mg₂B₂O₅w scaffold has a significant effect on the processing and the microstructure and properties of the composites. The optimum SiO₂ content was about 6–8 wt% of the total ceramic loading. A lower SiO₂ content resulted in incomplete infiltration, while a higher content led to the formation of a large quantity of Mg₂Si in the composite. The flexural strength of the composites seemed independent of the initial ceramic loading (10–20 vol%), whereas the compressive strength and elastic modulus increased considerably and the crack-growth fracture toughness decreased with increasing ceramic content. The mechanism for such variations was addressed.     

Processing,microstructure and properties of ultrasonically processed in situ MgO–Al2O3–MgAl2O4 dispersed magnesium alloy composites

AZ91 alloy matrix composites are synthesized by in situ reactive formation of hard MgO and Al₂O₃ particles from the addition of magnesium nitrate to the molten alloy. The evolved oxygen from decomposition of magnesium nitrate reacts with molten magnesium to form magnesium oxide and with aluminium to form aluminium oxide. Additionally, these newly formed oxides react with each other to form MgAl₂O₄ spinel. Application of ultrasonic vibrations to the melt increased the uniformity of particle distribution, avoided agglomeration, and decreased porosity in the castings. Ultrasound induced physical phenomena such as cavitation and melt streaming promoted the in situ chemical reactions. Well dispersed, reactively formed hard oxides increased the hardness, ultimate strength, and strain-hardening exponent of the composites. Presence of well-dispersed hard oxide particles and stronger interface resulting from cavitation-enhanced wetting of reactively formed particles in the AZ91 alloy matrix improved the sliding wear resistance of the composites.     

Production and mechanical properties of SiC<Subscript>p</Subscript> particle-reinforced 2618 aluminum alloy composites

In this study, 2618 aluminum alloy metal matrix composites (MMCs) reinforced with two different sizes and weight fractions of SiC_p particles upto 10% weight were fabricated by stir cast method and subsequent forging operation. The effects of SiC_p particle content and size of the particles on the mechanical properties of the composites such as hardness, tensile strength, hot tensile strength (at 120 °C), and impact strength were investigated. The density measurements showed that the samples contained little porosity with increasing weight fraction. Optical microscopic observations of the microstructures revealed uniform distribution of particles and at some locations agglomeration of particles and porosity. The results show that hardness and tensile strength of the composites increased, with decreasing size and increasing weight fraction of the particles. The hardness and tensile strength of the forged composites were higher than those of the cast samples.     

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.     

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.     

Preparation of B<Subscript>4</Subscript>C-ZrB<Subscript>2</Subscript>-SiC eutectic ceramics by arc melting method

The B₄C-ZrB₂-SiC ternary composites with super hard and high toughness were obtained by arc melting in argon atmosphere. Microstructures were observed by SEM, and phase compositions were analyzed by XRD. The hardness and fracture toughness of ternary composites are 28 GPa and 4.5 MPa·m^1/2. The eutectic mole composition is 0.39B₄C-0.25ZrB₂-0.36SiC, and the eutectic lamellar microstructure is composed of B₄C matrix with the lamellar ZrB₂ and SiC grains.     

Microstructure evolution and mechanical properties of Al<Subscript>2</Subscript>O<Subscript>3sf</Subscript>/AZ91D magnesium matrix composites fabricated by squeeze casting

The squeeze casting process was used to fabricate Al₂O_3sf/AZ91D magnesium matrix composites before thixoforging. The microstructural evolution process in Al₂O_3sf/AZ91D was investigated during partial remelting. Tensile mechanical properties of thixoforged automotive component were determined and compared with those of squeeze casting formed composites. The results show that the microstructural evolution during partial remelting exhibited four stages: the formation of liquid, structural fragmentation, the spheroidization of solid particles, and final coarsening. As the holding time increases, the size of solid particles decreases initially and then increases. However, the size of solid particles decreases monotonously as the temperature increases. Increasing holding time or temperature promotes the degree of spheroidization. It is also shown that the cylindrical feedstock of the Al₂O_3sf/AZ91D composites can be thixoforged in one step into intricate shapes in the semi-solid state. The tensile tests indicate that the yield strength and ultimate tensile strength for Al₂O_3sf/AZ91D thixoforged from starting material fabricated by squeeze casting and partial remelting are better than those of Al₂O_3sf/AZ91D fabricated by squeeze casting. This research confirms that thixoforging is a practical method for the near net shape forming of magnesium matrix composites.     

Mechanical properties and thermal stability of ZnAl<Subscript>2</Subscript>O<Subscript>4</Subscript>-coated aluminum borate whiskers reinforced 2024Al composite

ZnAl₂O₄-coated aluminum borate whiskers reinforced 2024Al composite was fabricated by squeeze casting. Interfacial microstructures and tensile properties of the composite were investigated. The results show that ZnAl₂O₄ coating of the whiskers can improve the wettability of the whiskers by molten aluminum during squeeze casting, resulting in the increase of tensile properties of the composite. During thermal exposure, ZnAl₂O₄ at the interface can effectively hinder harmful interfacial reactions, resulting in the improvement of thermal stability of the composite at high temperatures. Fracture mechanisms of the composite in as-cast and after thermal exposure were also investigated.