Fabrication and machining of ceramic composites — A review on current scenario

Ceramic matrix composites (CMCs) are the best-suited material for various engineering application due to their superior properties. The different processing methods involved in the fabrication and machining of these CMCs are a center for attraction to researchers and industrial society. This review article primarily focuses on the development of different processing methods and machining methods for ceramic matrix composites since the last few years. Out of these fabrication methods, powder metallurgy emerged as a most promising and cost-effective technique. In addition, electric discharge machining (EDM) has proved to be time saving, cost effective, and capable of machining complex shapes in composites. At the end, challenges in the processing and machining of ceramic matrix composites have been identified from the literature, and further benefits of microwave sintering and electric discharge machining of materials have been addressed in the paper.     

The effect of processing parameters on the properties of γ-alumina washcoats deposited on ceramic honeycombs

The coating of cordierite honeycomb specimens with -alumina slurries for the preparation of washcoats for automotive applications was investigated. The dependence of slurry viscosity on factors such as the solids content, the pH and the particle size distribution of the powder used, was determined. Slurry viscosity was correlated to the loading percentage achieved, as well as to the quality of the washcoat in terms of homogeneity and reproducibility. It was found than an adequate solids content in the slurry is necessary for the achievement of satisfactory loading per impregnation. When, though, the particle size of the powder employed is of colloidal dimensions, high solids content leads to extremely high viscosity values. Adjustment of the slurry viscosity is therefore necessary and this was achieved with the use of either HCl or ammonium poly-methacrylate, an organic polyelectrolyte. Optimum loading conditions were achieved when the slurry viscosity lied between 50–150 mPa·s. For a specific solids content, the organic polyelectrolyte led to lower viscosity slurries and resulted in better reproducibility of the loading percentage. With the use of ammonium poly-methacrylate, slurries of fine particles, up to 40 wt% solids content could be handled, resulting in reproducible loading percentages of the order of 15 wt%     

Effect of glass–ceramic microstructure on its in vitro bioactivity

Two routes were used to obtain a glass–ceramic composed of 43.5 wt % SiO₂ – 43.5 wt % CaO – 13 wt % ZrO₂. Heat treatment of a glass monolith produced a glass–ceramic (WZ1) containing wollastonite-2M and tetragonal zirconia as crystalline phases. The WZ1 did not display bioactivity in vitro. Ceramizing the glass via powder technology routes formed a bioactive glass–ceramic (WZ2). The two glass–ceramics, WZ1 and WZ2, were composed of the same crystalline phases, but differed in microstructure. The in vitro studies carried out on WZ2 showed the formation of an apatite-like layer on its surface during exposure to a simulated body fluid. This paper examined the influence of both chemical and morphological factors on the in vitro bioactivitity. The interfacial reaction product was examined by scanning and transmission electron microscopy. Both instruments were fitted with energy-dispersive X-ray analyzers. Measurements of the pH made directly at the interface of the two glass–ceramics were important in understanding their different behavior during exposure to the same physiological environment.     

Effect of nano-metal particles on the fracture toughness of metal–ceramic composite

A theoretical model is proposed to study the influence of nano-metal particles (NMPs) on the fracture toughness of metal–ceramic composites (MCC). In the framework of the model, the crack tip intersects the grain boundary of the NMPs. Stress concentration at crack tip initiates edge dislocations which makes a shielding effect on the crack and leads to fracture toughness of the MCC. The dependence of critical crack intensity factors on grain size of the NMPs was calculated. The calculation suggested that the existence of the NMPs lead to an increase of critical crack intensity factors by 14%.     

Effect of tool wear on microrods fabrication using reverse μEDM

Arrayed microrods are used to drill array of microholes in workpieces by Micro electrical discharge machining (μEDM). In comparison to a single microrod, the use of an array of microrods enables drilling of multiple microholes in lesser time, and hence it offers a higher productivity. The present work focuses on the effect of tool wear on the dimensions of the machined array of microrods through reverse micro electrical discharge machining (R-μEDM). The effects of the input parameters such as voltage, capacitance and feed rate on the obtained length and diameter of the microrods have been investigated. This study introduces a simple analytical model to evaluate the amount of tool wear and material removal from a bulk rod. As the levels of voltage and capacitance increase from lower to higher, the tool wear increases by 574%. At lower levels of voltage and capacitance, a straight array of microrods with a longer length of about 1.961?mm is obtained. On the other hand, at higher levels of voltage and capacitance, the obtained microrods are found to have a shorter length of 1.725?mm but with taper. Scanning electron microscope (SEM) and optical microscope images are also analyzed for describing the effects of tool wear on the shape and size of the fabricated microrods.     

Effect of notches on creep–fatigue behavior of a P/M nickel-based superalloy

A study was performed to determine and model the effect of high temperature dwells on notch low cycle fatigue (NLCF) and notch stress rupture behavior of a fine grain LSHR powder metallurgy (P/M) nickel-based superalloy. It was shown that a 90 second (s) dwell applied at the minimum stress (“min dwell”) was considerably more detrimental to the NLCF lives than similar dwell applied at the maximum stress (“max dwell”). The short min dwell NLCF lives were shown to be caused by growth of small oxide blisters which caused preferential cracking when coupled with high concentrated notch root stresses. The cyclic max dwell notch tests failed mostly by creep accumulation, not by fatigue, with the crack origin shifting internally to a substantial distance away from the notch root. The classical von Mises plastic flow model was unable to match the experimental results while the hydrostatic stress profile generated using the Drucker–Prager plasticity flow model was consistent with the experimental findings. The max dwell NLCF and notch stress rupture tests exhibited substantial creep notch strengthening. The triaxial Bridgman effective stress parameter was able to account, with some limitations, for the notch strengthening by collapsing the notch and uniform gage geometry test data into a singular grouping.     

Machinability analysis in drilling woven GFR/epoxy composites: Part I – Effect of machining parameters

The present paper deals with the effect of machining parameters (feed, speed and drill diameter) on the thrust force and machinability of woven glass fiber-reinforced epoxy (GFRE) composites. The selected machinability parameters were delamination size, surface roughness, and bearing strength. The results show that, delamination-free in drilling GFRE composites was not observed, in the range of the investigated cutting parameters. Surface roughness instrument can be used as an indication for the position of the internal delamination damage in drilling GFRE composites. The high values of correlation coefficients between thrust force and the machinability parameters confirm the importance of reducing the thrust force to improve the load carrying capacity of composite structure assembled by rivets or bolted joints.     

Effect of extrusion parameters on properties of rapidly solidified Al–Mg powder alloys

Abstract

Three rapidly solidified Al–Mg powder alloys have been consolidated by means of cold compaction followed by hot extrusion. The extrusion conditions of temperature, reduction ratio, and ram speed were varied, and it was observed that the mechanical properties of the extrudates were strongly process related. Relationships between properties and the temperature compensated strain rates during extrusion have been established. These alloys have strength/density properties superior to the strongest conventional ingot cast alloys. Good fracture toughness has been recorded in the Al–7 Mg alloy and all three alloys possess good resistance to stress corrosion cracking.

MST/498     

Experimental investigations of ceramic machining using µ-grinding and µ-rotary ultrasonic machining processes: A comparative study

Comparative experimental investigations of µ-grinding and µ-rotary ultrasonic machining (µ-RUM) were made on borosilicate and Zerodur materials to know the efficacy of the processes for micro electro mechanical system (MEMS) application. The electroplated diamond tool of Ø 300 µm for drilling operation and Ø 300 µm to Ø 6 mm for milling operation has been tried in the computer numerical control (CNC) machine with an HSK63 ultrasonic actuator. A suitable interface has been developed to hold the micro tool with the ER11 taper in the existing ER20 collet ultrasonic tool holder. Cutting force, edge-chipping area, and taper in drilling operation; and surface finish, material removal mode, specific energy and un-deformed chip thickness in milling operation were evaluated for both processes under the same material removal rate conditions. The experimental results showed that µ-RUM could perform in a less spindle speed machine as compared to µ-grinding. It was inferred that the maximum and minimum amount of reduction in cutting force, edge chipping, and taper were found to be (49.3%, 10.8%), (87%, 40%), and (95.56%, 4.76%), respectively, in µ-RUM compared to µ-grinding for drilling operation. It was also concluded that surface finish and ductile mode of fracture were higher in µ-RUM compared to µ-grinding for the milling operations. These effects were more pronounced as tool size decreased.     

Effect of an external electrostatic field on ultrasonic machining of a dielectric material—an experimental study

The paper deals with the experimental study of the effect of an applied electrostatic field on ultrasonic machining of glass. Cylindrical cavities are machined in glass specimens (? 1-3 mm thick), both without and in the presence of a field. It is found that the time required for a 0-38 mm deep cut is reduced by about 10-20% due to the presence of a field. Further, the tool penetration rate is found to increase with the penetration of the tool into the workpiece. Using the analysis of variance technique, the observed data are analysed to show that the change in the rate of machining in the two cases is not due to chance but due to the presence of the field.     

Effect of γ′ size on room temperature low cycle fatigue behaviour of a nickel base superalloy

Abstract

The results of a study on the effect of γ′ particle size on the room temperature (23°C) low cycle fatigue (LCF) behaviour of a Ni base superalloy, Nimonic 90, is reported. The γ′ particle sizes were estimated from transmission electron micrographs. Ranges of particle sizes corresponding to underaged, peak aged, and overaged conditions were identified by examining the age hardening response curve. The solutionised samples had longer LCF lives compared with the aged alloys. Coffin-Manson and cyclic stress–strain plots showed bilinearity at a plastic strain amplitude of around 0.4% in the solutionised, underaged, and peak aged conditions. The observed bilinearity could be attributed to a change in the deformation mode from single slip to multiple slip. The cyclic stress response showed relatively stable behaviour for the peak aged and the overaged specimens compared with the underaged and the solution treated specimens.     

Effect of microstructure and γ′ precipitate from undercooled DD3 superalloy on mechanical properties

The mechanical properties of DD3 superalloy solidified at various undercoolings were measured to investigate the effects of precipitate and microstructure on alloy properties. The influence of melt undercooling on the precipitation is also studied. It is found that not only the size of particle, but its distribution in the as-solidified structure is also drastically controlled by the melt undercooling. The analysis indicates that alloy solidified at a low undercooling is brittle, thus leading to a lower toughness and tensile strength. With increasing undercooling, the toughness and strength of the alloy increased accordingly, which may be attributed to the strengthening effect of precipitate and the reduced micro-segregation.     

Effect of processing parameters on textural and bioactive properties of sol–gel-derived borate glasses

A compositional range of recently developed bioactive sol–gel-derived borate glasses (SGBGs) have demonstrated remarkably rapid rates of conversion to hydroxy-carbonated apatite (HCA) in simulated body fluid (SBF). Although the composition of SGBGs did not greatly impact HCA conversion rates, it is still unknown how the sol–gel processing parameters affect the textural properties and thus bioactivity of the glass. In this study, a borate-substituted Bioglass^® “45S5” formulation [(46.1)B₂O₃-(26.9)CaO-(24.4)Na₂O-(2.6)P₂O₅; mol%] was fabricated using different sol–gel processing parameters including precursor materials, ageing time and temperature, along with calcination rate and temperature. It was found that a higher calcination temperature led to a partially crystallized glass with almost a magnitude decrease in specific surface area relative to the other glasses. All processing routes resulted in highly bioactive glasses according to Fourier transform infrared spectroscopy, X-ray diffraction, and scanning electron microscopy, which confirmed HCA formation in SBF in as little as 2 h. The majority of ion-exchange occurred within 30 min, facilitating this rapid conversion to bone-like HCA. Interestingly, the partially crystallized glasses (i.e., glass–ceramics) also underwent full conversion to HCA in SBF. Furthermore, ageing time and temperature did not affect the bioactive properties of these glasses, which allow for significantly reduced processing times. In summary, this study demonstrates that SGBGs can be tailored for targeted tissue engineering applications by varying the sol–gel processing parameters.     

Effect of welding parameters on diffusion bonding of type 304 stainless steel–copper bimetal

Abstract

Stainless steel AISI type 304 and electrolytic cold rolled copper were joined by diffusion bonding at temperatures ranging from 650 to 950°C, for times from 5 to 45 min, and at pressures from 2 to 12 MPa. After bonding the microstructure of the interface was investigated, including the grain size, and shear and tensile strengths of the bonded specimens were determined. From the results, it was seen that the bond shear strength was dependent on interface grain boundary migration and on grain growth during the bonding process. In addition, attempts were made to find a relationship between grain size and shear strength in the bonding area. Taking into account the results of shear testing and microstructural observation, for a sound bond, optimum bonding conditions were obtained at temperatures of 800–850°C for 15–20 min at 4–6.5 MPa. The fracture behaviour of the diffusion bonded joint was investigated by means of shear and tensile testing under different bonding conditions. It was found that both shear and tensile strengths of the bonds were sensitive to the bonding conditions, and the intermetallic phases did not affect these parameters. Furthermore, the value of shear strength of the bond surface determined by shear testing was higher than the shear strength of the fracture surface determined by tensile testing.     

Effect of cooling rate on the morphology of γ′ precipitates in a nickel-base superalloy under directional solidification

The morphological evolution of γ′ precipitates in a nickel-based superalloy K5 was studied by zone melting directional solidification under vacuum conditions. The results show that at the lower cooling rate of 12.42 K s⁻¹, γ′ precipitates remand big cuboids. γ′ particles become smaller at the cooling rate ranges from 12.42 to 38.80 K s⁻¹. For a rather fast cooling rate of 50.16 K s⁻¹, γ′ particles retain a spherical shape. The experiments show that big cuboids will become unstable and split into several small ones at the lower cooling rate of 1.1 K s⁻¹. The mechanism of the evolution of the γ′ morphologies is also analyzed by introducing a new parameter-shape factor which classifies the total energy into several energy levels. Based on this, the effect of the cooling rate on the γ′ morphology is discussed.     

Effect of elastic interaction energy on coarsening of γ′ precipitates in a mechanically alloyed ODS Ni-base superalloy

The coarsening behavior of precipitates with a uniform size distribution and with a bimodal size distribution in a mechanically alloyed ODS Ni-base superalloy were investigated to clarify the effect of elastic interaction energy on the coarsening behavior of precipitates. The coarsening rate decreased with increasing size of precipitates with a uniform size distribution, contrary to the classical LSW theory, and the coarsening behavior of precipitates with a bimodal size distribution exhibited Ostwald ripening in which the larger precipitates grow at the expense of smaller precipitates. The driving force for coarsening of precipitates was analyzed based on the two-particle model, considering the effect of elastic interaction energy in addition to the effect of interfacial energy. The contribution of elastic interaction energy on the total energy was found to increase with increasing size of precipitates, and the decelerated coarsening of precipitates was attributed to the decrease in the driving force for coarsening with increasing size of precipitates.     

Effect of Carbon on DA718 Alloy with P Addition

Lower content of carbon can further improve the stress rupture life of p-modified DA 718 alloy up to more than 270%.Meanwhile, the ductility of the alloy decreased a little. More boron atoms dissociate due to decreasing carbon content and interact with phosphorus which brings the longer stress rupture life of the alloy. Less carbon may induce more phosphorus segregating in the grain boundary and result in brittleness.     

Effect of processing parameters on the microstructure and mechanical properties of Al–steel composite foam

Al–steel composite foams comprise of steel hollow spheres embedded in an aluminum matrix and are processed using a gravity casting technique. The effect of processing parameters such as casting temperature and cooling rate on the microstructure and mechanical behavior was studied to establish structure–property relationships. Results show that the amount and composition of intermetallic phases present in the foam microstructure is directly related to casting temperature and cooling rate. Highest strength and energy absorption were obtained from Al–steel foams with fast solidification rates that minimize the growth of intermetallic phases.     

Effect of fabrication parameters on the microstructural quality of fibre–foil titanium metal matrix composites

The microstructure of fibre–foil Ti–6Al–4V (composition in weight per cent) and IMI 834 matrix metal matrix composites (MMCs), and corresponding foil-bonded alloys, are investigated in relation to fabrication parameters. Higher fabrication temperatures are required in IMI 834 MMCs, which results in a thicker interfacial reaction layer than in Ti–6Al–4V MMCs. The matrix microstructure in all materials is predominantly with intergranular , as a result of the slow cooling rate. MMCs reinforced with SM1240 fibres exhibit boron precipitates along foil bond lines, owing to diffusion during consolidation. Fabrication using fibre mats with 7.1 fibres per millimeter (FPM) results in an excellent microstructure in (Ti–6Al–4V)–SM1240. The larger diameter of the SM1140+fibre compared with SM1240 means that (Ti–6Al–4V)–SM1140+requires FPM significantly below 7.1 in order to produce acceptable microstructural quality. The higher residual stresses in IMI 834 MMCs result in cracking of the matrix and fibre–matrix interfacial region when a FPM of 7.1 is used. Acceptable microstructural quality is observed in IMI 834 MMCs when the FPM of fibre mats is reduced to 6.3. Interfibre cracking in IMI 834–SM1140+is enhanced by a higher matrix microhardness than the other materials. This high hardness may be caused by a high matrix carbon content.     

Effect of magnesium content on thermal and structural parameters of Al–Mg alloys directionally solidified

In this study, the influence of magnesium content on thermal and structural parameters during the unsteady-state unidirectional solidification of Al–Mg alloys is analyzed. Using a special device, Al–Mg alloys containing 5, 10, and 15 wt% Mg were submitted to unidirectional solidification. Using a data acquisition system, the temperature variations along the casting during solidification were measured. From these results, the variations of solidification parameters as growth rate of dendrite tips, thermal gradient, cooling rate, and local solidification time were determined. The variation of global heat transfer coefficient at metal/mould interface was estimated through the adjustment of experimental temperature variation close to the interface and numerical predictions. Primary and secondary dendrite arms spacing variations during solidification were measured by optical microscopy. From these results, comparative analysis were developed to determine the influence of magnesium content.