Wetting behaviour and interfacial microstructure of Sn–Ag–Zn solder alloys on nickel coated aluminium substrates

Abstract

Wetting behaviours of two lead free solders (Sn–2·625Ag–2·25Zn and Sn–1·75Ag–4·5Zn) on nickel coated aluminium substrates were investigated. Sn–2·625Ag–2·25Zn exhibited better wettability compared to Sn–1·75Ag–4·5Zn solder. Contact angles of the solders increased with increasing roughness of the substrate. The Young–Dupre equation was used to evaluate the work of adhesion of solder on the substrate. Sn–2·625Ag–2·25Zn solder exhibited higher work of adhesion than Sn–1·75Ag–4·5Zn. A thin continuous layer of Ni₃Sn was detected at the interface between Sn–2·625Ag–2·25Zn solder and nickel coated Al substrate. Sn–1·75Ag–4·5Zn solder exhibited scallop intermetallic compounds (IMCs) growing into the solder field as well as a thin continuous IMC in some cases. Ni₃Sn and Ni₃Sn₄ IMCs were observed at the interface of Sn–1·75Ag–4·5Zn solder and nickel coated Al.     

Wetting and interfacial behavior of Fe-based self-fluxing alloy–refractory compound systems

In this study the wettability and interfacial behaviour of the TiC–FeNiCrBSiC and TiB₂–FeNiCrBSiC systems were investigated. The wetting experiments were performed by the sessile drop method at 1150°C under a vacuum. The contact angles of TiC and TiB₂ wetting by melted Fe-based self-fluxing alloy were 51° and 36°, respectively. Thermodynamic calculations were carried out to understand the metal–ceramic interaction mechanism in the TiC–FeNiCrBSiC and TiB₂–FeNiCrBSiC systems. The structure of the interface region in the TiB₂–FeNiCrBSiC system was characterized by the optical microscopy and SEM-EDS analysis. The formation of Fe, Ni, Cr and Mo complex borides was revealed within the interface region of the TiB₂–FeNiCrBSiC system.     

Wetting and interfacial behavior of Ni–Si alloy on different substrates

Wetting of molten Ni–56 at.% Si alloy on different substrates (SiC ceramic, Ni- and Co-based superalloys, Kovar, and Mo) are performed under different experimental conditions by the sessile drop technique. Temperature, atmosphere, and substrate composition play the key roles in determining the wettability, the spreading characteristics, and the interfacial morphology of the final interfaces. The non-reactive wetting characteristics in Ni–Si/SiC system are confirmed, with a spreading rate increasing with temperature increasing. In the Ni–Si/metal systems the spreading process is determined by the competition between spreading along the substrate surface and the interfacial interactions. Excellent wettability and fast spreading are found in the Ni–Si/Co-based superalloy, Ni–Si/Kovar, and Ni–Si/Mo systems at both the temperatures (1100 and 1200 °C). These results can be used as a reference guide for joining SiC to these metallic components, or to itself, using the Ni–Si alloy as filler metal.     

Dilatometric behavior and microstructure of sintered Fe–NbC and Fe–TaC composites

Fe-reinforced composites were manufactured by the addition of 10–20 wt.% NbC or TaC particles aiming at improved mechanical and wear behavior. Two varieties of Fe powders from Hoeganaes Corp. were used, Ancorsteel 1000B and 45P. Composites produced using the former variety included a small amount of Fe₃P to induce liquid-phase sintering whereas 45P powder was pre-alloyed with P by the manufacturer. The hardness of the matrix was adjusted adding carbon to the composite mixture. The powders were milled for different times and annealed prior to pressing. A dilatometric study was carried out under hydrogen to establish optimum sintering profiles. Relative densities up to 97% TD were achieved. Both microstructure and density of the sintered pellets were evaluated in order to establish correlations involving composition, processing parameters and microstructure of the composite.     

Effects of high-temperature annealing on the microstructure and properties of C/SiC–ZrB2 composites

C/SiC–ZrB₂ composites prepared via precursor infiltration and pyrolysis (PIP) were treated at high temperatures ranging from 1200 °C to 1800 °C. The mass loss rate of the composites increased with increasing annealing temperature and the flexural properties of the composites increased initially and then decreased reversely. Out of the four samples, the flexural strength and the modulus of the specimen treated at 1400 °C are maximal at 216.9 MPa and 35.5 GPa, suggesting the optimal annealing temperature for mechanical properties is 1400 °C. The fiber microstructure evolution during high-temperature annealing would not cause the decrease of fiber strength, and moderate annealing temperature enhanced the thermal stress whereas weakened the interface bonding, thus boosting the mechanical properties. However, once the annealing temperature exceeded 1600 °C, element diffusion and carbothermal reduction between ZrO₂ impurity and carbon fibers led to fiber erosion and a strong interface, jeopardizing the mechanical properties of the composites. The mass loss rate and linear recession rate of composites treated at 1800 °C are merely 0.0141 g/s and 0.0161 mm/s, respectively.     

Wear behavior–hardness–microstructure relation of Fe–Cr–C and Fe–Cr–C–B based hardfacing alloys

The aim of this study is the investigation of the effect of ferroboron and the amount of powder mixture (ferroboron + ferrochromium) on wear resistance of Iron (Fe)–Chromium (Cr)–Carbon (C) based hardfacing alloys. Powder mixture, consisting of ferrochromium (FeCr) and ferroboron (FeB), was added to massive wire during welding process. Hardfaced layers were obtained by three different powder mixtures and two different powder/massive wire proportions. Hardfacing was applied to AISI 1020 steel substrate by open arc welding. Hardness test, Scanning Electron Microscope (SEM) and X-Ray Diffraction (XRD) analysis, dry sand/rubber wheel abrasion test were executed. Test results showed that increasing ferroboron content and increasing powder mixture amount enhanced the wear resistance.     

Effect of heat treatment on microstructure and wear behavior of Al–Si alloys with various iron contents

Effect of T6 heat treatment on microstructure and wear behavior of hypoeutectic Al–Si alloys with iron contents of 0.15, 0.7 and 1.2 wt% was studied. Dry sliding wear tests were performed on a pin-on-disk tribometer under normal loads of 20, 30 and 40 N. The alloy with 0.7 wt% iron showed the highest wear resistance before the heat treatment under the loads tested. T6 heat treatment improved the wear resistance of the alloys with different iron contents compared to the non-heat treated 0.7 wt% iron alloy under all applied loads. The improvements in the wear can be attributed to the decrease of length and volume fraction of hard and brittle β-Al₅FeSi iron-rich intermetallics and spherodization of the coarse eutectic silicon particles by diffusion of iron and silicon into the matrix upon solution heat treatment. The change in the morphology of the phase particles reduced the probability of nucleation and propagation of subsurface cracks and increased the wear resistance in the samples.     

Wetting and spreading of Ni–P brazes: effects of workpiece and braze composition

Abstract

The wetting behaviour of Ni–P braze alloys has been examined. In addition to detailed examinations of samples carried out after the wetting tests, real time observations of the wetting process have been made using a heating stage fitted to a light microscope. The work has concentrated on the Ni–11P (wt-%) eutectic braze alloy using laboratory produced Fe–Cr and Fe–Cr–Ni workpieces as well as commercial martensitic and austenitic steels and some nickel based alloys. The chromium content of the workpieces was found to dominate the spreading behaviour of the brazes. This is thought to be due to dissolution of the workpiece material and consequential dilution and complexing of phosphorus to increase the braze melting point. However, the behaviour of two commercial workpieces, Fecralloy and Hastelloy N, was anomalous.

MST/1177     

Wetting of Cu by Bi–Ag based alloys with Sn and Zn additions

Contact angles on copper substrate of Bi–Ag–Sn and Bi–Ag–Zn ternary alloys containing 3, 6, and 9 at.% of Sn and Zn, respectively, were studied with the sessile drop method. Wetting tests were carried out at 573 and 603 K with or without the use of a flux. Without the flux, the examined alloys do not wet copper, i.e., the observed contact angles are higher than 90°. However, in the presence of the flux wetting of copper is observed. In the case of alloys with Sn, the contact angles decrease with increasing content of Sn, while in the case of alloys with Zn no such tendency is observed. Solidified solder–substrate couples were cross-sectioned and examined with scanning electron microscopy coupled with electron dispersive X-ray analysis.     

Microstructural evolution of brazing Ti–6Al–4V and TZM using silver-based braze alloy

Microstructural evolution of the brazed Ti–6Al–4V and TZM joint using 95Ag–5Al braze alloy was studied. The Ti–6Al–4V substrate is well wetted by the molten braze at 900 °C. However, the TZM substrate cannot be wetted by the molten braze, even if the brazing temperature is increased to 950 °C. The brazed joint is comprised of the Ag-rich phase alloyed with Al and Ti. There is almost no interfacial reaction between the molten braze and TZM. On the other hand, the Ti–6Al–4V substrate reacts with the molten braze and formed TiAl interfacial layer. The growth of TiAl reaction layer can be significantly inhibited by the application of infrared brazing.     

Evaluation of properties and microstructure of non-heat treatable Al–Mg–Li–C–O alloys with variable Li concentration

Abstract

Fine grained Al–Mg–Li–C alloys, with lithium concentrations from 0.7 to 1.5 wt-%, have been produced by a mechanical alloying–powder metallurgy route. An initial range of compositions was chosen for manufacture into 10 kg billets which were uniaxially forged into plate; subsequently two compositions, alloy A (Al–3.7Mg–0.7Li–1.0C (wt-%) and alloy B (Al–4.4Mg–1.4Li–1.0C), were down-selected for a 20 kg scale-up exercise. Billets were forged at 300°C, using an 8:1 reduction ratio, which provided a sufficient level of work to develop properties, while avoiding excessive grain growth. Alloy B exhibited tensile properties (0.2% proof stress 450 MPa; ultimate tensile strength 510 MPa; strain to failure 6%) that exceeded the AECMA specification for AA 5091. Both alloys were confirmed as non-heat treatable and therefore exploitable in the as forged T1 condition. Microstructural analysis has confirmed that a fine grain size (<1 µm) and nanoscale Al₂O₃/Al₄C₃ and MgO dispersoids provided significant Hall–Petch and Orowan strengthening, respectively, capable of increasing the 0.2% proof stress to 450 MPa. Although optimisation of thermomechanical practice is still required, these Al–Mg–Li–C alloys show considerable potential for aerospace, land, and space applications.     

Effects of Zn on microstructure,mechanical properties and corrosion behavior of Mg–Zn alloys

In this study, binary Mg–Zn alloys were fabricated with high-purity raw materials and by a clean melting process. The effects of Zn on the microstructure, mechanical property and corrosion behavior of the as-cast Mg–Zn alloys were studied using direct observations, tensile testing, immersion tests and electrochemical evaluations. Results indicate that the microstructure of Mg–Zn alloys typically consists of primary α-Mg matrix and MgZn intermetallic phase mainly distributed along grain boundary. The improvement in mechanical performances for Mg–Zn alloys with Zn content until 5% of weight is corresponding to fine grain strengthening, solid solution strengthening and second phase strengthening. Polarization test has shown the beneficial effect of Zn element on the formation of a protective film on the surface of alloys. Mg–5Zn alloy exhibits the best anti-corrosion property. However, further increase of Zn content until 7% of weight deteriorates the corrosion rate which is driven by galvanic couple effect.     

Ablation behavior and mechanism of SiC/Zr–Si–C multilayer coating for PIP-C/SiC composites under oxyacetylene torch flame

To improve the ablation resistance of PIP-C/SiC composites, SiC/Zr–Si–C multilayer coating was prepared by chemical vapor deposition (CVD) using methyltrichlorosilane (MTS) and hydrogen as the precursors and molten salt reaction using KCl–NaCl, sponge Zr and K₂ZrF₆, then the ablation capability of the coated composites was tested under oxyacetylene torch flame. The linear and mass ablation rates were much lower than those of uncoated samples. The linear and mass ablation rates of the three coating coated samples reached 0.0452 mm/s and 0.031 g/s, decreased by 27.3% and 27.1%, respectively. Moreover, the linear and mass ablation rates of the five coating coated samples reached 0.0255 mm/s and 0.0274 g/s, decreased by 59.0% and 35.5%. The gases released during ablation could take away a lot of heat, which was also helpful to the protection of the composites.     

Effect of C/C preform density on microstructure and mechanical properties of C/C–SiC composites prepared by alloyed reactive melt infiltration

Abstract

Low cost C/C–SiC composites were prepared by alloyed reactive melt infiltration. Effects of the density of C/C preforms on mechanical properties and microstructure of the C/C–SiC composites are reviewed. The results show that with increasing the density of C/C preforms, the flexural strength of the resulting composites increases, while the density of the composites decreases. The flexural strength can reach 341 MPa for the composite produced from the C/C preform of 1·3 g cm^?3. The phases in the composites produced from low density C/C preforms are Si, SiC, ZrSi₂ and carbon, while no Si phase is found in the composites with high density C/C preforms. Furthermore, the mechanism of the microstructure evolution of the C/C–SiC composites is proposed.     

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.     

Effect of silicon content on the microstructure and properties of Fe–Cr–C hardfacing alloys

In this study, the surface of St52 steel was alloyed with preplaced powders 55Fe39Cr6C, 49Fe39Cr6C6Si, and 45Fe39Cr6C10Si using a tungsten-inert gas as the heat source. Following surface alloying, conventional characterization techniques, such as optical microscopy, scanning electron microscopy, and X-ray diffraction were employed to study the microstructure of the alloyed surface. Microhardness measurements were performed across the alloyed zone. Room-temperature dry sliding wear tests were used to compare the coatings in terms of their tribological behavior. It was found that the as-deposited coatings contained higher volume fractions of carbides (Cr₇C₃). The presence of 6%Si in the preplaced powders caused an increase in microhardness and wear resistance.     

Influence of notch radius and microstructure on the fracture behavior of Al–Zn–Mg–Cu alloys of different purity

The influence of notch radius on the fracture behavior of two high-strength Al–Zn–Mg–Cu alloys with different Fe content in the T73 condition was investigated. The fracture toughness tests were performed on non-fatigue-precracked notched bending specimens with different notch radii ranged from 0.15 mm to 1.0 mm. The obtained data were interpreted using the concept of Notch Fracture Mechanics combined with finite-element method (FEM) calculations. It was found that both alloys are very sensitive to the notch radius. The fracture toughness increases with increasing notch radius. For a given notch radii, the increase in fracture toughness is more significant for the more pure alloy. The fracture behavior of investigated alloys with respect to microstructural features and their relation with the fracture micromechanisms were analyzed.     

Processing,microstructure, and properties of Mg–SiC composites synthesised using fluxless casting process

Abstract

In the present study, elemental magnesium and magnesium–silicon carbide composites were synthesised using the methodology of fluxless casting followed by hot extrusion. Microstructural characterisation studies revealed low porosity and a completely recrystallised matrix in every material. The average size of the recrystallised grains was found to decrease with an increasing presence of SiC particulates. For the reinforced magnesium, fairly uniform distribution of SiC particulates and good SiC–Mg interfacial integrity was realised. The results of X-ray diffraction studies indicated the absence of oxide phases and no evidence of interfacial reaction products except in the case of Mg–26.0 wt-%SiC sample. Results of physical and mechanical properties characterisation revealed that an increase in the amount of SiC particulates incorporated leads to an increase in macrohardness and elastic modulus, which does not affect the 0.2% yield strength and reduces the ultimate tensile strength, ductility, and coefficient of thermal expansion. The weight percentage of SiC particulates when plotted against hardness and 0.2% yield strength revealed a linear correlationship. An attempt is made to investigate the effect of increasing amount of SiC particulates on the microstructural features, and physical and mechanical properties of the magnesium matrix.     

Machining behavior of AA6351–SiC–B4C hybrid composites fabricated by stir casting method

ABSTRACT

This study presents an effective approach to assess the machinability of 6351 aluminum alloy matrix, reinforced with 5 wt.% silicon carbide (SiC) and (0, 5, and 10 wt.%) boron carbide (B₄C) particles. The turning tests are carried out with a polycrystalline diamond (PCD) tool to identify the effect of the B₄C particles addition to the composite, with an objective to improve the material removal rate (MRR) and to reduce the surface roughness (Ra) and power consumption (P). The significant level of each factor, which contributes to affect the output response, is found through analysis of variance (ANOVA). The results show that the inclusion of B₄C particles in the hybrid composite significantly affects the machinability, with a contribution to the surface roughness by 7.87% and P by 6.36%. The increase in MRR affects the quality of the material, irrespective of the composites.     

Effect of carbon content on microstructure and corrosion behavior of hypereutectic Fe–Cr–C claddings

The aim of this study was to examine the influence of carbon content on the microstructures and corrosion characteristics. The results showed that the hypereutectic microstructure comprised primary (Cr,Fe)₇C₃ carbides and the eutectic colonies [γ-Fe + (Cr,Fe)₇C₃]. The amounts of primary (Cr,Fe)₇C₃ carbides increased from 33.81 to 86.14% when carbon content increased from 3.73 to 4.85 wt%. The corrosion resistance of the hypereutectic alloy with 4.85 wt% C was about 20 times higher than that with 3.73 wt% C. The galvanic corrosion occurred in all claddings due to difference of corrosion potential between primary carbide and austenite. The dense distribution of primary carbides could retard the austenitic matrix from selective corrosion. The austenite dissolved the Fe²⁺ ions and formed a Cr₂O₃ film under 3.5% NaCl aqueous solution.