Effect of carbon-fibre powder on friction and wear properties of copper-matrix composites

ABSTRACT

The copper-matrix composite contains carbon-fibre powder which is prepared using a powder metallurgy sintering process in an effort to examine the effects of 50-mesh (270?μm) carbon-fibre powder on the microstructure and, friction and wear properties of copper matrix composites at high speed. When carbon-fibre powder is added within a certain range, the friction coefficient of the composite material is increased and the amount of wear is greatly reduced, When the content of carbon-fibre powder is 0.2wt-%, the hardness, density, friction and wear properties of the copper-based composite material has the best combination.     

Microstructures and mechanical properties of ultrafine-grained Ti/AZ31 magnesium matrix composite prepared by powder metallurgy

The microstructure of ultrafine grain for magnesium alloys can result in drastic enhancement in their room temperature strength, but the issue of low strength at elevated temperature becomes more serious as well due to grain boundary slide. Here ultrafine-grained Ti/AZ31 magnesium matrix composites with high strength at both room and elevated temperature were prepared by vacuum hot pressing and subsequent hot extrusion. The microstructure of the composite samples before and after consolidation processing was characterized, and the mechanical properties of the as-consolidated bulk samples were measured at room and elevated temperatures. The results indicate that after extrusion ultrafine-grained magnesium alloys were obtained and Ti particulates with particulate size of ～310?nm disperse in Mg matrix. The magnesium grain of AZ31-15at.%Ti grows from 66?nm to 800?nm. Meanwhile, the relative densities of Ti/AZ31 composites are higher than 99%. The yield strength (YS) of extruded AZ31-15at.%Ti composite at room temperature is 341?MPa, being 2.4 times higher than original AZ31 alloy. Theoretical estimation shows that remarkably enhanced room-temperature mechanical strength attributes to grain boundary strengthening with the contribution ratio of 74%. In addition, the peak stress of extruded AZ31-15at.%Ti composite at 573?K is 82?MPa and ultrafine Ti dispersions are responsible for the enhanced strength.     

Recent advances in ferrous powder metallurgy

Ferrous Powder Metallurgy (P/M) has advanced significantly over the past thirty years in providing opportunity for a parts designer and producer to make high strength net shape parts. Currently, for example, transmission gears in U.S. built cars use P/M parts. This review addresses recent advances in the area of ferrous powder for the P/M industry. Development of molybdenum prealloyed powder for increased density, Cr-Mn containing powder for through hardenability and improved wear resistance, binder treated powders for higher control of alloying ingredients and increasing compaction rates are presented. Two major innovations, namely achievement of higher compaction densities through warm compaction and improved magnetic properties by dielectric coating on iron powders are presented.     

Study of the properties of low-cost powder metallurgy titanium alloys by 430 stainless steel addition

Titanium is a lightweight metal with an outstanding combination of properties which make it the material of choice for many different applications. Nonetheless, its employment at industrial level is not widespread due to higher production costs with respect to competitor metals like steel and aluminium. In this work the production of low-cost titanium alloys is attempted by combining the utilisation of a powder metallurgy process and cheap alloying elements (i.e. commercial 430 stainless steel powder optimised for the powder metallurgy industry). Low-cost titanium alloys are fabricated by blending elemental titanium with stainless steel. The behaviour of the powders as well as that of the sintered materials are analysed and compared to that of a master alloy addition Ti6Al4V alloy. The produced low-cost titanium alloys show comparable properties to both wrought and powder metallurgy titanium alloys and, therefore, they are proposed as an alternative to obtain structural component made out of titanium alloys.     

Al_2O_3颗粒镀铜对铜基粉末冶金摩擦材料Al_2O_3-Fe-Sn-C/Cu摩擦磨损性能的影响

通过对陶瓷摩擦组元的表面进行化学镀铜来改善铜基粉末冶金摩擦材料中陶瓷相与基体间的结合效果,从而提高材料摩擦磨损性能。分别采用镀铜Al2O3颗粒和未镀铜Al2O3颗粒与铜粉和铁粉等经混合、压制、加压烧结制备Al2O3-Fe-Sn-C/Cu摩擦磨损试样。测试并分析了摩擦材料的微观结构、力学性能及摩擦磨损性能。结果表明:摩擦组元镀铜可使硬质颗粒与铜基体结合紧密;摩擦材料的布氏硬度增加了12%,弹性模量提高了约7%,摩擦系数提高了5%~10%,线磨损量降低了20%~50%;表面镀铜后的Al2O3颗粒不易脱落,摩擦系数稳定性提高了13%~23%。研究结果表明,摩擦组元表面镀铜可提高材料的综合性能。     

Cu对粉末冶金Fe3Al基复合材料性能的影响

研究了Cu含量对粉末冶金Fe3Al基复合材料的烧结性能和力学性能的影响,分析了施加载荷和改变转速对加入不同量铜粉末冶金Fe3Al基复合材料的摩擦磨损性能的影响,并借助电子显微镜和能谱分析了不同铜含量Fe3Al基复合材料的磨损机理.结果表明:加入12%的Gu可使Fe3Al基复合材料具有良好的烧结性能和力学性能;载荷和转速对复合材料的磨损形式受铜的加入量的影响;铜的加入影响复合材料的磨损形式和磨损机理,当含铜量较少时,复合材料以磨粒磨损为主,随加入铜的量的增多,其磨损形式变为磨粒磨损和轻微的粘着磨损形式,加入大量铜时,则以粘着磨损为主.     

CBN grain wear and its effects on material removal during grinding of FGH96 powder metallurgy superalloy

Grinding with cubic boron nitride (CBN) superabrasive is a widely used method of machining superalloy in aerospace industries. However, there are some issues, such as poor grinding quality and severe tool wear, in grinding of powder metallurgy superalloy FGH96. In addition, abrasive wheel wear is the significant factor that hinders the further application of CBN abrasive wheels. In this case, the experiment of grinding FGH96 with single CBN abrasive grain using different parameters was carried out. The wear characteristics of CBN abrasive grain were analyzed by experiment and simulation. The material removal behavior affected by CBN abrasive wear was also studied by discussing the pile-up ratio during grinding process. It shows that morphological characteristics of CBN abrasive grain and grinding infeed direction affect the CBN abrasive wear seriously by simulation analysis. Attrition wear, micro break, and macro fracture had an important impact on material removal characteristics. Besides, compared with the single cutting edge, higher pile-up ratio was obtained by multiple cutting edges, which reduced the removal efficiency of the material. Therefore, weakening multiple cutting edge grinding on abrasive grains in the industrial production, such as applying suitable dressing strategy, is an available method to improve the grinding quality and efficiency. The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-022-00412-2     

HA晶须的制备及在HA/Mg生物复合材料中的应用

利用水热法合成羟基磷灰石晶须(HA_W), 采用浆料-粉末冶金法制备羟基磷灰石晶须/镁金属基复合材料(HA_W/Mg)。用XRD、 FTIR、 FESEM和TG对材料进行表征。分析了尿素含量对HA物相和晶体结构的影响, 以及HA_W/Mg复合材料的热稳定性和显微结构。结果表明: 在本实验条件下, 得到的产物均为带状、 含碳酸根的HA_W; 随着尿素添加量的增加, HA_W逐渐变长且结晶度增加; HA_W与Mg之间在600 ℃以下无化学反应, 且HA不会加剧Mg的氧化; HA_W在HA_W/Mg复合材料中分散均匀, 不易折断。      

The effect of copper granules on interfacial bonding and properties of the copper-graphite composite prepared by flake powder metallurgy

The study evaluates the effect of introducing Cu granules and control milling on the microstructure, interfacial bonding and mechanical properties including sintered density, hardness, compressive strength, flexural strength and electrical conductivity of Copper-Graphite (Gr) composite synthesize by flake powder metallurgy (Flake PM). It develops the flake composite particles by control mechanical alloying (MA) which further laminates over the refine granules surface. This encapsulation facilitates the strong interfacial bonding among the composite constituents during sintering. Results highlight that the 10% Cu granules in Cu-10Gr composite exhibit excellent mechanical properties. It increases the relative density, hardness, compressive strength, and flexural strength by 4.19%, 28.23%, 98.31%, and 11.8% respectively. However, the electrical conductivity increases by 6.73% (%IACS) for 15% of Cu granules in the Cu-10Gr composite. The improvements in the results are the synergistic coordination of dispersion homogeneity, surface integrity, work hardening, and the superior interfacial adhesion between composite powder and Cu granules.     

Strengthening the mechanical properties and wear resistance of CoCrFeMnNi high entropy alloy fabricated by powder metallurgy

In this study, an equiatomic CoCrFeMnNi high entropy alloy (HEA) was fabricated by a rapid solidified gas atomization process. Subsequently, the high-energy mechanical milling was carried out to further refine the microstructure of pre-alloyed powder to improve the sintering ability and strengthening of HEAs. The microscopic results show that the powder morphology significantly changed from spherical to flatten, flake, irregular, and partially spherical shape with increasing milling time. The XRD results exhibited HEA bulks consisting of major FCC and minor Cr₇C₃ phases. The hardness of HEA bulks increased from 270±10 Hv to 450±10 Hv with increasing milling time, while the compressive yield strength increased from 370 MPa to 1050 MPa due to grain boundary strengthening and dislocation strengthening. Meanwhile, the lowest coefficient of friction ～0.283 and specific wear rate ～1.03×10^-5 mm³/Nm were obtained for the 60 min milled HEA due to increased surface hardness and oxidation behavior. The developed powder metallurgy approach could be considered as a promising way to improve the strength and wear resistance when compared to the conventional processed CoCrFeMnNi HEAs.     

粉末冶金原位合成VC/Fe复合材料的动力学过程研究

应用不同烧结温度制备VC颗粒增强铁基复合材料,用扫描电镜(SEM)观察各烧结温度下的微观结构,应用该组分做差热分析(DTA)、高温X射线衍射分析(XRD)对Fe-V-C体系原位合成VC的动力学过程进行研究,该动力学研究将为VC/Fe复合材料制备提供了理论依据。结果表明,在700℃时左右σ相(Fe V)在石墨的作用下发生分解,变成固溶了大量钒的α-Fe,随着温度的升高,V与C发生反应生成VC;温度越高,VC发生反应越激烈,并释放出大量的热量;1 100℃真空烧结后的组织为珠光体基体上分布着大小均匀呈球形的VC颗粒。     

V8C7增强铁基复合材料的制备和性能

用一种将粉末冶金和原位合成相结合的全新方法原位合成了V8C7颗粒增强铁基复合材料,对其微观组织、耐磨性及其磨损机理进行了分析,并探讨了FE-V-C三元体系原位合成V8C7的机理.结果表明:石墨的存在降低了σ-(FeV)相的稳定性,使其分解为固溶大量V的α-Fe, C与V发生碳化反应生成V8C7;原位合成的V8C7颗粒增强铁基复合材料由增强相V8C7和α-Fe相组成,V8C7颗粒均匀分布在珠光体基体上;在重载干滑动摩擦条件下,V8C7颗粒增强铁基复合材料显示出良好的耐磨性能.     

Cavitation resistance of powder metallurgy aluminum matrix composite with AlN dispersoids

The cavitation erosion resistance of P/M aluminum alloy sintered composite with AlN dispersoids, prepared via the in situ synthesis and the conventional premixing process, was evaluated by using a magnetostrictive-vibration type equipment. In situ synthesized AlN particles were effective for the improvement of the erosion resistance of the composite because of their good bonding with the aluminum matrix. The additive AlN by the premixing process were easily detached from the specimen surface due to the insufficient coherence with the matrix, and caused the poor resistance. The cavitation resistance also depended on the porosity of the sintered composite. The continuously opened pores accelerated the wear phenomena by the cavitation due to the high pressure attack on the primary particle boundaries of sintered materials in the collapse of the bubbles.     

In‐situ composite coating on powder metallurgy master alloy fabricated by vacuum hot‐pressing sintering technology

A material consisting of an in‐situ titanium carbide reinforced nickel‐aluminide (Ni₃Al) coating and a powder metallurgy master alloy was fabricated by vacuum hot‐pressing sintering technology. A metallurgical bonded, pores‐free interface between composite coating and powder metallurgy master alloy was formed at the sintering temperature of 1050 °C, pressure of 10^‐4 Pa and pressing pressure of 40 MPa. The phase, microstructure and wear behavior of composite coating were investigated. The results showed that polygonal titanium carbide particulates with various sizes were homogeneously distributed in nickel‐aluminide matrix. The sintering temperature, pressing pressure and heat from as‐reactions‐formed coating green compact facilitated the pore infiltration with transiently generated liquid phases and ensured the high‐intensity metallurgical bonding between composite coating and powder metallurgy master alloy. Due to the abnormal elevated‐temperature properties of nickel‐aluminide matrix, titanium carbide particulates reinforcement and the mechanically mixed layer protection, TiC/Ni₃Al‐coated parts demonstrated superior wear resistance and lower friction coefficient while compared with Ni₃Al‐coated parts and H13 steel.     

绝缘剂用量对FeSiAl磁粉芯性能影响的研究

探讨了不同绝缘剂用量对磁粉芯综合性能的影响，实验选用粒径为100gm以下机械破碎制备的合金粉末，绝缘剂用量为1％～5％（质量分数）。绝缘剂用量控制在2％以内，粉芯样品有较高的磁导率，可达到130左右；当用量加到3％时，样品频率特性较好，在f=50kHz、Bm=100mT的测试条件下损耗为550mW／cm^3，具有良好的综合性能。     

Prediction of mechanical properties and modeling on sliding wear behavior of LM25/TiC composite using response surface methodology

Aluminum LM25/TiC (10?wt%) metal matrix composite was developed using the liquid metallurgy route. The microstructural examination and the mechanical properties such as hardness and tensile strength were investigated on the composite specimens. The tribological behavior of the composite was studied using central composite design (CCD) based on response surface methodology (RSM) under the influence of wear process parameters such as applied load, sliding velocity and sliding distance. Pin-on-disc tribometer was utilized for conducting the experimental runs and the model was constructed based on the obtained wear rates. Confirmation experiments and analysis of variance were performed to ensure the adequacy of the constructed model. Microstructural examination reveals that uniform dispersion was attained in the composite, which enhances the hardness and the tensile strength. The wear results showed that the wear rate increased with increase in load, decreases with increase in velocity and varies nonlinearly with sliding distance. Scanning electron microscopic (SEM) analysis was performed to examine the worn surface morphologies and the worn surfaces revealed that TiC reinforcement protects the matrix from more material removal at all conditions. The developed composite can be utilized for the tribological applications like engine block, cylinder liners and pistons.     

An investigation on machined surface quality and tool wear during creep feed grinding of powder metallurgy nickel-based superalloy FGH96 with alumina abrasive wheels

In this study, the machined surface quality of powder metallurgy nickel-based superalloy FGH96 (similar to Rene88DT) and the grinding characteristics of brown alumina (BA) and microcrystalline alumina (MA) abrasive wheels were comparatively analyzed during creep feed grinding. The influences of the grinding parameters (abrasive wheel speed, workpiece infeed speed, and depth of cut) on the grinding force, grinding temperature, surface roughness, surface morphology, tool wear, and grinding ratio were analyzed comprehensively. The experimental results showed that there was no significant difference in terms of the machined surface quality and grinding characteristics of FGH96 during grinding with the two types of abrasive wheels. This was mainly because the grinding advantages of the MA wheel were weakened for the difficult-to-cut FGH96 material. Moreover, both the BA and MA abrasive wheels exhibited severe tool wear in the form of wheel clogging and workpiece material adhesion. Finally, an analytical model for prediction of the grinding ratio was established by combining the tool wear volume, grinding force, and grinding length. The acceptable errors between the predicted and experimental grinding ratios (ranging from 0.6 to 1.8) were 7.56% and 6.31% for the BA and MA abrasive wheels, respectively. This model can be used to evaluate quantitatively the grinding performance of an alumina abrasive wheel, and is therefore helpful for optimizing the grinding parameters in the creep feed grinding process.The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-020-00305-2     

Investigations into dry-sliding wear behaviour of a novel composite (aluminium-magnesium-silicon-copper-silicon carbide) produced by powder metallurgy route

Metal-matrix aluminium composites are satisfactory successor not only for steels, but also for aluminium-alloys in several automotive units and components. There are various paths to get light-weight materials with-out compromising their toughness, strength and safety demands. Tests on dry-sliding or un-lubricated pin-on-disc tests can be performed to obtain the wear-characteristics of metal-matrix composites built on aluminum. In the present study, we studied the behavior of wear resistance during sliding of metal matrix aluminium composites (AMMC) at sliding speeds of 1.5 m/s and loads of 20 N and 40 N in a normal environment, and experiments have been conducted using pin-on-disk tribometer (Make: DUCOM tribometer). The composites were manufactured by powder treatment and presented a number of problems, such as defective bonds and inter-facial product reactions, which alter the tribological and mechanical properties. The results have shown that wear-rates of the prepared composites are much lesser than those of matrix-alloy and decreased further with increasing silicon carbide content. As the normal loads increases, the cracks and combination of abrasions, delimitation and wear of the adhesives of silicon carbide particles were observed. The composite samples were studied using a scanning electron microscope before and after the wear tests and systematically analysed.     

Development of Ni-base metal matrix composites by powder metallurgy hot isostatic pressing for space applications

In this work, near-net-shape powder metallurgy hot isostatic pressing (NNS PM HIP) of Ni-base metal matrix composite (Ni-MMC) was developed to improve the hardness and wear properties of turbopumps mechanical seals. Silicon carbide (SiC) and titanium diboride (TiB₂) fine powders were used as reinforcements with different ratios to improve the hardness and consequently the tribological properties of the developed Ni-MMC material. Powder characterisation was performed on the blended powders to check the homogeneity of the mixed powders. The hot isostatically pressed (HIPed) Ni-MMC microstructures were analysed using scanning electron microscope (SEM) and energy dispersive X-ray spectroscopy (EDS) techniques. The HIPed material showed a fully dense microstructure with a continuous network of ceramic reinforcement particles at the prior particle boundaries (PPBs). Furthermore, microhardness tests were performed on IN625, IN625-SiC and IN625-TiB₂ to understand the impact of the reinforcement on the microhardness. It was demonstrated that the volume percentage of ceramic reinforcement in the IN625 matrix plays a crucial role in achieving higher hardness by increasing the fraction of hard phases appearing in the microstructure of the developed Ni-MMC material. The final part of the work focuses on the canister design and manufacture of a near-net-shape (NNS) mechanical gas seal using IN625 based MMC to demonstrate the feasibility of manufacturing mechanical seals through the NNS PM HIP technique. Overall, IN625 based MMCs resulted in a drastic improvement in tribological properties if compared to the base material. Furthermore, the employment of the PM HIP consolidation technique resulted in a fully dense and homogeneous microstructure, highlighting the potentials of PM HIP in the generation of novel composite materials.     

Formation of Al3Ti/Mg composite by powder metallurgy of Mg–Al–Ti system

An in situ titanium trialuminide (Al₃Ti)-particle-reinforced magnesium matrix composite has been successfully fabricated by the powder metallurgy of a Mg–Al–Ti system. The reaction processes and formation mechanism for synthesizing the composite were studied by differential scanning calorimetry (DSC), x-ray diffractometry (XRD), scanning electron microscopy (SEM) and energy-dispersive x-ray spectroscopy (EDS). Al₃Ti particles are found to be synthesized in situ in the Mg alloy matrix. During the reaction sintering of the Mg–Al–Ti system, Al₃Ti particles are formed through the reaction of liquid Al with as-dissolved Ti around the Ti particles. The formed intermetallic particles accumulate at the original sites of the Ti particles. As sintering time increases, the accumulated intermetallic particles disperse and reach a relatively homogeneous distribution in the matrix. It is found that the reaction process of the Mg–Al–Ti system is almost the same as that of the Al–Ti system. Mg also acts as a catalytic agent and a diluent in the reactions and shifts the reactions of Al and Ti to lower temperatures. An additional amount of Al is required for eliminating residual Ti and solid-solution strengthening of the Mg matrix.