Fabrication of Al-3 Wt pct Mg matrix composites reinforced with Al2O3 and SiC particulates by the pressureless infiltration technique

In Al-3 wt pct Mg/Al₂O_3p (or SiC _p ) composites fabricated by the pressureless infiltration method, the infiltration behavior of molten metal, the mechanical properties, and the interfacial reactions were investigated. The spontaneous infiltration of the molten Al-3 wt pct Mg alloy into the powder bed occurred at a relatively low temperature (700 °C for 1 hour under a nitrogen atmosphere). Spontaneous infiltration of the molten metal is related to the formation of Mg₃N₂ by the reaction of Mg and nitrogen. The tensile strength and 0.2 pct offset yield strength and elongation tend to decrease with increasing infiltration temperature and time, because of an increased interfacial reaction. In Al-3Mg/Al₂O₃ composites, MgAl₂O₄ was observed at interfaces between Al₂O₃ and the matrix, as well as at oxide films of the Al powder surface. In addition, MgO was observed at interfaces between Al₂O₃ and the matrix. On the other hand, Al₄C₃ was formed at interfaces between SiC and the matrix in Al-3Mg/SiC composites. In addition, MgAl₂O₄ was observed as a reaction product at the interfaces between oxide films of SiC and the matrix, as well as at oxide films of the Al powder surface. Since the Si released as a result of the interfacial reaction is combined with Mg, age hardening can occur by the precipitation of Mg₂Si via T6 treatment.     

Aluminum matrix composites: Fabrication and properties

Aluminum alloy matrix composites containing 1 to 30 wt pct of fibrous and particulate nonmetals varying in size from 0.06 μm to 840 μm were fabricated. The composites were cast into cylindrical molds for friction and wear tests, hot extrusion and tensile tests. The distribution of the nonmetals in the cast ingots was homogeneous. Friction and wear tests were done on a pin (52100 bearing steel) and dish type machine without lubrication. It was found that composites containing ∼10 wt pct or more of SiC, TiC, Si₃N₄, Al₂O₃, glass, solid waste slag, and silica sand wear less than the pure matrix alloy, but have slightly higher average coefficients of friction. Wear in composites containing soft particles, especially MgO and boron nitride was higher than the pure matrix alloy. The average coefficient of friction of all the composites was in the range of 0.35 to 0.58. Increasing the sliding velocity reduced this range to ∼ 0.4 to 0.45. The longitudinal tensile properties of the extruded composites (with the exception of loss of ductility in some cases) are comparable to that of the matrix alloys. Improvements in strength or ductility were noted. For example, addition of 15 wt pct of 3 μm size Al₂O₃ particles raised the yield and ultimate strength of the Al-4 pct Cu-0.75 pct Mg alloy matrix from 227 to 302 MPa, and 356 to 403 MPa, respectively. The corresponding percent elongation decreased from 25.8 to 12.5. The fact that the various composites can be readily cast and hot formed suggests a variety of engineering applications. AKIRA SATO, formerly Visiting Scientist at Massachusetts Institute of Technology, Cambridge.     

Processing copper and silver matrix composites by electroless plating and hot pressing

A simple process was developed to fabricate ceramic-reinforced copper and silver matrix composites by electroless plating and hot pressing at 873 K and 300 MPa, in air. Composites were produced containing 10 to 40 vol pct ceramic reinforcements of different sizes and shapes including silicon carbide whiskers (SiC _w ), alumina particles (Al₂O_3p ), carbon short fibers (Carbon _sf ), and Saffil short fibers (Saffil _sf ) (3.8 pct SiO₂-96.2 pct Al₂O₃) uniformly distributed within the matrix. The hardness and bending strength of the composites were much higher than those of the pure matrices. The electrical conductivity, measured by a four-point probe method, was similar to that of traditional CdO/Ag electrical contact materials. The surface morphologies and cross-sectional microstructures of the arc-eroded Al₂O_3p /Ag composites were similar to those of conventional CdO/Ag and SnO₂/Ag and exhibited a good arc-erosion resistance. These composites combine the high strength and elevated-temperature stability of the ceramic reinforcements with the good electrical and thermal conductivity of the two metallic matrices.     

Nanostructure Particle-Reinforced Transient Liquid Phase Diffusion Bonding: a Comparative Study

Particle-reinforced aluminum–metal matrix composites (Al-MMCs) are used in many engineering applications, because they provide significant advantages when compared to monolithic aluminum alloys. However, there still exists the need to identify a suitable joining process for these materials, which minimizes particulate disruption and retains the strength of the MMC within the joint region. This study presents a comparison between joint qualities achieved when a monolithic interlayer is used vs when a nanoparticle-reinforced composite interlayer is used during transient liquid phase diffusion bonding of Al-6061 alloy containing 15 vol pct of Al₂O₃ particles. Examination of the joint region using scanning electron microscopy (SEM), wavelength dispersive spectroscopy (WDS), and X-ray diffraction (XRD) showed the formation of eutectic phases such as Al₃Ni, Al₉FeNi, and Ni₃Si within the joint zone. The results indicate that the addition of nanoparticle reinforcements into the interlayer can be used to improve joint strength and minimize particle segregation.     

Reinforcement shape effects on the fracture behavior and ductility of particulate-reinforced 6061-Al matrix composites

Particle shape effects on the fracture and ductility of a spherical and an angular particulate-reinforced 6061-Al composite containing 20 pct vol Al₂O₃ were studied using scanning electron microscopy (SEM) fractography and modeled using the finite element method (FEM). The spherical particulate composite exhibited a slightly lower yield strength and work hardening rate but a considerably higher ductility than the angular counterpart. The SEM fractographic examination showed that during tensile deformation, the spherical composite failed through void nucleation and linking in the matrix near the reinforcement/matrix interface, whereas the angular composite failed through particle fracture and matrix ligament rupture. The FEM results indicate that the distinction between the failure modes for these two composites can be attributed to the differences in the development of internal stresses and strains within the composites due to particle shape.     

Synergistic effects of wear and corrosion for Al2O3 particulate-reinforced 6061 aluminum matrix composites

Wear corrosion of alumina particulate-reinforced 6061 aluminum matrix composites in a 3.5 wt pct NaCl solution with a revised block-on-ring wear tester has been investigated. The studies involved the effects of applied load, rotational speed, and environments (dry air and 3.5 pct NaCl solution) on the wear rates of materials. Also various specimens with Al₂O₃ volume fractions of 0, 10, 15, and 20 pct were employed in this work. Electrochemical measurements and electron micrographic observations were conducted to clarify the micromechanisms of wear corrosion in such metal matrix composites. Experimental results indicated that the wear rate of monolithic 6061 Al in either dry wear or wear corrosion was reduced by adding alumina reinforcements. However, the effect of volume fraction on wear rate is only minor in dry wear, while it is significant in the case of wear corrosion. Wear-corrosion tests also showed that the corrosion potential shifted to the active side and the current density for an applied potential increased with the decrease of Al₂O₃ volume fraction in the materials and the increase in applied load and rotational speed. Although the incorporation of reinforcement in these aluminum matrix composites was deterimental to their corrosion resistance, the influence on wear corrosion was favorable.     

Fabrication of Al2O3-reinforced Ni3Al composites by a novel in situ route

A novel in situ technique has been used to fabricate an Al₂O₃-reinforced Ni₃Al matrix composite. The composite was prepared by first incorporating a low volume fraction of continuous Al₂O₃ fibers in a Ni₃Al alloy containing 0.34 at. pct Zr. Pressure casting was used to embed the fibers. Casting resulted in partial reduction of the Al₂O₃ fiber by the Zr present in the matrix and the formation of a layer of ZrO₂ on the surface of the fibers. The final composite was then prepared by air annealing the precursor composite at 1100 °C for 10 days. Air annealing led to the formation of networks of Al₂O₃ around the fibers. The matrix in the immediate vicinity of the networks consisted of Ni₃Al particles in a matrix of disordered α-Ni(Al). The Al₂O₃ networks raised the yield and tensile strength of the material by 35 and 18 pct, respectively. The composite had a tensile ductility of 14 pct.     

Interfacial Reactions in Al-Mg (5083)/SiCp Composites during Fabrication and Remelting

The interfaces of aluminum alloy composites (5083) reinforced by SiC particles (as-received, oxidized 3.04 wt pct and 14.06 wt pct) were studied. The composites were fabricated by compocasting and certain samples were also remelted at 800 °C for 30 minutes. The reaction mechanisms between SiC _p and liquid Al and between the SiO₂ layer and Al(Mg) are discussed. The crystal boundaries of the MgO (or MgAl₂O₄) reaction products are believed to be the diffusion paths (or channels) during the interfacial reactions. A SiO₂ layer, formed by oxidation of the SiC particles prior to their incorporation into the melt, plays an important role in preventing the SiC _p from being attacked by the matrix. The interfacial reaction products are affected by both the alloy composition and the thickness of the initial SiO₂ layer.     

Creep rupture life prediction of short fiber-reinforced metal matrix composites

The creep rupture life of an Al/Al₂O₃ composite and its creep behavior were studied. The metal matrix composite was produced by using a squeeze casting technique. High-temperature tensile tests and creep experiments were conducted on a 15 vol pct alumina fiber-reinforced AC2B Al alloy metal matrix composite (MMC). The high-temperature tensile strength of Al/Al₂O₃ composite is 14 pct higher than that of an AC2B Al alloy. The steady-state creep rate and the creep life were measured. The stress exponent in Norton’s equation and the activation energy were computed. The stress exponents of the AC2B and Al/Al₂O₃ composites were found to be 4 and 12.3, respectively. The activation energy of the AC2B and Al/Al₂O₃ composites was found to be 242.74 and 465.35 kJ/mol, respectively. A new equation for predicting creep life was established, which was based on the conservation of the creep strain energy. The theoretical predictions were compared with those of the experiment results, and a good agreement was obtained. It was found that the creep life is inversely proportional to the (n + 1)th power of the applied stress and strain failure energy of creep is conserved. The creep fracture surface, examined by scanning electron microscopy (SEM), showed that the MMC specimen failed in a brittle manner.     

Preparation and casting of metal-particulate non-metal composites

A new process for the preparation and casting of metal-particulate non-metal composites is described. Particulate composites of ceramic oxides and carbides and an Al-5 pet Si-2 pct Fe matrix were successfully prepared. From 10 to 30 wt pct of A1₂O₃, SiC, and up to 21 wt pct glass particles, ranging in size from 14 to 340 ώ were uniformly distributed in the liquid matrix of a 0.4 to 0.45 fraction solid slurry of the alloy. Initially, the non-wetted ceramic particles are mechanically entrapped, dispersed and prevented from settling, floating, or agglomerating by the fact that the alloy is already partially solid. With increasing mixing times, after addition, interaction between the ceramic particles and the liquid matrix promotes bonding. Efforts to mix the non-wetted particles into the liquid alloy above its liquidus temperature were unsuccessful. The composite can then be cast either when the metal alloy is partially solid or after reheating to above the liquidus temperature of the alloy. End-chilled plates and cylindrical slugs of the composites were sand cast from above the liquidus temperature of the alloy. The cylindrical slugs were again reheated and used as starting material for die casting. Some of the reheated composites possessed “thixotropy.” Distribution of the ceramic particles in the alloy matrix was uniform in all the castings except for some settling of the coarse, 340ώ in size, particles in the end-chilled cast plates.     

Superplasticity in a high strength powder aluminum

The superplastic properties of a rapidly solidified, high strength P/M Al alloy and the same alloy reinforced with SiC particulates (SiC _p ) have been studied. To prepare superplastic test materials, a matrix alloy powder of composition 7.2Zn-2.4Mg-2Cu-0.2Zr-0.12Cr-0.2Co (Kaiser PM-64) and the powder mixed with 10 to 20 vol pct SiC _p (~5 μm diameter) were thermomechanically processed to very fine equiaxed grain structures of ~6 μm and ~8 μm, respectively. Superplasticity in these materials was evaluated by characterizing (1) high temperature stability, (2) dynamic grain growth, (3) strain rate sensitivity, (4) flow stress behavior, (5) cavitation and cavitation control, and (6) total superplastic strain. It was observed that the PM-64 alloy could achieve a total elongation of over 800 pct, while the SiC_p reinforced alloy could attain an elongation greater than 500 pct before failure. Also, it was shown that with the use of hydrostatic pressure during superplastic flow, cavitation could be controlled. Observations were made of the effect SiC _p reinforcement particles had on the superplastic flow stress behavior. Interpretations are proposed to explain the role of particulates during superplastic straining.     

Processing,microstructure, and mechanical properties of cast <Emphasis Type="Italic">in-Situ</Emphasis> Al(Mg,Mn)-Al<Subscript>2</Subscript>O<Subscript>3</Subscript>(MnO<Subscript>2</Subscript>) composite

Cast particulate composites, containing in-situ generated reinforcing particles of alumina, have been developed by solidification of slurry obtained by dispersion of externally added manganese dioxide particles (MnO₂) in molten aluminum, and alumina is formed by reaction of manganese dioxide with molten aluminum. The chemical reaction also releases manganese into molten aluminum. Magnesium is added to the melt in order to help wetting of alumina particles by molten aluminum and to retain the particles inside the melt. The present work aims to understand the influence of key parameters such as processing temperature, time, and the amount of MnO₂ particles added on the microstructure and mechanical properties of the resulting cast in-situ composites. The sequence of addition of MnO₂ particles and magnesium has significant influence on the microstructure and mechanical properties. Increasing processing temperature and time increases the extent of reduction of MnO₂ particles, generating more alumina particles as well as releasing more manganese to the matrix alloy. Alumina helps to nucleate finer and sometimes blocky MnAl₆ in the matrix of the composite and thereby results in relatively higher ductility and increased strength in the composite as compared to the base alloy of similar composition. Even in the presence of relatively higher porosity of 8 to 9 vol pct, one observes a percent elongation not below 7 to 8 pct, which is considerably higher than those observed in cast Al(Mg)-Al₂O₃ composite synthesized by externally added alumina particles.     

Superplastic behavior and cavitation in high-strain-rate superplastic Si3N4p /Al-Mg-Si composites

High-strain-rate superplastic behavior has been investigated for Si₃N_4p /Al-Mg-Si (6061) composites with a V _f =20 and 30 pct, respectively, where V _f is the volume fraction of reinforcements. A maximum elongation was attained at a temperature close to the onset temperature for melting for both composites. The maximum elongation for the 30 vol pct composite was larger than that for the 20 vol pct composite. Development of cavities transverse to the tensile direction is responsible for the lower maximum elongation of the 20 vol pct composite. However, development of the transverse cavities was limited to the optimum superplastic temperature for the 30 vol pct composite. The differential scanning calorimetry (DSC) investigation showed that a sharp endothermic peak appeared for the 30 vol pct composite, indicating that sufficient partial melting occurs. It is, therefore, likely that the stress concentrations are sufficiently relaxed by a liquid phase and that the development of transverse cavities is limited for the 30 vol pct composite.     

Intermetallic-reinforced light-metal matrix in-situ composites

Transition-metal trialuminide intermetallics such as Al₃Zr and Al₃Ti, having low densities and high elastic moduli, are good candidates for the in-situ reinforcement of light-metal matrices based on Al and Mg alloys. In this work, in-situ composites based on Al and Al-Mg matrices reinforced with an Al₃Zr intermetallic were successfully processed by conventional ingot metallurgy. The microstructural studies showed that “needle” or “feathery”-like particles of Al₃Zr phase, whose volume fraction increased with increasing concentration of Zr, were formed in the Al matrix in the investigated range of Zr contents from 0.9 to 11.6 at. pct. Properties of Al-Zr alloys were investigated as a function of volume fraction of Al₃Zr. It is shown that the density, hardness, and yield strength of the in-situ Al/Al₃Zr composites can be quite adequately described by the composite rule-of-mixtures (ROM) behavior. Alloying of a binary Al-2.4 at. pct Zr alloy with Mg up to ∼25 at. pct reduces profoundly its density and, additionally, strengthens the matrix by a Mg solid-solution strengthening mechanism.     

Development of Wear-Resistant Cu-10Cr-3Ag Electrical Contacts with Nano-Al<Subscript>2</Subscript>O<Subscript>3</Subscript> Dispersion by Mechanical Alloying and High Pressure Sintering

Cu-10Cr-3Ag (wt pct) alloy with nanocrystalline Al₂O₃ dispersion was prepared by mechanical alloying and consolidated by high pressure sintering at different temperatures. Characterization by X-ray diffraction and scanning electron microscopy or transmission electron microscopy shows the formation of nanocrystalline matrix grains of about 40 nm after 25 hours of milling with nanometric (<20 nm) Al₂O₃ particles dispersed in it. After consolidation by high pressure sintering (8 GPa at 400 °C to 800 °C), the dispersoids retain their ultrafine size and uniform distribution, while the alloyed matrix undergoes significant grain growth. The hardness and wear resistance of the pellets increase significantly with the addition of nano-Al₂O₃ particles. The electrical conductivity of the pellets without and with nano-Al₂O₃ dispersion is about 30 pct IACS (international annealing copper standard) and 25 pct IACS, respectively. Thus, mechanical alloying followed by high pressure sintering seems a potential route for developing nano-Al₂O₃ dispersed Cu-Cr-Ag alloy for heavy duty electrical contact.     

Microscopic examination of the interface region in 6061-Al/SiC composites reinforced with as-received and oxidized SiC particles

Aluminum (6061) matrix composites reinforced with different SiC particles were processed. Black SiC particles were used in their as-received form or after artificial oxidation, leading to a 50-nm-thick SiO₂ layer surrounding the SiC particles. The manufacturing route used was the compocasting technique, which allows maintenance of the semisolid slurry at relatively low temperatures (<650 °C) during the incorporation of the reinforcement. Before squeeze casting, the liquid alloy is held at 700 °C for 5 to 10 minutes. The interface between the aluminum matrix and SiC was characterized by transmission electron microscopy (TEM). Results show that no reaction takes place during compocasting between the as-received SiC particles and the molten aluminum. This is a consequence of the low temperatures and short holding times in the liquid state of the 6061 alloy, possible with this process. Prolonged holding at 800 °C of this material leads to extensive formation of A1₄C₃. In the case of artificially oxidized SiC particles, the SiO₂ layer surrounding the SiC particles reacts with the molten Al-Mg-Si alloy to produce MgAl₂O₄. However, the amount of Mg from the base alloy lost to form this spinel phase is not sufficient to prevent age hardening of the material.     

A Study of the Effect of Nanosized Particles on Transient Liquid Phase Diffusion Bonding Al6061 Metal–Matrix Composite (MMC) Using Ni/Al2O3 Nanocomposite Interlayer

Transient liquid phase (TLP) diffusion bonding of Al-6061 containing 15 vol pct alumina particles was carried out at 873 K (600 °C) using electrodeposited nanocomposite coatings as the interlayer. Joint formation was attributed to the solid-state diffusion of Ni into the Al-6061 alloy followed by eutectic formation and isothermal solidification of the joint region. An examination of the joint region using an electron probe microanalyzer (EPMA), transmission electron microscopy (TEM), wavelength-dispersive spectroscopy (WDS), and X-ray diffraction (XRD) showed the formation of intermetallic phases such as Al₃Ni, Al₉FeNi, and Ni₃Si within the joint zone. The result indicated that the incorporation of 50 nm Al₂O₃ dispersions into the interlayer can be used to improve the joint significantly.     

Electron and laser beam welding of high strain rate superplastic Al-6061/SiC composites

The welding characteristics of a fine-grained 6061 Al and three 6061/1, 5, and 20 pct SiC composites under high energy electron beam welding (EBW) and laser beam welding (LBW) were examined. The three composites exhibited high strain rate superplasticity (HSRS). The 6061 Al was more readily welded by EBW than by LBW, and the situation was reversed in the reinforced composites. In the reinforced composites, the fusion zone contained the once fully melted matrix and fully reacted SiC, and the heat affected zone (HAZ) contained the partially melted matrix and nearly unreacted SiC. This effect was particularly apparent in the 20 pct SiC composite. With increasing SiC content from 0 to 20 pct, the reflection of the laser beam decreased, and the melt viscosity increased due to the increasing amount of Al₄C₃ compounds. For the HSRS fine-grained 6061/20 pct SiC composite, there formed a sharp V-notch under EBW. The high viscosity or low fluidity of the melt inside the fusion zone of 6061/20 pct SiC resulted in incomplete backfill and notch formation. The postweld mechanical performance and joint efficiency both became seriously degraded. The original fine structures in the HSRS composites could not be restored after welding.     

Interfacial characteristics for brazing of aluminum matrix composites with Al-12Si filler metals

Discussions concerning the interfacial reactions and characterizations in brazing aluminum matrix composites are documented in this study. Joints of alumina particulate reinforced 6061 aluminum matrix composites were made using an Al-12 (wt pct) Si filler metal by vacuum brazing. The resulted maximum bonding strengths were 75.4, 81.5, and 71.8 MPa for 10, 15, and 20 vol pct alumina reinforcement, respectively. The microstructural examinations revealed that the bonding strength was strictly related to the reinforced alumina particles and the reaction products presented at the joint interfaces. During brazing, Mg segregated at the joining interface and alumina/6061 Al interface. Further, reactions between alumina and 6061 Al matrix resulted in the formation of Mg-rich phases, such as MgAl₂O₄ and MgO, near the joining interface and the alumina reinforcement. The Si in the filler material penetrated into the metal matrix composites (MMCs) matrix and segregated at the alumina/6061 Al interfaces. This phenomenon can be confirmed by a joint between two alumina bulk specimens.     

Combustion synthesis of Ni3Al and Ni3Al-matrix composites

The self-propagating mode of combustion synthesis (SHS) of Ni₃Al starting from compacts of stoichiometrically mixed Ni and Al powders readily forms fully reacted structures with about 3 to 5 pct porosity, if green density of the compacts is greater than about 75 pct of theoretical. SHS-produced Ni₃Al matrix composites with up to 2 wt pct A1₂O₃ whiskers also have relatively low porosity levels. Porosity increases rapidly with lower green densities, higher Al₂O₃, or SiC whisker contents, and the degree of reaction completeness diminishes. The SiC whiskers undergo reaction with the matrix, while Al₂O₃ whiskers are nonreactive. All of these observations correlate well with temperature measurements made during the course of the reaction. The SHS mode can be achieved with agglomerated particle size ratioD _Al/D _Ni ≥ 1, larger than the limit established from studies of the thermal explosion mode of combustion synthesisD _Al/D _Ni ≃ 0.3. This paper is based on a presentation made in the symposium “Reaction Synthesis of Materials” presented during the TMS Annual Meeting, New Orleans, LA, February 17–21, 1991, under the auspices of the TMS Powder Metallurgy Committee.