Microstructure and Mechanical Properties of Al356/SiCp Cast Composites Fabricated by a Novel Technique

In this study, SiC_p containing composite powders were used as the reinforcement carrier media for manufacturing cast Al356/5 vol.% SiC_p composites. Untreated SiC_p, milled particulate Al-SiC_p composite powder, and milled particulate Al-SiC_p-Mg composite powder were injected into Al356 melt. The resultant composite slurries were then cast from either a fully liquid state (stir casting) or semisolid state (compocasting). The results revealed that by injection of composite powders, the uniformity of the SiC_p in the Al356 matrix was greatly improved, the particle-free zones in the matrix were disappeared, the SiC particles became smaller, the porosity was decreased, and the matrix microstructure became finer. Compocasting changed the matrix dendritic microstructure to a finer non-dendritic one and also slightly improved the distribution of the SiC_p. Simultaneous utilization of Al-SiC_p-Mg composite powder and compocasting method increased the macro- and micro-hardness, impact energy, bending strength, and bending strain of Al356/SiC_p composite by 35, 63, 20, 20, and 40%, respectively, as compared with those of the composite fabricated by injection of untreated SiC_p and stir casting process.     

Using ARB process as a solution for dilemma of Si and SiCp distribution in cast Al-Si/SiCp composites

A major challenge in achieving the best potential of SiC_p-reinforced aluminum composites is to homogeneously disperse SiC particles within the aluminum alloys. The presence of coarse Si fibers with non-uniform distribution in cast Al-Si alloys, which may lead to poor mechanical properties, is another important problem that limits the application of these alloys. In order to eliminate these problems, accumulative roll bonding (ARB) process was used in this study as a very effective method for improving the microstructure and mechanical properties of the Al356/SiC_p composite. It was found that when the number of ARB cycles was increased, the uniformity of the Si and SiC_p in the aluminum matrix improved, the Si particles became finer and more spheroidal, the free zones of Si and SiC particles disappeared, the porosity of composite decreased, the bonding quality between SiC_p and matrix improved, and therefore mechanical properties of the composites were improved. The microstructure of the manufactured Al356/SiC_p composite after six ARB cycles indicated a completely modified structure so that its tensile strength and elongation values reached 318 MPa and 5.9%, which were 3.1 and 3.7 times greater than those of the as-cast composite, respectively.     

Production of Al-Si-SiCp cast composites by injection of low-energy ball-milled Al-SiCp powder into the melt

Al-7wt%Si-10wt%SiC_p composite with uniformly distributed reinforcement particles with the average size of about 3 microns was produced by a special compocasting method in which the reinforcement was injected into the melt in the form of particulate Al-SiC_p composite powder instead of SiC_p. The effects of the reinforcement addition form, the solid fraction of primary alpha-aluminum particles at pouring, and stirring speed on the incorporation of reinforcement particles into the matrix were investigated. Injection of particulate Al-SiCp composite led to improved incorporation and dispersion and reduced size of SiC_p. Casting from the semisolid state significantly improved the incorporation of SiC_p into the matrix. The optimal solid fraction of primary alpha-aluminum particles to achieve a reasonable combination of reinforcement incorporation and fluidity of the composite slurry was recognized to be about 0.1. The incorporation of SiC_p was improved by increasing the stirring speed up to 500 rpm and then gradually decreased.     

Fabrication and characterization of cast magnesium matrix composites by vacuum stir casting process

A vacuum stir casting process is developed to produce SiC_p reinforced cast magnesium matrix composites. This process can eliminate the entrapment of external gas onto melt and oxidation of magnesium during stirring synthesis. Two composites with Mg-Al9Zn and Mg-Zn5Zr alloys as matrices and 15 vol.% SiC particles as reinforcement are obtained. The microstructure and mechanical properties of the composites and the unreinforced alloys in as-cast and heat treatment conditions are analyzed and evaluated. In 15 vol.% SiC_p reinforced Mg-Al9Zn alloy-based composite (Mg-Al9Zn/15SiC_p), SiC particles distribute homogenously in the matrix and are well bonded with magnesium. In 15 vol.% SiC_p reinforced Mg-Zn5Zr alloy-based composite (Mg-Zn5Zr/15SiC_p), some agglomerations of SiC particles can be seen in the microstructure. In the same stirring process conditions, SiC reinforcement is more easily wetted by magnesium in the Mg-Al9Zn melt than in the Mg-Zn5Zr melt. The significant improvement in yield strength and elastic modulus for two composites has been achieved, especially for the Mg-Al9Zn/15SiC_p composite in which yield strength and elastic modulus increase 112 and 33%, respectively, over the unreinforced alloy, and increase 24 and 21%, respectively, for the Mg-Zn5Zr/15SiC_p composite. The strain-hardening behaviors of the two composites and their matrix alloys were analyzed based on the microstructure characteristics of the materials.     

SiCp/Al复合材料电子束焊接接头组织及性能

对SiCp/Al复合材料自身进行电子束焊接,研究了其接头成形、焊缝组织、热影响区组织及接头力学性能.结果表明,SiCp/Al复合材料自身直接电子束焊接时,接头的主要缺陷是焊缝成形差、易形成两侧堆积颗粒物的凹槽;焊缝组织中存在界面反应产生的灰白色初生硅、深灰色针状相Al4C3以及Al-Si共晶中的浅灰色针状共晶硅,形成脆性区,拉伸断裂位置便在此处,断裂为脆性断裂.熔合区附近硬度较高,与焊缝区组织及硬度差异较大.接头的最高强度为73 MPa,仅占母材平均抗拉强度的41％.     

SiCp/Al复合材料与Fe36Ni合金超声波钎焊

利用超声波钎焊方法使用ZnAlSi钎料实现了Fe36Ni合金与45%SiC_p/2024Al和55%SiC_p/A356两种复合材料的连接,并得到由SiC颗粒增强的复合焊缝.通过扫描电镜、能谱等方法对焊缝的微观结构以及断口形貌进行了观察,对接头的压剪强度进行了测试,分析了Fe36Ni与两种复合材料钎焊接头微观组织和接头强度的差异.结果表明,在Fe36Ni与两种复合材料的钎缝中,钎料与两侧母材界面均形成良好的冶金结合,SiC颗粒均匀分布于焊缝中.Fe36Ni与45%SiC_p/2024Al的接头抗剪强度为110~145 MPa,Fe36Ni与55%SiC_p/A356的接头抗剪强度为75~85 MPa.Fe36Ni与45%SiC_p/2024Al的接头断裂位置为钎缝中,而Fe36Ni与55%SiC_p/A356的接头断裂位置位于Fe36Ni与钎料的界面上.     

SiC_p/2024与2219铝合金电子束焊接

分别采用电子束对中焊、偏束焊技术,研究了Si C颗粒增强铝基复合材料Si Cp/2024与2219铝合金的接头组织及力学性能.结果表明,对中焊时接头易出现Si C增强相的偏聚,同时发生严重的界面反应,生成大量脆性相Al4C3,接头抗拉强度最高为104 MPa.采用偏束焊工艺可以很好地抑制界面反应,通常只在焊缝上部与Si Cp/Al热影响区上部生成少量脆性相Al4C3,接头抗拉强度最高可达131 MPa.试件均断裂在母材界面反应层上,且为明显的脆性断裂.不同工艺下接头横截面硬度分布存在突变区,该区域在Si Cp/2024熔合区附近,该处脆性相Al4C3的生成导致硬度升高.     

Development of a Novel Cast 6351 Al-Al4SiC4 In Situ Composite

In this research work 6351 Al-Al₄SiC₄ composite has been developed through stir casting route with incorporation of fine TiC powder in 6351 Al melt. During stir casting, round shaped Al₄SiC₄ particles were generated as TiC reacted with molten aluminum. These Al₄SiC₄ particles were found to be acting as nucleation sites for primary α (causing grain refinement) along with engulfment effects promoting particle distribution without clustering. Furthermore, as the volume fraction of Al₄SiC₄ particles increased, the proportion of dendritic region decreased (more equiaxed grains appeared) and the overall grain size of the matrix decreased. This resulted in an improved strength and ductility of the composite. Equations were developed with a reasonable accuracy correlating the strength with microstructural parameters. An excellent combination of strength (UTS = 215 MPa) and ductility (%Elongation = 10) was obtained for 6351 Al-7 vol.% Al₄SiC₄ composite as compared to base cast 6351 Al alloy (UTS = 121 MPa, %Elongation = 3).     

Microstrucmral characteristics and properties in centrifugal casting of SiCp/Zl104 composite

The microstructural characteristics and Brinell hardness of a cylinder produced by centrifugal casting were investigated using 20% (volume fraction) SiC_p/Zl104 composites. Macrostructure and XRD analysis show that most of SiC particles segregate to the external circumference of the cylinder, the other SiC particles maintain in the inner circumference of the cylinder, and a free particle zone is left in the middle circumference of the cylinder. Microstructural characteristics and quantitative assessment of SiC particles show that most of congregated SiC particles in 20%SiC_p/Zl104 composites are dispersed by centrifugal force, and the other congregated SiC particles and most of alumina oxide are segregated to the inner circumference of the cylinder. The SiC particles in aluminum melt can promote the refinement of primary α(Al) during solidification, and fine primary α(Al) grains can also promote the uniform distribution of SiC particles. Brinell hardness of SiC_p/Zl104 composites is connected with not only the volume fraction of SiC particles, but also the distribution of SiC particles in matrix alloy.     

Effect of forging temperature on the microstructures and mechanical properties of the SiCp/AZ91 magnesium matrix composite

In this paper, 10 vol. pct SiC_p/AZ91 magnesium matrix composite was fabricated by stir casting technology. The ingots were forged at temperatures of 320, 370 and 420 ℃, respectively. XRD, OM and SEM were used to characterize microstructure of the composites. It was shown that the clusters of particles in the as-cast composite were largely eliminated, and that the tensile strength was improved obviously.     

Thermal conductive properties of Ni-P electroless plated SiCp/Al composite electronic packaging material

Electroless plated SiC_p/Al composites with a high thermal conductivity are required for electronic packaging application. In this paper, in-plane thermal conductive properties of SiC_p/Al composites with and without electroless plated Ni-P coatings are compared, and influence of various characteristics of Ni-P coatings are investigated. It is found that in addition to thickness of the coatings, phosphorus concentration and microstructure of the plated layers also influence the thermal conductive properties of plated composites. Based on the results, it is suggested that a low phosphorus concentration and a properly tailored crystalline microstructure of the Ni-P coatings, together with a reasonable choice of coating thickness, may contribute to optimization of thermal conductive properties of the composite material.     

Effects of nano-SiCp content on microstructure and mechanical properties of SiCp/A356 composites assisted with ultrasonic treatment

nano-SiC_p/A356 composites with different nano-SiC_p contents were prepared by squeeze casting after ultrasonic treatment (UT). The effects of SiC_p content on the microstructure and mechanical properties of the nanocomposites were investigated. The results show that with the addition of nano-SiC_p, the microstructure of nanocomposites is obviously refined, the morphology of the α(Al) grains transforms from coarse dendrites to rosette crystals, and long acicular eutectic Si phases are shortened and rounded. The mechanical properties of 0.5%, 1% and 2% (mass fraction) SiC_p/A356 nanocomposites are improved continuously with the increase of nano-SiC_p content. Especially, when the SiC_p content is 2%, the tensile strength, yield strength and elongation are 259 MPa, 144 MPa and 5.3%, which are increased by 19%, 69% and 15%, respectively, compared with those of the matrix alloy. The improvement of strength is attributed to mechanisms of Hall-Petch strengthening and Orowan strengthening.     

Compressive behavior of SiCp/AlSi9Mg composite foams

Closed-cell AlSi₉Mg foams and SiC_p/AlSi₉Mg composite foams with different SiC_p volume fractions were prepared successfully by means of direct foaming of melt using CaCO₃ blowing agent in this paper. The compressive behaviors of these foams were studied. In comparison with the compressive stress–strain curve of AlSi₉Mg foams that of SiC_p/AlSi₉Mg composite foams is not smooth and exhibits some serrations. At the same relative density of composite foams, the yield stress and collapse stress of the composite foams increase with increasing SiC_p volume fraction. The relationship of yield stress, relative density and SiC_p volume fraction of SiC_p/AlSi₉Mg composite foams with a given particle size was obtained.     

Production and mechanical properties of nano SiC particle reinforced Ti–6Al–4V matrix composite

Different mass fractions (0, 5%, 10%, and 15%) of the synthesized nano SiC particles reinforced Ti–6Al–4V (Ti64) alloy metal matrix composites (MMCs) were successfully fabricated by the powder metallurgy method. The effects of addition of SiC particle on the mechanical properties of the composites such as hardness and compressive strength were investigated. The optimum density (93.33%) was obtained at the compaction pressure of 6.035 MPa. Scanning electron microscopic (SEM) observations of the microstructures revealed that the wettability and the bonding force were improved in Ti64 alloy/5% nano SiC_p composites. The effect of nano SiC_p content in Ti64 alloy/SiC_p matrix composite on phase formation was investigated by X-ray diffraction. The correlation between mechanical parameter and phase formation was analyzed. The new phase of brittle interfaced reaction formed in the 10% and 15% SiC_p composite specimens and resulted in no beneficial effect on the strength and hardness. The compressive strength and hardness of Ti64 alloy/5% nano SiC_p MMCs showed higher values. Hence, 5% SiC_p can be considered to be the optimal replacement content for the composite.     

Fabrication and Wear Behavior of Nanostructured Plasma-Sprayed 6061Al-SiCp Composite Coating

6061Al powder with 15 wt.% SiC particulate (SiC_p) reinforcement was mechanically alloyed (MA) in a high-energy attrition mill. The MA powder was then plasma sprayed onto weathering steel (Cor-Ten A242) substrate using an atmospheric plasma spray process. Results of particle size analysis and scanning electron microscopy show that the addition of SiC particles as the reinforcement influences on the matrix grain size and morphology. XRD studies revealed embedment of SiC_p in the MA-processed composite powder, and nanocrystals in the MA powder and the coating. Microstructural studies showed a uniform distribution of reinforced SiC particles in the coating. The porosity level in the coating was as low as 2% while the coating hardness was increased to 232VHN. The adhesion strength of the coatings was high and this was attributed to higher degree of diffusion at the interface. The wear rate in the coatings was evaluated using a pin-on-disk type tribometer and found to decrease by 50% compared to the 6061Al matrix coating. The wear mechanism in the coating was delamination and oxidative type.     

Pitting corrosion of artificially aged T6 AA2024/SiCp composites in 3.5 wt.% NaCl aqueous solution

The pitting corrosion behavior of the underaged (UA), peakaged (PA) and overaged (OA) T6 AA2024/0, 8, 14, 19, 24 vol.% 40 μm SiC_p(particles) composites was studied. The processing route used for the materials was the compocasting technique. Corrosion potentials (E_cor), pitting potentials (E_pit) as well as protection potentials (E_prot) were extracted from Double Cycle Polarization (DCP) curves contacted in aerated 3.5 wt.% NaCl aqueous solution. In addition 40 days immersion tests carried out and weight loss curves as well as total pit depth measurements were acquired. Pitting initiation and propagation as the main corrosion mechanism was driven by the aging kinetics which is ruled by the reduction in the retained vacancy concentration and at the same time by the increase in dislocation density as SiC_p volume fraction increases. Thus, alteration in pitting behavior among composites of different SiC_p content took place, although their ageing status was exactly the same.     

Thixoforming of AA 2017 aluminum alloy composites

A comparative evaluation has been carried out on the microstructure of aluminum based SiC and Al₂O₃ particle reinforced composites produced by semi-solid direct squeeze forming of composite powder at temperatures of 635-645 °C. The study is focused on the distribution of the reinforcement and the intermetallic phases, the porosity content, the microstructure of the matrix phase, the interfacial state and mechanical properties. The particle size of the reinforcements, the time of the high-energy ball milling procedure for the fabrication of composite powder and the semi-solid forming temperature had a strong influence on the quality of sample in terms of distribution of reinforcement and interfacial interaction. Ball milling improves the interface formation between reinforcement and matrix and influences the remelting behaviour. Increasing ball milling time and decreasing semi-solid forming temperature with isothermal holding time resulted in relatively homogenous microstructures and in a reduced amount of interaction between SiC and metal matrix. Best results were obtained for 5 vol.% SiC_p composites after 3 h ball milling, semi-solid formed at 635 °C and held for 10 min.     

Microstructures and mechanical properties of Al 2519 matrix composites reinforced with Ti-coated SiC particles

Ti-coated SiC_p particles were developed by vacuum evaporation with Ti to improve the interfacial bonding of SiC_p/Al composites. Ti-coated SiC particles and uncoated SiC particles reinforced Al 2519 matrix composites were prepared by hot pressing, hot extrusion and heat treatment. The influence of Ti coating on microstructure and mechanical properties of the composites was analyzed by scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS). The results show that the densely deposited Ti coating reacts with SiC particles to form TiC and Ti₅Si₃ phases at the interface. Ti-coated SiC particle reinforced composite exhibits uniformity and compactness compared to the composite reinforced with uncoated SiC particles. The microstructure, relative density and mechanical properties of the composite are significantly improved. When the volume fraction is 15%, the hardness, fracture strain and tensile strength of the SiC_p reinforced Al 2519 composite after Ti plating are optimized, which are HB 138.5, 4.02% and 455 MPa, respectively.     

High temperature oxidation behaviour of a TiAl-Al2O3 intermetallic matrix composite

A TiAl-based intermetallic matrix composite has been produced through sintering of mechanically milled Al/TiO₂ composite powder. The composite contains 42-50 vol.% of α-Al₂O₃ as the particulate reinforcement phase. Oxidation experiments were carried out at 800-900 °C in air up to 500 h to evaluate its oxidation and scale spallation resistance. A cast Ti-50at.%Al alloy was also tested for comparison. The composite samples showed much lower oxidation mass gain than the cast alloy under all testing conditions. Moreover, the composite samples exhibited extremely strong scale spallation resistance. Spallation could never be recorded and observed even under long-time intensive cyclic oxidation exposure. Based on the kinetic and microstructural studies, the mechanisms for the improved oxidation and spallation resistance are discussed.     

电弧超声对SiC_p/AlMMCs焊缝组织与性能的影响

以Ti合金作为填加材料,以氮氩混合气作为离子气,对SiCp/6061Al基复合材料进行电弧超声等离子弧原位合金化焊接,研究了电弧超声对等离子弧焊接头组织和性能的影响.结果表明,在不加超声时,焊缝中新生AlN相呈细长条状,Al3Ti相粗大,TiC,TiN等新生增强颗粒分布不均匀;在加入超声后,焊缝组织细密,TiC,TiN,AlN等增强相呈细小颗粒状存在,数量增加,且分布均匀,Al3Ti相尺寸减小,数量减少,从而有效改善了焊接接头的组织和性能,使焊接接头抗拉强度最大值达到225MPa,比不加超声时提高了约7%.