Microstructural and mechanical behavior of multi-walled carbon nanotubes reinforced Al–Mg–Si alloy composites in aging treatment

Microstructural and mechanical behavior of heat treatable Al–Mg–Si (6XXX series) alloy composites reinforced with multi-wall carbon nanotubes (MWCNTs) fabricated by powder metallurgy process were investigated by SEM-EDS, XRD, tensile test and Vicker’s hardness test. As-extruded P/M 6063 alloy composites with CNT reinforcements indicated a small increment of mechanical strength compared to the monolithic 6063 alloy with no CNT before T6 heat treatment. When T6 heat treatment was applied to the specimens, the 6063 composite with CNTs showed a noticeable decrease of yield stress (YS) improvement, compared to the monolithic Al alloy. It means that Mg₂Si precipitates hardening effect by the artificial aging treatment was insufficient for the composite containing CNTs. This was mainly because Mg alloying elements were diffused around CNTs and consumed to form Al₂MgC₂ compounds, and resulted in the incomplete matrix strengthening behavior by Mg₂Si precipitation after the aging treatment.     

Synthesis,microstructure, and mechanical properties of WC–TiC–Co ceramic composites

A ceramic composite constituting the formula 78 wt% WC–16 wt% TiC–6 wt% Co denoted as the 78WC–16TiC–6Co ceramic composite was fabricated using a powder metallurgy process, by utilising commercially available WC and Co powders, and laboratory produced TiC powders. TiC powders were produced from machining chips of Grade 4 Titanium. Five different procedures were followed for the manufacturing process by altering the amount of the binding agent (stearic acid) and/or compacting pressure and/or sintering regime (temperature and time) and/or mixing process (dry mixing and mechanical alloying). Characterisation investigations conducted on the sintered samples revealed that stearic acid as the binding agent resulted in the decrease of the relative density while mechanical alloying (MA) induced finer microstructures. The 78WC–16TiC–6Co composites manufactured from commercially available and laboratory produced TiC powders using similar process procedures (including MA) exhibited similar characteristics in terms of relative density, hardness, and wear performance.     

Study of the mechanical and structural properties of Zn–Ni–Co ternary alloy electroplating

Ternary zinc–nickel–cobalt alloys were electrodeposited on steel substrates from sulfate bath by direct current. Microstructural and mechanical properties of Zn–Ni–Co ternary alloy coatings were investigated and contrasted with the characteristics of Zn–Ni and Zn–Co alloy coatings. It was found that the obtained Zn–Ni–Co alloy exhibited more preferred surface morphology and mechanical properties as compared to the other alloy coatings electroplated at the same conditions. X-ray diffraction studies showed that the deposits of Zn–Ni–Co alloy coatings consisted of Zn, ZnNi₃, and ZnCo₁₃ phases. The structure, surface morphology, and surface topography of the deposited alloys were characterized by X-ray diffraction (XRD), scanning electron microscopy (SEM) with energy dispersive X-ray microanalysis (EDS), and atomic force microscopy (AFM). In addition, hardness, elasticity modulus, and adhesion strength of coated alloys were measured with dynamic ultra-microhardness (DUH) and Scratch tester.     

Floating catalyst chemical vapor infiltration of nanofilamentous carbon reinforced carbon/carbon composites – Densification behavior and matrix microstructure

Nanofilamentous carbon (NFC) reinforced carbon/carbon composites were prepared by floating catalyst film boiling chemical vapor infiltration from xylene pyrolysis at 1000–1100 °C using ferrocene as a catalyst. The influence of the catalyst content on the densification behavior and matrix microstructure of the composites was studied. Results showed that the deposition rate of pyrocarbon (PyC) was enhanced remarkably by the catalyst. The density of the composites deposited at a catalyst content of 0–2.0 wt% decreased along both the axial and the negative radial directions. Rough laminar (RL) PyC matrix was formed at 0–0.8 wt% catalyst content by heterogeneous nucleation and growth. A hybrid matrix consisting of RL and isotropic (ISO) PyCs appeared at a catalyst content of 1.2–2.0 wt%. The reasons for this ISO PyC formation were attributed to the deposition of carbon encapsulated iron particles and homogeneous nucleation. A reinforcing network composed of NFCs and vapor grown carbon fibers was formed on the fiber/matrix interface and within the matrix in this floating catalyst process. The structure of NFC transformed from nanotube to nanofiber when the catalyst content was over 0.5 wt%, around which composites of a high density of 1.75 g/cm³ and uniform RL PyC matrix were produced rapidly.     

Fabrication and mechanical properties of Al2O3–TiC ceramic composites synergistically reinforced with multi-walled carbon nanotubes and graphene nanoplates

In this study, Al₂O₃–TiC composites synergistically reinforced with multi-walled carbon nanotubes (MWCNTs) and graphene nanoplates (GNPs) were prepared via spark plasma sintering (SPS). The effects of the MWCNT and GNP contents on the phase composition, mechanical properties, fracture mode, and toughening mechanism of the composites were systematically investigated. The experimental results indicated that the composite grains became more refined with the addition of MWCNTs and GNPs. The nanocomposites presented high compactness and excellent mechanical properties. The composite with 0.8 wt% MWCNTs and 0.2 wt% GNPs presented the best properties of all analysed specimens, and its relative density, hardness, and fracture toughness were 97.3%, 18.38 ± 0.6 GPa, and 9.40 ± 1.6 MPa m^1/2, respectively. The crack deflection, bridging, branching, and drawing effects of MWCNTs and GNPs were the main toughening mechanisms of Al₂O₃–TiC composites synergistically reinforced with MWCNTs and GNPs.     

Thermophysical properties of carbon fiber reinforced multilayered (PyC–SiC)n matrix composites

Three kinds of carbon fiber reinforced multilayered (PyC–SiC)_n matrix (C/(PyC–SiC)_n) composites (n = 1, 2 and 4) were prepared by means of layer-by-layer deposition of PyC and SiC via chemical vapor infiltration. Thermal expansion behaviors in the temperature range of 800–2500 °C and thermal conductivity from room temperature to 1900 °C of C/(PyC–SiC)_n composites with various microstructures were investigated. The results show that with increasing PyC–SiC sequences number (n), the coefficients of thermal expansion of the composites decrease due to the increase of interfacial delamination, providing room for thermal expansion. The thermal diffusivity and thermal conductivity also decrease with the increase of sequences number, which are attributed to the enhancement of phonon-interface scattering resulted from the increasing number of interfaces. Modified parallel and series models considering the interfacial thermal resistance are proposed to elaborate thermal conductivity of the composites, which is in accordance with the experimental results.     

Structure and properties of electrodeposited Ni–Co–YZA composite coatings

The aim is to develop an economical composite coating with high thermal stability. Ni–Co alloys are found to possess better thermal, physical and mechanical properties compared to Ni. Also, oxide particles as distributed phase can impart better thermal stability. Hence, particulates of composite Yttria stabilised zirconia, a commonly used high temperature material and alumina (YZA) were reinforced in various Ni–Co alloy matrices through electrodeposition. The influence of YZA on the microhardness, tribology and corrosion behaviour of Ni–Co alloys with Co contents of 0 wt.%, 17 wt.%, 38 wt.% and 85 wt.% was evaluated. Optical and Scanning Electron Microscopy (SEM) confirmed the presence of YZA particles and Energy Dispersive X-ray Analysis (EDX) revealed the composition. Tribology testing showed that composite containing 38 wt.% Co displayed better wear resistance. It was found from the immersion corrosion studies that Ni–17Co–YZA coating displayed improved corrosion resistance. Thermal stability studies showed that Ni–85Co–YZA coating retained its microhardness at temperatures of 600 °C. Thus, these coatings can be tailored for various applications by varying the cobalt content.     

Effect of ZrB2 on the microstructure,mechanical and tribological properties of Mo–Si–B matrix composites

Composites with good mechanical and tribological properties are in high demand for engineering applications. Toward this aim, the Mo–12Si–8.5B alloy with 2.5–10 wt% ZrB₂ ceramic was prepared. The effects of the ZrB₂ content on the microstructure, mechanical properties, and tribological behavior were thoroughly investigated. The composites exhibited reduced density and enhanced hardness and strength owing to the dispersion strengthening of ZrB₂ particles, thus resulting in improved wear resistance. The frictional properties are highly dependent on the ZrB₂ content and counterpart materials. When coupled with GCr15 steel, it shows much slighter abrasive and adhesive wear; therefore, it presents a more preferable anti-wear performance. The wear rate of the composite with 7.5 wt% ZrB₂ showed a minimum value of 2.71 × 10⁻⁷ mm³N⁻¹m⁻¹.     

Pulse current electrodeposition and corrosion properties of Ni–W alloy coatings

Ni–W alloy coatings were prepared on a mild steel substrate by means of pulse current (PC) and compared to the coatings electrodeposited by direct current (DC). In particular the study dealt with the influence of the frequency using pulse current on the surface morphology while maintaining a constant duty cycle. A constant charge for DC and PC electrodeposition of Ni–W alloy coatings was used. The morphology of the coatings was explored by scanning electron microscopy and the composition of the coatings was analysed by X-ray powder diffraction and energy dispersive X-ray analysis. Corrosion resistance of Ni–W alloy coatings was investigated by potentiodynamic polarization in a chloride medium. The corrosion products were analysed by Raman spectroscopy. It was found that the temperature of the electrolysis affects current efficiency of the DC and PC electrodeposition. The frequency of pulse electrodeposition alters the morphology of the Ni–W alloy coatings. There was evidence of the positive influence of increased tungstate concentration in the electrolyte on corrosion resistance of the Ni–W alloy coatings.     

Densification,microstructure and mechanical properties of ZrB2–SiCw ceramic composites

ZrB₂–SiCw composites were prepared through hot-pressing at a low temperature of 1800 °C, and Al₂O₃ plus Y₂O₃ were added as sintering aids. Analysis revealed that additives may react with impurities (i.e. surface oxygen impurities and residual metallic impurities) to form a transient liquid phase, thus promote the sintering and densification of ZrB₂–SiCw composites. The content of additives was found to have a significant influence on the sinterability, microstructure and mechanical properties of ZrB₂–SiCw composites. ZrB₂–SiCw composite prepared with a small amount of additives (3 vol.%) provided the optimal combination of microstructure (relative density of 98.3%) and excellent properties, including flexural strength of 783 MPa and fracture toughness of 6.7 MPa m^1/2. With further addition of additives, SiC whiskers were inclined to gather together and be enveloped by excessive liquids to form core-rim-like structures, which lead to little decrease in mechanical properties.     

Structure,microstructure and corrosion properties of brush-plated Cu–Ni alloy

Cu–Ni alloy coatings on copper substrate by the brush-plating process have been investigated using XRD and AFM. The X-Ray diffraction analysis revealed that the brush-plated Cu–Ni alloy was heterogeneous and composed of cubic Cu_3.8Ni phases. Uniform surface coverage of the substrate by granular morphology was observed from AFM. The corrosion protection performance of the brush-plated Cu–Ni alloy on copper substrate has been assessed using electrochemical corrosion tests. These results indicated a high charge transfer and low I _corr for the alloy system compared with copper deposits and the copper substrate.     

Investigation of microstructure and mechanical properties of Cu/Ti–B–SiCp hybrid composites

In this study, Cu/Ti–B-SiC_p hybrid composite materials were produced by powder metallurgy method using three different sintering temperatures (950, 1000, 1050 °C). The optimum sintering temperature of Cu main matrix composites reinforced with Ti–B-SiC_p reinforcement materials at 2-4-6-8 wt.% were determined and their microstructure and mechanical properties were investigated. As a result of microstructure studies, it was determined that reinforcement elements have a homogeneous interface in the main matrix. The hardness of the produced composites was determined by the Brinell hardness method. The highest hardness value (77.74 HB) was determined in the sample with 6 wt% reinforcement ratio. In the tensile and three point bending tests, maximum strength values (112.96 MPa, 37.76 MPa) were found in samples with a reinforcement ratio of 4 wt%. It was determined that increasing reinforcement ratios and sintering temperature made a positive contribution to the hybrid composite materials produced.     

Effect of diamond volume fraction on the microstructure and mechanical properties of SPS WC–Co/diamond composites

In this research, the effect of the volume percentage of diamond additive on the sintering behavior, microstructure, and mechanical properties of WC–Co was investigated. WC–Co/diamond composites with different percentages of 0%, 2.5%, 5%, 7.5%, and 10% by volume of diamond were made by spark plasma sintering at 1300°C and 40 MPa for 5 min. A small amount of phase transformation from the diamond phase to the graphite phase was observed. The amount of graphitization was low due to low temperature and short sintering time. The addition of diamond leads to a significant enhancement in both the hardness and fracture toughness of the composites, overcoming the trade-off between hardness and toughness typically observed in WC-based materials. The sample reinforced with 5% by volume of diamond showed simultaneously the highest hardness (22.9 GPa), the highest fracture toughness (22.7 MPa m^1/2), and the highest flexural strength (1896 MPa). The uniform dispersion, good bonding of the superhard diamond phase with the matrix, and the fine microstructure caused the high hardness and toughness of composite. The main effective mechanisms in increasing the fracture toughness of the composite were crack deflection, bridging, and blocking of crack propagation by diamond particles.     

Surface microstructure and corrosion resistance of electrodeposited ternary Zn–Ni–Co alloy

The electroplating of ternary Zn–Ni–Co alloy, the influence of cobalt codeposition on crystal orientation, surface topography and corrosion resistance were investigated and contrasted with the characteristics of Zn–Ni electrodeposits. It was found that the Zn–Ni–Co alloy showed better corrosion resistance, in 3% sodium chloride, in comparison with Zn–Ni alloy electroplated under similar conditions. The best corrosion resistance was observed for ternary deposits having 11.24% Ni and 6.52% Co. The crystal orientation and surface topography were characterized by means of X-ray diffraction analysis and scanning electron microscopy, respectively.     

Effect of WC particle size on the microstructure and mechanical properties of Ni–Co coarse grain cemented carbide

The effect of different WC grain size additions on the microstructure and grain distribution of Ni–Co coarse crystalline cemented carbide was studied. And then the effect of grain distribution on the mechanical properties of cemented carbide was discussed. The effect of WC grain size on the grain size and coherency of cemented carbide was analyzed by microstructure. And the distribution of grains in the microstructure was investigated by the truncation method. The addition of fine (1.1–1.4 μm), medium (2.3–2.7 μm), and coarse WC (5.6–6.0 μm) particles can increase the nucleation rate of WC grains in the bonded phase. And the higher grain growth driving force can produce the theoretical limitation of nucleation and inhibit the coarsening of WC grains to a certain extent. The WC grain size has an insignificant effect on the frequency of the occurrence of super-coarse grains in coarse crystalline cemented carbide. The average grain size and super coarse grains in microstructure gradually decrease, which promotes the improvement of transverse rupture strength. The increase of the adjacent degree and the decrease of the mean free path reduce which is beneficial to the improvement of the corrosion resistance of the alloy. The best overall performance of the alloy is achieved when fine-grained WC is added.     

Electrochemical characterization of Ni–P and Ni–Co–P amorphous alloy deposits obtained by electrodeposition

Ni–P and Ni–Co–P amorphous alloy deposits were obtained by electrodeposition at 80 °C on carbon steel substrates. The influence of the electrolyte Co²⁺ concentration and of applied current density was investigated. The corrosion behaviour of amorphous and crystalline deposits was evaluated by polarization curves and electrochemical impedance spectroscopy in NaCl 0.1 M solution at room temperature. Impedances were measured for samples under total immersion (free potential against time) and for polarized samples in predefined regions of the polarization curves. It was found that the alloy deposit composition is highly affected by the composition of the electrolyte but displays no significant dependence on applied current density. The results showed that the presence of Co on Ni–P amorphous alloys improves the deposit performance in the studied corrosive medium. It was also verified that the amorphous structure provides higher corrosion resistance to both Ni–P and Ni–Co–P alloys.     

Preparation and microstructure of 3D framework TiC–TiB2 ceramics and their reinforced steel matrix composites

An efficient method for in-situ fabrication of a three-dimensional framework based on heterogeneous TiC–TiB₂ materials with different B₄C content has been reported in the present study. Interpenetrating TiC–TiB₂/steel composites were subsequently prepared by infiltrating molten steel into TiC–TiB₂ framework. The XRD and SEM analyses confirmed that three-dimensional ceramics framework mainly consisted of heterogeneous TiC–TiB₂ phases with the ceramic particles closely connected with each other. TiC–TiB₂ ceramics framework exhibited a high porosity in the range 87.11%–95.95% and low bulk density of 0.17–0.22 g/cm³. The sample with ceramic framework containing 20 wt% B₄C exhibited the strongly continuous microstructure, whereas the sample with ceramic framework containing 25 wt% B₄C had the weakly continuous framework. The Vickers hardness and fracture toughness in the composites reached 284.5 HV and 23.7 MPa m^1/2, respectively. An optimal TiC: TiB₂ mass ratio of 37:55 could effectively inhibit the decomposition of TiB₂ in the molten steel. Inspecting the fracture surface, the dominated fracture modes was noted to be the quasi-cleavage and trans-granular dimple fracture, which could be attributed to novel three-dimensional bi-continuous structure formed between ceramic framework and steel substrate.     

Organic–inorganic interface enhancement for boosting mechanical and tribological performances of carbon fiber reinforced composites

The limitation in the poor interface would severely affect the further development and application of carbon fiber reinforced composites (CFRP). Unique organic–inorganic hybrid architectures of MOF-5-NH₂ and carboxymethyl cellulose (CMC) were established on the fiber/matrix interphase for promoting mechanical and tribological performances of the composites. The existence of above interfacial reinforced structure was in favor of generating abundant micromechanical interaction sites for enhancing mechanical interlocking. Meanwhile, high-density chemical crosslinking networks played a positive role in elevating interfacial adhesion, further relieving stress concentration and hindering crack propagation. The tensile strength of CFRP-2, CFRP-3, CFRP-4, and CFRP-5 exhibited a significant rising of 27.18%, 30.64%, 27.75%, and 36.88%, respectively. The friction coefficient of MOF-5-NH₂/CMC modified sample increased from 0.0953 to 0.1219, while the drop in the wear rate of the composites achieved 68.51%. This work provides an effective method for achieving the structure–function integrated design of composite materials according to the organic–inorganic interface enhancement of MOF-5-NH₂/CMC.     

Floating catalyst chemical vapor infiltration of nanofilamentous carbon reinforced carbon/carbon composites – Integrative improvement on the mechanical and thermal properties

Nanofilamentous carbon (NFC) reinforced carbon/carbon composites were produced by floating catalyst chemical vapor infiltration with ferrocene content ranging 0–2.0?wt%. The NFCs and increased graphitization degree led to an improvement on the mechanical and thermal properties. An excellent combination of high strength and thermal conductivity (TC), and low coefficient of thermal expansion (CTE) was reached by adding 0.5–0.8?wt% catalyst. When the content exceeded 0.8wt%, the strength and TC were decreased by the limited NFC growth and matrix transited from rough laminar to isotropic pyrocarbon. After the treatment of 2500?°C, the strength and CTE decreased whereas the TC was increased. With the catalyst contents at 0.5–0.8?wt%, the flexural and shear strength retention ratios achieved a high value of 73.1–74.5 and 79.1–79.4%, respectively, and the in-plane and out-of-plane TCs exhibited maxima of 339.1 and 72.5?W/(m?K). Relatively low CTE was obtained at 2.0?wt% catalyst owing to the increased amount of cracks and pores.     

Oxidation mechanisms of SiC-fiber–reinforced Si eutectic alloy matrix composites at elevated temperatures

SiC-fiber–reinforced binary Si eutectic alloy composites have been developed for aerospace applications using the melt infiltration method. In this study, the oxidation mechanisms of various binary Si eutectic alloys were evaluated at elevated temperatures. We suggest that the oxidation resistance of eutectic alloys could be predicted using the Gibbs energy change for the oxidation reaction. Based on these calculations, eutectic alloys of Si-16at%Ti, Si-17at%Cr, Si-22at%Co, Si-38at%Co, and Si-27at%Fe were prepared. These alloys produced uniform SiO₂ layers and showed the same oxidation resistance as Si at 1000°C under humid conditions. Therefore, SiC composites using Si alloys with excellent oxidation resistance can be predicted using thermodynamic calculations.