Effect of Al<Subscript>2</Subscript>O<Subscript>3</Subscript> particles on the microstructure and sliding wear of 7075 Al alloy manufactured by squeeze casting method

Aluminum (Al) alloy 7075 reinforced with Al₂O₃ particles was prepared using the stir casting method. The microstructure of the cast composites showed some degree of porosity and sites of Al₂O₃ particle clustering, especially at high-volume fractions of Al₂O₃ particles. Different squeeze pressures (25 and 50 MPa) were applied to the cast composite during solidification to reduce porosity and particle clusters. Microstructure examinations of the squeeze cast composites showed remarkable grain refining compared with that of the matrix alloy. As the volume fraction of particles and applied squeeze pressure increased, the hardness linearly increased. This increase was related to the modified structure and the decrease in the porosity. The effect of particle volume fraction and squeeze pressure on the dry-sliding wear of the composites was studied. Experiments were performed at 10, 30, and 50 N with a sliding speed of 1 m/s using a pin-on-ring apparatus. Increasing the particle volume fraction and squeeze pressure improved the wear resistance of the composite compared with that of the monolithic alloy, because the Al₂O₃ particles acted as load-bearing constituents. Also, these results can be attributed to the fact that the application of squeeze pressure during solidification led to a reduction in the porosity, and an increase in the solidification rate, leading to a finer structure. Moreover, the application of squeeze pressure improved the interface strength between the matrix and Al₂O₃ particles by elimination of the porosity at the interface, thereby providing better mechanical locking.     

Fabrication of A356 composite reinforced with micro and nano Al2O3 particles by a developed compocasting method and study of its properties

Aluminum/alumina composites are used in automotive and aerospace industries due to their low density and good mechanical strength. In this study, compocasting was used to fabricate aluminum-matrix composite reinforced with micro and nano-alumina particles. Different weight fractions of micro (3, 5 and 7.5 wt.%) and nano (1, 2, 3 and 4 wt.%) alumina particles were injected by argon gas into the semi-solid state A356 aluminum alloy and stirred by a mechanical stirrer with different speeds of 200, 300 and 450 rpm. The microstructure of the composite samples was investigated by Optical and Scanning Electron Microscopy. Also, density and hardness variation of micro and nano composites were measured. The microstructure study results revealed that application of compocasting process led to a transformation of a dendritic to a nondendritic structure of the matrix alloy. The SEM micrographs revealed that Al₂O₃ nano particles were surrounded by silicon eutectic and inclined to move toward inter-dendritic regions. They were dispersed uniformly in the matrix when 1, 2 and 3 wt.% nano Al₂O₃ or 3 and 5 wt.% micro Al₂O₃ was added, while, further increase in Al₂O₃ (4 wt.% nano Al₂O₃ and 7.5 wt.% micro Al₂O₃) led to agglomeration. The density measurements showed that the amount of porosity in the composites increased with increasing weight fraction and speed of stirring and decreasing particle size. The hardness results indicated that the hardness of the composites increased with decreasing size and increasing weight fraction of particles.     

Examination of wire electrical discharge machining of Al2O3p/6061Al composites

Alumina particle reinforced 6061 aluminum matrix composites (Al₂O₃p/6061Al) have excellent physical and chemical properties than those of a traditional metal; however, their poor machinability lead to worse surface quality and serious cutting tool wear. In this study, wire electrical discharge machining (WEDM) is adopted in machining Al₂O₃p/6061Al composite. In the experiments, machining parameters of pulse-on time were changed to explore their effects on machining performance, including the cutting speed, the width of slit and surface roughness. Moreover, the wire electrode is easily broken during the machining Al₂O₃p/6061Al composite, so this work comprehensively investigates into the locations of the broken wire and the reason of wire breaking.The experimental results indicate that the cutting speed (material removal rate), the surface roughness and the width of the slit of cutting test material significantly depend on volume fraction of reinforcement (Al₂O₃ particles). Furthermore, bands on the machined surface for cutting 20 vol.% Al₂O₃p/6061Al composite are easily formed, basically due to some embedded reinforcing Al₂O₃ particles on the surface of 6061 aluminum matrix, interrupt the machining process. Test results reveal that in machining Al₂O₃p/6061Al composites a very low wire tension, a high flushing rate and a high wire speed are required to prevent wire breakage; an appropriate servo voltage, a short pulse-on time, and a short pulse-off time, which are normally associated with a high cutting speed, have little effect on the surface roughness.     

TiP/AM60复合材料的组织与力学性能

采用超声振动辅助半固态搅拌法在不同搅拌速度下制备了钛颗粒增强AM60镁基复合材料。显微组织结果表明,加入Ti颗粒后,晶粒尺寸增大,Ti颗粒界面处析出Al₈Mn₅相,Ti颗粒与Mg基体的界面结构为结合良好的共格界面。拉伸试验结果表明,Ti_P/AM60复合材料的抗拉强度高于AM60镁合金基体。随着搅拌速度从300 r/min增加到900 r/min,抗拉强度和伸长率均先增大后减小。当搅拌速度为 600 r/min时,Ti_P/AM60复合材料的抗拉强度和伸长率分别达到最大值183 MPa和14.3%。与AM60基体合金相比,复合材料的抗拉强度提高了15%,延伸率提高了51%。     

Formation and microstructure of an in situ aluminum composite by oxygen spray technique

In situ particulate-reinforced Al and Al-Mg matrix composites were successfully fabricated by an oxygen spray technique. The results indicate that Al₂O₃ and MgAl₂O₄ particles directly nucleate and grow via gas-liquid oxidation reaction. The Al₂O₃ particles with the size of 0.1 to 0.5 μm are formed into the Al melt, according to an appropriate system and processing parameters. The reinforcements show a good wettability with the matrix. The hot-rolling process results in an improvement of the uniformity of the particle distribution in the matrix and an increase in the hardness of the composites.     

Aluminum matrix composites reinforced by in situ Al2O3 and Al3Zr particles fabricated via magnetochemistry reaction

Aluminum matrix composites reinforced by in situ Al₂O₃ and Al₃Zr particles are fabricated from A356-Zr(CO₃)₂ system via magnetochemistry reaction, and the morphologies, sizes and distributions of the in situ particles as well as the microstructures, mechanical mechanisms of the composites are investigated by XRD, SEM, TEM and in situ tensile tests. The results indicate that with the pulsed magnetic field assistance, the morphologies of the in situ particles are mainly with ball-shape, the sizes are in nanometer scale and the distributions in the matrix are uniform. The interfaces between the in situ particles and the aluminum matrix are net and no interfacial outgrowth is observed. These are due to the strong vibration induced by the applied magnetic field in the aluminum melt, which in turn, accelerates the melt reactions. The effects of the magnetic field on the above contributions are discussed in detail.     

Characteristic evaluation of Al2O3/CNTs hybrid materials for micro-electrical discharge machining

The characteristic evaluation of aluminum oxide (Al₂O₃)/carbon nanotubes (CNTs) hybrid composites for micro-electrical discharge machining (EDM) was described. Alumina matrix composites reinforced with CNTs were fabricated by a catalytic chemical vapor deposition method. Al₂O₃ composites with different CNT concentrations were synthesized. The electrical characteristic of Al₂O₃/CNTs composites was examined. These composites were machined by the EDM process according to the various EDM parameters, and the characteristics of machining were analyzed using field emission scanning electron microscope (FESEM). The electrical conductivity has a increasing tendency as the CNTs content is increased and has a critical point at 5% Al₂O₃ (volume fraction). In the machining accuracy, many tangles of CNT in Al₂O₃/CNTs composites cause violent spark. Thus, it causes the poor dimensional accuracy and circularity. The results show that conductivity of the materials and homogeneous distribution of CNTs in the matrix are important factors for micro-EDM of Al₂O₃/CNTs hybrid composites.     

Feasible process for producing in situ Al/TiC composites by combustion reaction in an Al melt

In situ Al/TiC composites with a homogeneous distribution of TiC reinforcements were prepared by adding a reactant mixture of Al-Ti-C to an Al melt. A certain amount of CuO addition facilitates a combustion reaction of the Al-Ti-C system and thereby enables the formation of in situ TiC at a reasonably low temperature range of 750–920 °C. Synthesised TiC particles with sizes of 1–2 μm are present in the Al matrix along with Al₃Ti. Besides the CuO addition, the melt temperature plays a significant role in the final microstructure of the composites. Increase in the melt temperature up to 920 °C with CuO provides more external heat input and initiates the combustion reaction within a few seconds. Pellet microstructure evidently shows that the polygonal Al₃Ti originates from the unreacted layer of which the distance is significantly shortens by increasing the melt temperature. The suppression of the Al₃Ti formation is the most likely to occur at 920 °C, with producing a large volume fraction of TiC in situ synthesised.     

Preparation and characterization of Mo/Al2O3 composites

In order to improve the performance of molybdenum, the Mo/Al₂O₃ composites were prepared by using a hydrothermal method for the synthesis of the precursor powders and subsequent powder metallurgical processing. The morphologies of the composite powders and the microstructures and properties of the composites were investigated. Compared with the pure Mo powder, the grains of composite powders are smaller because of the existence of the fine Al₂O₃ particles. The results from the sintered composites show that the fine Al₂O₃ particles are evenly distributed in the Mo matrix and well bonded with the Mo matrix. With increasing Al₂O₃ content, all the values of the micro-hardness, compressive strength and flow stress at 0.08 strain are increased. The strengthening effect is more remarkable at elevated temperatures. At room temperature, the compressive strength and the flow stress at 0.08 strain of the composite with 40 vol.% Al₂O₃ are 1.67 and 2.01 times greater than those of pure molybdenum, respectively, while the values are up to 2.02 and 2.52 at 1100 °C.     

Centrifugal casting of an Al-12Si-2Mg/Al2O3-particulate MMC. Part II: Evaluation of soundness and structure

A technique for the preparation of an MMC using centrifugal casting has been developed and tested for its feasibility in preparing Al-12Si-2Mg/Al₂O₃- particulate composites. The process is evaluated by observing the structure, measuring the homogeneity in the distribution of the ceramic particles, the porosity type and distribution, and by analysing the metal/ceramic interface for possible reactions.

The different processing conditions applied are: rotational frequency 16, 22.7 and 33.3 Hz (960, 1360 and 2000 rpm), Al₂O₃ particle size 30, 47, 60 and 89 μn, melt superheat 20, 100 and 150°C, specimen radius of rotation from 145 to 180 mm.

Because the ceramic particles are close packed, a uniform particle distribution with no agglomeration is obtained, and the interparticle distance depends only on the alumina particle size. The metal/ceramic interface was sharp with no reaction. Microporosity is observed in some locations due to incomplete infiltration between the alumina particles. Increasing rotational speed, particle size, superheat, and radius of rotation help to decrease the microporosity. The macrostructure along the composite length showed columnar grains followed by equiaxed grains. The type and size of the structure depend mainly on the composition of the matrix and not on the presence of the alumina particles.     

Microstructures and mechanical properties of BP/7A04 Al matrix composites

The microstructures and interface structures of basalt particle reinforced 7A04 Al matrix composites (BP/7A04 Al) were analyzed by using OM, TEM, SEM and EDS, and the mechanical properties of 7A04 Al alloy were compared with those of BP/7A04 Al matrix composites. The results show that the basalt particles are dispersed in the Al matrix and form a strong bonding interface with the Al matrix. SiO₂ at the edge of the basalt particles is continuously replaced by Al₂O₃ formed in the reaction, forming a high-temperature reaction layer with a thickness of several tens of nanometers, and Al₂O₃ strengthens the bonding interface between basalt particles and Al matrix. The dispersed basalt particles promote the dislocation multiplication, vacancy formation and precipitation of the matrix, and the precipitated phases mainly consist of plate-like η (MgZn₂) phase and bright white band-shaped or ellipsoidal T (Al₂Mg₃Zn₃) phase. The bonding interface, high dislocation density and dispersion strengthening phase significantly improve the mechanical properties of the composites. The yield strength and ultimate tensile strength of BP/7A04 Al matrix composites are up to 665 and 699 MPa, which increase by 11.4% and 10.9% respectively compared with 7A04 Al alloy without basalt particles.     

Welding of AA6061-(Al2O3 )p composite: effect of weld process variables and post-welding heat treatment on microstructure and mechanical properties

Abstract

Metal–matrix composites reinforced with Al₂O₃ particles combine the properties of the matrix (ductility and toughness) with the ceramic properties of the reinforcements (high strength). However, their wide application as structural materials requires a proper development of their joint process. The present work describes the results obtained from microstructural (optical and scanning electron microscopy) and mechanical evaluation (hardness and tensile tests) of the welded aluminium–matrix composite (AA6061) reinforced with 10% and 20% volume fraction Al₂O₃ particles (W6A10 and W6A20, respectively) using the MIG (metal inert gas) welding process and ER5356 (AlMg5) as filler material. A characteristic of the welds carried out in composites is that the size of the melt pool is wider than in the unreinforced materials, for the same welding conditions. This is caused by the lower thermal conductivity of the composites. Furthermore, composites act as an insulator reducing the cooling rate of the bath. The thermal effect of welding on different types of joints results in a loss of the mechanical properties in the heat affected zones (HAZ). These properties can be recovered with post-welding heat treatment.     

Production of High-Strength Al/Al2O3/WC Composite by Accumulative Roll Bonding

In this study, Al/Al₂O₃/WC composites were fabricated via the accumulative roll bonding (ARB) process. Furthermore, the microstructure evolution, mechanical properties, and deformation texture of the composite samples were reported. The results illustrated that when the number of cycles was increased, the distribution of particles in the aluminum matrix improved, and the particles became finer. The microstructure of the fabricated composites after eight cycles of the ARB process showed an excellent distribution of reinforcement particles in the aluminum matrix. Elongated ultrafine grains were formed in the ARB-processed specimens of the Al/Al₂O₃/WC composite. It was observed that as the strain increased with the number of cycles, the tensile strength, microhardness, and elongation of produced composites increased as well. The results indicated that after ARB process, the overall texture intensity increases and a different-strong texture develops. The main textural component is the Rotated Cube component.     

Microstructural evolution in liquid metal processed Al-alloy/SiCp composites

Al-Zn-Mg/SiC_P composites processed by a liquid metal processing (stir casting) technique have been microstructurally characterised in the as-cast and extruded conditions. Uniform distribution of SiC_P is observed with few defects, such as particle clusters, which are due to partial wetting and associated gas porosity. The constituent particles are associated with SiC_P although their composition remains unaffected compared with the control alloy. Hot extrusion of the composite using a shear type die showed banding of particles in the extruded direction with 9 vol. % composite. Such defects however, are not predominant in 18% SiC_P extruded composites. The presence of Mg₂Si is detected at the particle matrix interface as well as in the matrix.     

Tensile and wear properties of rolled Al5Mg-Al<Subscript>2</Subscript>O<Subscript>3</Subscript> or C particulate composites

Al5Mg alloy matrix composites reinforced with different percentages of Al₂O₃ (60 μm) or C (90 μm) particulates were prepared by the vortex method. The composites were then subjected to hot or cold rolling with different reduction ratios. The microstructures of the rolled composites revealed that the matrix grains moved around the particulate causing deformation. By continuing deformation, the particulates rearranged themselves in the matrix, leading to lensoid distortion. It was found that the addition of Al₂O₃ or C particulates increased the 0.2% proof stress and reduced both the tensile strength and ductility, compared with the monolithic alloy. Scanning electron microscopy (SEM) fractographic examinations showed that the composites reinforced with Al₂O₃ particulates failed through particulate fracture and matrix ligament rupture. However, the failure of the composites reinforced with C particulates was through particulate decohesion, followed by ductile failure of the matrix. Abrasive wear results showed that the wear rate of the Al5Mg alloy decreased with the addition of C particulates. However, increasing the volume fraction of C particulates did not have a prominent effect on the wear rate. The composites reinforced with Al₂O₃ particulates exhibited a higher wear rate than that of the unreinforced alloy. Furthermore, addition of both C and Al₂O₃ particulates into the Al5Mg matrix alloy did not significantly improve the wear resistance. For all composites studied in this work, hot or cold rolling had a marginal effect on the wear results.     

Experimental and Morphological Investigations Into Electrical Discharge Surface Grinding (EDSG) of 6061Al/Al2O3p 10% Composite by Composite Tool Electrode

In this study, a special experimental setup of EDSG using EDM and surface grinding machine has been developed in the laboratory to investigate the effect of seven input parameters namely tool polarity, peak current, pulse on-time, pulse off-time, rotational speed, abrasive particle size, and abrasive particle concentration on material removal rate (MRR) as performance measure of the process. The novelty of the present research work is that successful efforts have been made to machine the 6061Al/Al₂O_3p 10% metal matrix composites (MMC) by composite tool itself. The copper-based composite tool electrodes were fabricated by powder metallurgy route with different sizes of abrasives of silicon carbide, while 6061Al/Al₂O_3p 10% MMC were fabricated through stir-casting process. The research outcome will identify the important parameters and their effect on MRR of 6061Al/Al₂O_3p 10% composite in EDSG. The experimental results reveal that tool polarity, peak current, and rotational speed are the most influential parameters that affect MRR in EDSG process. The micro-structural and morphological analysis of machined surfaces has also been carried out to analyze the surface topography. It has been concluded that the abrasive particles substantially improves the MRR after removing the resolidified layer from the machined surface.     

Formation of Al<Subscript>2</Subscript>O<Subscript>3</Subscript>/Al Composites by Directed Melt Oxidation of Al-Si-Zn Alloy

Observations are presented on the initiation and growth of Al₂O₃/Al composites by the directed melt oxidation of Al-Si alloys containing metallic Zn or using external dopant ZnO. Thermal gravimetric analysis, optical microscopy, and x-ray diffraction analysis were employed to characterize the progress of oxidation and the nature of oxidation products. Both Zn and ZnO dopants were able to initiate the directed melt oxidation of Al-Si alloys without any Mg being present. Al₂O₃/Al composites were produced when the alloying Zn concentration exceeding 3 wt.%. The incubation period of the oxidation process for Al-Si-Zn alloys was shortened markedly and the amount of composite products increased with the increasing of Zn content in the alloy. In addition, doping with ZnO powder resulted in dense composite formation. A macroscopically planar surface and a fine microstructure promote oxidation growth in Al₂O₃/Al composites. Doping with ZnO powder offers a significant advantage over using metallic Zn for the directed melt oxidation of Al-Si alloy.     

Microstructure and mechanical properties of 7075 Al alloy based composites with Al2O3 nanoparticles

A new method was used to fabricate 7075 Al alloy based composites with Al₂O₃ nanoparticles to improve the distribution of particles. In this study, nano-sized particles were fed into the molten alloy through the flow of argon gas, then the Al₂O₃/7075 composites were prepared by solid-liquid mixed casting. The results indicated that the composite samples showed fine microstructure and achieved a homogeneous distribution of particles. Also, it was found that relative to the as-cast 7075 alloy, the Al₂O₃/7075 composites exhibited higher mechanical properties, which is due to the effect of uniform distributed Al₂O₃ nanoparticles reinforcement.     

Microstructure and strength of a squeeze cast aluminium piston alloy composite reinforced with alumina short fibre using Al2O3 binder

Abstract

Alumina short fibre preforms were fabricated using an Al₂O₃ binder and infiltrated with aluminium piston alloy melt by squeeze casting. Al₂O₃ binder is thermodynamically more stable than the conventional SiO₂ binder and reduces the fibre/matrix interfacial reaction. The effects of fibre volume fraction, temperature and heat treatment on the yield strength and tensile strength of the composite were investigated. The Al₂O₃ binder provided a satisfactory interfacial bond between the fibre and the matrix without any interfacial reaction or fibre damage. Aging behaviour was not changed by reinforcement. At every temperature, the composites showed the highest strength with a fibre volume fraction of 18%. The strength of the composite was improved by T6 heat treatment. Examination of the fracture surfaces and calculation of the tensile strength using the rule of mixtures indicated that the 18% fibre reinforced composite had a strong interfacial bond even at high temperatures.     

Preparation of Al2O3–ZrO2–SiO2 ceramic composites by high-gravity combustion synthesis

By a furnace-free technique of high-gravity combustion synthesis, Al₂O₃–ZrO₂–SiO₂ ceramic composites were prepared via melt solidification instead of conventional powder sintering. The solidification kinetics and microstructure evolution of the ceramic composites in high-gravity combustion synthesis were discussed. The phase assemblage of the ceramic composites depended on the chemical composition, where both (Al₂O₃ + ZrO₂) and (mullite + ZrO₂) composites were obtained. The ceramic composites consisted of ultrafine eutectics and sometimes also large primary crystals. In the (mullite + ZrO₂) composites, two different morphologies and orientations were observed for the primary mullite crystals, and the volume fraction of mullite increased with increasing SiO₂ content. The ceramic composites exhibited a hardness of 11.2–14.8 GPa, depending on the chemical composition and phase assemblage.