A nano-indentation study on the mechanical behaviour of the matrix material in an AA6061 - Al2O3 MMC

The nano-indentation technique is a suitable technique to measure hardness and elastic moduli profiles of AA6061 reinforced with Al₂O₃ particles, since it allows measurements of mechanical properties on a micrometer range. To investigate possible local variations in mechanical behaviour of the matrix material due to precipitation reactions being affected by the presence of ceramic reinforcements, nano-indentation tests were done on both metal matrix composite (MMC) as well as unreinforced reference material, in three different heat treatment conditions. Matrix response depends on heat treatment condition, but is approximately equal for the MMC and the base reference alloy. Due to the various imposed heat treatments, magnesium enrichment around the ceramic particles was observed, but hardness and elastic modulus of this interfacial layer could not be measured. To confirm the preferential segregation of Mg near the particle/matrix interface, linescans were made with a Scanning Electron Microscope (SEM) equipped with EDS (Energy Dispersive Spectrum) facilities. The limited width of the Mg rich zone explains the absence of typical 'interphase' indentations in this investigation. Hardly any differences in calculated elastic moduli and hardness values were found for the three heat treatment conditions investigated, when comparing results of AA6061 reference material with results of an AA6061 matrix in an MMC. This result is of great importance when modelling the mechanical behaviour of MMCs using the finite element method, since it permits the assumption that the MMC matrix material behaves similar to the same aluminium alloy without ceramic reinforcements.     

Modelling fracture in an Al2O3 particle reinforced AA 6061 alloy using Weibull statistics

Fracture in an AA 6061 based metal matrix composite (MMC) containing 20 vol % Al₂O₃ particles is modelled using an axisymmetrical finite element model and a statistical approach for calculating the strength of reinforcing ceramic particles via the Weibull model. Within this model, variables such as the volume fraction, particle size and matrix alloy properties can be varied. When modelling the fracture behaviour of one particle, it is assumed that the survival probability of the ceramic particle is governed by a Weibull distribution. Fracture statistics of the MMC is examined by plotting the survival probability of an Al₂O₃ particle vs. the macroscopic axial stress applied on the whole MMC. Based on initial calculations it can be concluded that the relation between the macroscopic applied stress on the MMC and the survival probability of the ceramic particle can be described by the Weibull modulus m, as long as the stress distribution in the matrix surrounding the particle is proportional to the applied load and that triaxial loading of the MMC results in a lower survival probability compared to uniaxial loading. Fracture behaviour of MMCs can well be described and a 'mastercurve' can be made for various characteristic stresses and matrix yield stresses at a specific hardening exponent for the matrix material.     

Thermomechanical fatigue of short fibre reinforced aluminium matrix piston alloy

Abstract

The technical potential of short fibre reinforced aluminium matrix composites lies in their higher stiffness and higher strength at elevated temperatures compared with unreinforced matrix alloys. In the present investigation, thermal cycling creep tests were conducted on the piston alloy AlSi12CuMgNi reinforced with 20% Saffil (Al₂O₃) short fibres, to simulate the cold start conditions of combustion engines. After processing of the metal matrix composite (MMC) by direct squeeze casting, four heat treatment conditions were produced. Specimens under constant load were thermally cycled between 50 and 300°C, whereby a heating and cooling speed of 12.5 K s1 was achieved. Series of up to 5000 cycles at tensile stresses between 20 and 80 MPa were executed, comparing reinforced specimens and unreinforced matrix material. The results of these experiments showed that the creep properties of the alloy, especially minimum creep rate and lifetime to fracture, were improved by the reinforcement. Furthermore, the creep rate of the MMC was essentially independent of the heat treatment condition, whereas the minimum creep rate was increased significantly for the matrix material by overaging. It can be concluded that precipitation strengthening influenced the creep properties of unreinforced specimens only, which is in good agreement with theoretical considerations. An analysis of fibre length revealed that the majority of the fibres broke at between 50 and 75% of the lifetime, just before the beginning of tertiary creep. Metallographic investigations using a scanning electron microscope did not show fibre pullout, but multiple fracture of fibres along the whole specimen. Micromechanical models for isothermal creep in short fibre reinforced aluminium alloys confirm the above results, since tertiary creep is assumed to be a consequence of fibre fracture.     

Particle reinforced AA 6061 and A359 aluminium alloys under cyclic thermal loading conditions

Abstract

The thermal cycling creep characteristics of aluminium matrix composites AA 6061+22 vol.-%Al₂O₃particles and A359+20 vol.-%SiC particles were analysed with respect to the dependence of the behaviour on the applied external stress and on different heat treatment conditions. The specimens were thermally cycled using a triangular waveform between 50 and 300°C with dwell times of 3 s at the minimum and maximum temperatures. An enhanced lifetime was found for reinforced aluminium alloy 6061 compared with A359+20 vol.-%SiC and it was found that overaging of the matrix prior to the thermal cycling experiments increases the creep rates significantly in both composites. The determination of the true, thermally compensated strain revealed a much higher in cycle strain evolution in A359+20 vol.-%SiC. Reverse creep during the cooling sequence was observed in both composites where it depends on the applied stress.     

Creep behavior of an Al-6061 metal matrix composite produced by liquid metallurgy processing

Constant stress creep tests were conducted on an Al-6061 metal matrix composite reinforced with alumina microspheres and produced using liquid metallurgy processing. By introducing a threshold stress into the creep analysis, it is concluded that creep occurs by viscous glide in the matrix with a stress exponent of ≈ 3 and an activation energy of ≈125 kJ mol⁻¹. The threshold stress is probably associated with the presence of fine spinel crystals which have been identified in the matrix of the composite.     

Microstructure,tensile and fatigue properties of AA6061/20 vol.%Al2O3p friction stir welded joints

Metal matrix composites reinforced with Al₂O₃ particles combine the matrix properties with those of the ceramic reinforcement, leading to higher stiffness and superior thermal stability with respect to the corresponding unreinforced alloys. However, their wide application as structural materials needs proper development of a suitable joining processes. The present work describes the results obtained from microstructural (optical and scanning electron microscopy) and mechanical evaluation (hardness, tensile and low-cycle fatigue tests) of an aluminium alloy (AA6061) matrix composite reinforced with 20 vol.% fraction of Al₂O₃ particles (W6A20A), welded using the friction stir welding process. The mechanical response of the FSW composite was compared with that of the base material and the results were discussed in the light of microstructural modifications induced by the FSW process on the aluminium alloy matrix and on the ceramic reinforcement. The FSW reduced the size of both particles reinforcement and aluminium grains and also led to overaging of the matrix alloys due to the frictional heating during welding. The FSW specimens, tested without any post-weld heat treatment or surface modification showed lower tensile strength and higher elongation to failure respect to the base material. The low-cycle fatigue life of the FSW composite was always lower than that of the base material, mainly at the lower strain-amplitude value. The cyclic stress response curves of the FSW composite showed evidence of progressive hardening to failure, at all cyclic strain-amplitudes, while the base material showed a progressive softening.     

Joining of alumina short-fibre reinforced AA6061 alloy to AA6061 alloy and to itself

The weldability of aluminium short-fibre reinforced AA6061 alloy (FRM) to AA6061 alloy and to itself using aluminium brazing materials has been investigated. AA4045 and BA03 were selected as brazing materials. When FRM was brazed to AA6061 alloy with AA4045 sheet, a disorder of fibre orientation near the interface was recognized at a brazing temperature above 863 K. Furthermore, the interface became very irregular and porous. The tensile strength achieved was about 100 MPa on brazing below 863 K. On the other hand, BA03 sheet, which has thin AA4045 layers on an AA3003 alloy layer, made the joint strong. The strength was about 200 MPa. BA03 induced little disorder of fibre arrangement and better contact at the interfaces. The BA03/AA6061 alloy interface was more porous than the FRM/BA03 interface and, hence, weaker. FRM/FRM joints with BA03 sheet had good strengths above 200 MPa.     

Material characterisation and mechanical properties of Al2O3-Al metal matrix composites

The mechanical properties of metal matrix composites (MMCs) are critical to their potential application as structural materials. A systematic examination of the effect of particulate volume fraction on the mechanical properties of an Al₂O₃-Al MMC has been undertaken. The material used was a powder metallurgy processed AA 6061 matrix alloy reinforced with MICRAL-20, a polycrystalline microsphere reinforcement consisting of a mixture of alumina and mullite. The volume fraction of the reinforcement was varied systematically from 5 to 30% in 5% intervals. The powder metallurgy composites were extruded then heat treated to the T6 condition. Extruded liquid metallurgy processed AA 6061 was used to establish the properties of the unreinforced material.     

Fatigue behaviour of a Saffil-reinforced aluminium alloy (AA6061)

Fatigue crack growth properties of squeeze-cast AA6061 alloy reinforced with 20 volume% of Saffil fibres, the squeeze-cast matrix and the matrix alloy in the form of cold-rolled sheet were studied. Both ΔK_th,nom and ΔK_th,eff are significantly higher in the composite than in the matrix alloys. Conversely, fibre reinforcement impairs the resistance to fatigue crack growth at higher ΔK where the matrix alloys are superior to the composite. The highest crack closure level was found in the composite. Quantitative fractography showed that the fibres and not the grain size control the crack path in the composite. It is shown, partly quantitatively, that crack deflection and crack branching reduce the local stress intensity factor at the crack tip, an effect that is most pronounced in the composite and in the squeeze-cast matrix. Increased stiffness and cyclic hardening of the composite over the matrix alloys further improve its resistance to near-threshold fatigue crack growth.     

The influence of Al2O3 particulate reinforcement on cyclic stress response and fracture behavior of 6061 aluminum alloy

The cyclic stress response characteristics and cyclic fracture behavior of aluminum alloy 6061 discontinuously reinforced with particulates of Al₂O₃ are presented and discussed. The 6061/Al₂O₃ composite specimens and the unreinforced 6061 aluminum alloy were cyclically deformed using tension-compression loading under constant total strain amplitude control. Both the composite and the unreinforced alloy exhibited softening to failure from the onset of cyclic deformation. The degree of softening was observed to increase at the elevated test temperature for both the composite and the unreinforced counterpart. The intrisic micromechanisms controlling the stress response characteristics during fully-reversed cyclic straining are highlighted and rationale for the observed behavior is discussed. The cyclic fracture behavior of the composite is discussed in terms of the competing influences of intrinsic microstructural effects, deformation characteristics arising from a combination of mechanical and microstructural contributions, cyclic stress response, and test temperature.     

Creep and microstructure in powder metallurgy 15 vol.% SiC<Subscript>p</Subscript>–2009 Al composite

The creep behavior and microstructure of powder metallurgy (PM) 15 vol.% silicon particulate-reinforced 2009 aluminum alloy (SiCp–2009 Al composite) and its matrix PM 2009 Al were investigated over six orders of magnitude of strain rate and at temperatures in the range 618–678 K. The results show that the creep behavior of PM 15% SiC_p–2009 Al composite resembles that of PM 2009 Al with regard to (a) the variations in both the apparent stress exponent and the apparent activation energy for creep due to applied stress, (b) the value of the true stress exponent, (c) the value of the true activation energy for creep, (d) the interpretation of creep in terms of a threshold stress, and (e) the temperature dependence of threshold stress. This resemblance implies that deformation in the matrix governs deformation in the composite. Analysis of the creep data in terms of creep rate against an effective stress shows that the creep behaviors of the composite and unreinforced alloy are consistent with the operation of viscous glide creep at low stresses. A comparison between the creep data of the composite and those of the unreinforced matrix revealed that the composite exhibited more creep-resistant characteristics than its matrix over the entire range of applied stresses.     

Optimization of friction stir welding process parameters to maximize tensile strength of stir cast AA6061-T6/AlNp composite

Aluminium Matrix Composites (AMCs) reinforced with particulate form of reinforcement has replaced monolithic alloys in many engineering industries due to its superior mechanical properties and tailorable thermal and electrical properties. As aluminium nitride (AlN) has high specific strength, high thermal conductivity, high electrical resistivity, low dielectric constant, low coefficient of thermal expansion and good compatibility with aluminium alloy, Al/AlN composite is extensively used in electronic packaging industries. Joining of AMCs is unavoidable in many engineering applications. Friction Stir Welding (FSW) is one of the most suitable welding process to weld the AMCs reinforced with particulate form of ceramics without deteriorating its superior mechanical properties. An attempt has been made to develop regression models to predict the Ultimate Tensile Strength (UTS) and Percent Elongation (PE) of the friction stir welded AA6061 matrix composite reinforced with aluminium nitride particles (AlN_p) by correlating the significant parameters such as tool rotational speed, welding speed, axial force and percentage of AlN_p reinforcement in the AA6061 matrix. Statistical software SYSTAT 12 and statistical tools such as analysis of variance (ANOVA) and student’s t test, have been used to validate the developed models. It was observed from the investigation that these factors independently influenced the UTS and PE of the friction stir welded composite joints. The developed regression models were optimized to maximize UTS of friction stir welded AA6061/AlN_p composite joints.     

Fabrication of AA6061/Al2O3 nano ceramic particle reinforced composite coating by using friction stir processing

Nano ceramic particle reinforced composite coatings were created by incorporating Al₂O₃ ceramic particles into the surface of AA6061-T6 alloy plate with multiple pass friction stir processing (FSP). Optical microscopy and Micro-Vickers hardness tests were employed to investigate the influence of axial force and the number of FSP pass on the distribution of the ceramic particles and the hardness of the generated nano ceramic particle reinforced composite coating. Results show that the composite coating is as deep as the length of the pin probe. No distinct interface was developed between the coating and the base metal. The composite region becomes greater as the axial force and the number of FSP pass increased. At the same time, the distribution of the ceramic particles became more homogeneous. Nano particles in the coating have no significant effect on the macro-hardness of AA6061-T6 aluminum alloy even in the composite zone due to the softening of matrix material resulted from overaging. Spindle torque of the tool increased with increasing axial force, while it became less variable and smaller in subsequent pass compared to that in the first pass.     

Different reinforcement strategies of hybrid surface composite AA6061/(B4C+MoS2) produced by friction stir processing

Aluminum surface composites have gained huge importance in material processing due to their noble tribological characteristics. The reinforcement of solid lubricant particles with hard ceramics further enriches the tribological characteristics of surface composites. In the current study, friction stir processing was chosen to synthesize hybrid surface composites of aluminum containing B₄C and MoS₂ particles with anticipated improved tribological behavior. B₄C and MoS₂ powder particles in 87.5: 12.5 ratio were reinforced into the AA6061 by hole and groove method. Microstructural observations indicated that reinforcement particles are well distributed in the matrix. The hardness and wear resistance of hybrid surface composites improved as compared to the base material, due to well distributed abrasive B₄C and solid lubricant MoS₂ particles in AA6061. The hybrid surface composites achieved ∼32 % increased average hardness as compared to the base material. Hole method revealed ∼13 % better wear resistance compared to the groove method for friction stir processed hybrid surface composite, attributing to an improved homogeneity of particle distribution shown by zigzag hole pattern. Moreover, friction stir processed AA6061 without reinforcement particles exhibited reduced hardness and wear resistance due to loss of strengthening precipitates during multi-pass friction stir processing.     

SiCw／6061A1复合材料温度循环拉伸变形行为

本文采用热循环拉伸试验方法研究了ＳｉＣｗ／６０６１Ａ１复合材料的变形行为．结果表明，ＳｉＣｗ／６０６１Ａ１复合材料温度循环拉伸变形行为与蠕变类似分为初始变形阶段、稳态变形阶段和快速断裂三个阶段；温度循环拉伸变形稳态流变速率明显提高；温度循环拉伸变形的应力指数低于恒温蠕变的应力指数．     

Effect of fibre-matrix-binder interactions on the matrix composition and age-hardening behaviour of 6061-based MMCs

Reactions between magnesium, alumina fibre and silica binder, during the manufacture of 6061 metal matrix composite (MMC) by the pressure infiltration technique, have been investigated for their effect on the structure, composition and age-hardening response of the MMC with increasing infiltration distance. The structure and composition were examined using optical and scanning electron microscopy, and electron probe microanalysis. The age-hardening behaviour, of both the MMC and unreinforced alloy, was determined using hardness measurements. There was a progressive depletion of magnesium in the MMC with increasing infiltration distance, which was particularly marked when the silica binder content exceeded 1 wt % (in a 20% V _f preform). This has been explained in terms of a reaction which results in the formation of an oxide at the fibre/matrix interface and a release of silicon into the matrix. The depletion of magnesium was associated with a reduction in the age-hardening response of the MMC, consistent with predicted behaviour based on the Al-Mg₂Si pseudo-binary phase diagram. In spite of these effects, the overall ageing behaviour of the MMC was enhanced compared with the unreinforced alloy, showing both higher peak-aged hardnesses and enhanced ageing kinetics, particularly at lower ageing temperatures.     

Investigation of the Tool Wear Rate in Tungsten Powder-Mixed Electric Discharge Machining of AA6061/10%SiCp Composite

This paper presents the experimental investigation on tool wear rate (TWR) in powder-mixed electrical discharge machining (PMEDM) of aluminum 6061 alloy reinforced with 10% silicon carbide particles (AA6061/10%SiC_p composite). Composite material is fabricated by mechanical stir casting process and further characterized by scanning electron microscope (SEM) and energy dispersive spectroscopy (EDS). Tungsten powder with concentration of 4 g/L is mixed in the dielectric fluid. To know the influence of powder suspension in dielectric fluid on TWR, comparative study is done on the basis of experiments performed using basic EDM and PMEDM process. Experiments have been designed as per central composite rotatable design (CCRD) using response surface methodology (RSM) approach. Four process parameters, namely, peak current, pulse-on time, pulse-off time, and gap voltage have been considered for TWR investigation. Individual and interactive influence of various parameters on TWR is explained with the help of analysis of variance and three-dimensional graphs. Using RSM approach, results have been further optimized. PMEDM approach provides 51.12% reduction in TWR for machining of AA6061/10%SiC_p composite.     

Sliding wear of Al2O3P/6061 Al composite

The mild sliding wear behaviour of a 15 vol % Al₂O_3P/6061 Al composite has been investigated by using a pin-on-disc reciprocating sliding machine. The composite has been shown to exhibit an excellent wear resistance as compared to the unreinforced matrix alloy. The wear rate of the composite under dry wear conditions with a 12N load is approximately one tenth of that in the 6061 aluminium alloy. The wear rate of the composite under lubrication with 15W/40 gear oil under a 100N load is only one thousandth ofthat in the 6061 aluminium alloy.The dry wear resistance of an over-aged sample is shown here to be better than a peak aged or under-aged sample when the composite was aged at 160°C. The coefficient of friction of the composite was approximately 0.5–0.6 under dry conditions and 0.07 in lubricated wear experiments.In the initial stage, the worn surface of the composite under dry conditions is primarily composed of ploughed grooves and ductile tear. The composite makes a conducting contact with the steel pin. The worn surface is composed of compacted powder and the contact potential gradually increases when the period of the wear experiment goes beyond 2 h.     

Fabrication and characteristics of AA6061/SiCp composites by pressureless infiltration technique

The tensile properties and microstructures of AA6061/SiC_p composites fabricated by the pressureless infiltration method under a nitrogen atmosphere were examined. Since the spontaneous infiltration of molten AA6061 into the powder bed containing SiC_p occurred at 800 °C for 1 hour under a nitrogen atmosphere, it was possible to fabricate composites reinforced with SiC_p. Reaction product (Al₄C₃) was formed at the interface between SiC_p and Al alloy matrix. In addition, the amount and size of the Al₄C₃ is increased significantly by increasing the infiltration temperature. The reaction product (AlN) was formed as a result of the in situ reaction in both the control alloy and the composite. A significant strengthening even in the control alloy occurred due to the formation of in situ AlN particle even without an addition of SiC_p. While a further strengthening of the composite was produced by the reinforced SiC_p, strain to failure of the composite fabricated at 800 °C showed the lowest value (1.3%) in the T6 condition due to the formation of the severe reaction product (Al₄C₃). The grain size of the control alloy significantly decreased to about 20 m compared to 50 m for the commercial alloy. In addition, the grain size in the composite reinforced with SiC_p further decreased to about 8.0 m. This grain refinement contributed to strengthening of the control alloy and composite.     

Development of Al3Ti and Al3Zr intermetallic particulate reinforced aluminum alloy AA6061 in situ composites using friction stir processing

Aluminum rich intermetallic particles are potential reinforcements for discontinuously reinforced aluminum matrix composites (DRAMCs). The objective of the present work is to produce AA6061/Al₃Ti and AA6061/Al₃Zr composites using in situ casting technique and applying friction stir processing (FSP) to enhance the distribution and morphology of Al₃Ti and Al₃Zr particles. AA6061/Al₃Ti and AA6061/Al₃Zr DRAMCs were produced by the in situ reaction of inorganic salts K₂TiF₆ and K₂ZrF₆ with molten aluminum. The microstructure was observed using optical and scanning electron microscopy. AA6061/Al₃Ti DRAMC exhibited clusters of Al₃Ti particles while the segregation of needle shape Al₃Zr particles was observed in AA6061/Al₃Zr DRAMC. The prepared composites were subjected to FSP. Significant changes in the distribution and morphology of Al₃Ti and Al₃Zr particles were observed after FSP. The changes in microhardness and sliding wear behavior of AA6061/Al₃Ti and AA6061/Al₃Zr DRAMCs before and after FSP is detailed in this paper.