Fabrication of aluminium matrix composites reinforced by submicrometre and nanosize Al2O3 via accumulative roll bonding

Abstract

Aluminium matrix composites reinforced with submicrometre and nanosize Al₂O₃ particles were successfully manufactured in the form of sheets through eight cycles of accumulative roll bonding process. The mechanical properties of the produced composite are compared with accumulative roll bonded commercially pure aluminium. It is shown that only 1 vol.-% of submicrometre or nanosize alumina particles as reinforcement in the structure can significantly improve the yield and ultimate tensile strengths. Scanning electron microscopy revealed that particles have a random and uniform distribution in the matrix especially in the less volume fraction of alumina particles, and strong mechanical bonding occurs at the interface of the particle matrix. According to the results of the tensile tests, it is observed that with less alumina content, the composite reinforced by nanosize particles has higher strength than that by submicrometre size particles. However, more reinforcement up to 3 vol.-% of submicrometre particles, as a result of including fewer microstructural defects, leads to better mechanical properties in comparison to the nanoparticle composite.     

Extrusion modelling of 6061 aluminium alloy and particle reinforced MMCs

Abstract

Extrusion modelling was performed for 6061 aluminium alloy and three particle reinforced MMCs (10%Al₂O₃/6061, 15%SiC/6061, 20%Al₂O₃/6061) using constitutive equations previously obtained from torsion test data. In applying the finite element software DEFORM, suitable heat transfer, friction, and velocity boundary conditions were chosen based on a direct extrusion press. Simulations were run for various extrusion conditions and the outputs for the four materials were compared. The simulation results were validated by comparison with real life extrusions and modelling of other researchers. The results showed that an increase in billet temperature, a reduction in ram speed, or a reduction in extrusion ratio had the effect of reducing the ram load. In consequence, extrusion conditions could be selected so that extrusion of the composite was carried out with the same peak ram load as the alloy.     

Grain structure of laser remelted 7075 aluminium alloy in presence of Al2O3 particles

Abstract

The effect of inert particles on grain structure development from alloy melt during laser rapid solidification has been investigated. It is found that the presence of Al₂O₃ particles may disrupt the usual epitaxial grain structure evolution of an aluminium 7075 alloy when processed by laser surface remelting. This result, in addition to observations of crystal termination at the particles and grain refinement in particle dense regions, indicates that a mechanism of particle restricted grain growth operates.     

Microstructure,tensile properties and fracture behaviour of Al2O3 particulate-reinforced aluminium alloy metal matrix composites

The tensile deformation and fracture behaviour of aluminium alloy 2014 discontinuously-reinforced with particulates of Al₂O₃ was studied with the primary objective of understanding the influence of reinforcement content on composite microstructure, tensile properties and quasi-static fracture behaviour. Results reveal that elastic modulus and strength of the metal-matrix composite increased with reinforcement content in the metal matrix. With increase in test temperature the elastic modulus showed a marginal decrease while the ductility exhibited significant improvement. The improved strength of the Al-Al₂O₃ composite is ascribed to the concurrent and mutually interactive influences of residual stresses generated due to intrinsic differences in thermal expansion coefficients between constituents of the composite, constrained plastic flow and triaxiality in the soft and ductile aluminium alloy matrix due to the presence of hard and brittle particulate reinforcements. Fracture on a microscopic scale initiated by cracking of the individual or agglomerates of Al₂O₃ particulates in the metal matrix and decohesion at the matrix-particle interfaces. Failure through cracking and decohesion at the interfaces increased with reinforcement content in the matrix. The kinetics of the fracture process is discussed in terms of applied far-field stress and intrinsic composite microstructural effects.     

Hot deformation behaviour of aluminium alloy 6061/SiCp MMCs made by powder metallurgy route

Abstract

The hot deformation behaviour of a 20 vol.-%SiC particle reinforced Al alloy 6061 composite and Al alloy 6061, made via a powder metallurgy (PM) route and treated by a T4 temper, were studied by compression testing over a range of temperatures (300–500°C)and at strain rates of 0.005, 0.05, and 0.09 s^-1. It was observed that the flow stresses of the composites were significantly higher than those of the alloy at lower deformation temperatures. However, the stress–strain curves of both the composite and the alloy showed significant softening during deformation at the lowest strain rate, the softening for the composite being faster than that of the alloy. The activation energy for hot deformation was determined for different strains, using a power law equation, and was found to change significantly with strain for both the alloy and the composite. This phenomenon was explained by the occurrence of dynamic precipitation and coarsening during deformation.     

Continuous elimination of Al2O3 particles in molten aluminium using electromagnetic force

Abstract

A new method for continuous elimination of inclusions by using electromagnetic force was designed in this study. The principle is that as the electromagnetic force induced in metal scarcely acts on inclusions owing to their low electric conductivity; they are moved in the direction opposite electromagnetic force and can be separated from the melt. To do this, numerical analysis was conducted by employing the principle of electromagnetic braking. Numerical results agreed well with the experimental ones. Using the continuous electromagnetic separation system designed in this study, it was determined that Al₂O₃ particles whose size was larger than ~ 14 μm immersed in flowing aluminium melt could be removed under the electromagnetic conditions (electric current density 7.96 × 10⁵ A m^-2, magnetic flux density 0.35 T) when the flow velocity was ~ 150 mm s^-1.     

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.     

The fibre distribution of Al2O3/Al–Cu alloy composites

Two methods which rely on direct microstructural measurements to assess the fibre distribution in alumina continuous fibre-reinforced Al–Cu alloy composites produced via an infiltration process, are outlined. The first is based on distance analysis, i.e. the distance distribution of nearest neighbours; and the second is based on fibre–cell structures. Specimens with two fibre volume fractions, 0.39 and 0.50, were employed in this study. It was found that the fibres in both kinds of specimen appear to have a rough thread-like distributions, and the local volume fraction of the fibres varies over a larger range in the specimen with lower fibre volume fraction than does that in the specimen with the larger one. Quantitative relationships between fibre distribution and the composite defects are deduced. Some data on the microsegregation of copper and the macrosegregation of eutectic phase are given in relation to the fibre distributions. The reasons for the uneven fibre distributions are also discussed.     

Effect of Al2O3 particulates as reinforcement in age hardenable aluminium alloy composites

Abstract

This paper investigates the behaviour of aluminium based composites, reinforced with aluminium oxide particulates, manufactured using a powder processing route and various sintering times. It is found that a softening effect, compared with the monolithic material, coincides with migration of magnesium from the matrix to the matrix/reinforcement interface and to the specimen surface. The addition of 5 wt-%Si to the matrix alloy results in a retention of hardness in the specimens given short sinter times (0.5 and 1 h). This coincides with reduced migration of magnesium from the matrix. It is postulated that the excess silicon in the matrix results in sufficient magnesium being retained in the matrix during short sinter times to take part in the formation of Mg₂Si precipitates necessary for the hardening of the Al alloy 6061 matrix.     

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.     

High strength Al2O3p/6061 Al composites: effect of particles,subgrains and precipitates

Abstract

Composites of 6061 Al reinforced by Al₂O₃ particles have been produced by squeeze casting followed by hot extrusion and a T4 precipitation hardening treatment. The tensile properties at room temperature have been determined and analysed based on microstructural parameters. The strength contributions from the matrix, particles, subgrains and precipitates have been estimated individually, and then based on an assumption of linear additivity, the yield stress values of the composites under the extruded and heat treated conditions have been calculated. Good agreement between the calculated and experimental values has been found, illustrating the suitability of the process for the manufacture of strong composites, with a maximum yield stress of 524 MPa obtained for a composite containing 60 vol.-%Al₂O₃.     

Fabrication of AA6061/Al2O3p composites from elemental and alloy powders

The tensile properties and microstructures of AA6061/Al₂O_3p composites fabricated by the pressureless infiltration method under a nitrogen atmosphere were examined. Since the spontaneous infiltration of molten metal into elemental powders bed as well as alloy powders bed occurred at 700°C for 1 hour under a nitrogen atmosphere, it was possible to fabricate 6061 Al matrix composite reinforced with Al₂O_3p irrespective of the type of metal powders. Both MgAl₂O₄ and MgO were formed at interfaces between Al₂O₃ and the matrix. In addition, MgAl₂O₄ was formed at within the matrix by in situ reaction during composite fabrication. Fine AlN was formed by in situ reaction in both composites. A significant strengthening in the composites occurred due to the formation ofin situ AlN particle and addition of Al₂O₃ particles, as compared to the commercial alloy, while tensile properties in the both elemental and alloy powders composites showed similar trend.     

Al2O3@Y3Al5O12纳米短纤维对铝合金基复合材料的增强作用

采用一种具有芯-壳结构的复合纳米纤维增强铝合金复合材料,可以在提高抗拉强度的同时增加塑性。通过真空热压烧结技术制备了Al₂O₃@Y₃Al₅O₁₂复合纳米短纤维增强2024铝合金复合材料。研究了纤维添加质量分数对复合材料致密度、硬度、抗拉强度及延伸率的影响;并探究了芯-壳结构在复合材料增韧中的作用。结果表明:Al₂O₃@Y₃Al₅O₁₂纳米短纤维具有良好的分散性,在超声分散及机械搅拌混粉后均匀吸附在铝合金颗粒表面,无分层及团聚现象;经热压烧结后,Al₂O₃@Y₃Al₅O₁₂纳米短纤维以短纤维形态均匀分散在铝合金基体内,少量添加Al₂O₃@Y₃Al₅O₁₂纳米短纤维起到了桥联和孔洞填充作用,使复合材料致密度和硬度提高;添加质量分数为1wt%时,抗拉强度和延伸率取得最大值,由铝合金的249.3 MPa、2.9%增加到299.1 MPa、4.3%。Al₂O₃@Y₃Al₅O₁₂纳米短纤维的添加可以细化晶粒,阻碍裂纹扩展,且在拔出/断过程中Al₂O₃@Y₃Al₅O₁₂纳米短纤维芯-壳结构的塑性变形起到了增强增韧作用。      

Superplasticity in an aluminum alloy 6061/Al(2)O(3)p composite

The superplasticity of an Al(2)O(3)p/6061Al composite, fabricated by powder metallurgy techniques, has been investigated. Instead of any special thermomechanical processing or hot rolling, simple hot extrusion has been employed to obtain a fine grained structure before superplastic testing. Superplastic tensile tests were performed at strain rates ranging from 10(-2) to 10(-4) s(-1) and at temperatures from 833 to 893 K. A maximum elongation of 200% was achieved at a temperature of 853 K and an initial strain rate of 1.67x10(-3) s(-1). The highest value obtained for the strain rate sensitivity index (m) was 0.32. Differential scanning calorimeter was used to ascertain the possibility of any partial melting in the vicinity of optimum superplastic temperature. These results suggested that no liquid phase existed where maximum elongation was achieved and deformation took place entirely in the solid state.     

Single-point scratching of 6061 Al alloy reinforced by different ceramic particles

Aluminium alloys reinforced by ceramic particles have been widely used in aerospace and automotive industries for their high stiffness and wear resistance. However, the machining of such materials is difficult and would usually cause excessive tool wear. The effect of ceramic particles on the cutting mechanisms is also unclear. The purpose of this study is to investigate the cutting mechanisms and the relationship between specific energy of scratching and depth of cut (size effect). The single-point scratch test was carried out on 6061 Al and its composites reinforced by Al₂O₃ and SiC ceramic particles using a pyramid indenter. The results indicated that the scratch process was composed of rubbing, ploughing, plastic cutting and reinforcement fracture. A simple model was proposed to interpret the apparent size effect. The effect of reinforcement on the specific energy was correlated to the ratio of volume fraction to particle radius. The paper found that for machining MMCs, a larger depth of cut should be used to maintain a lower machining energy, especially for those with a larger ratio of volume fraction to particle radius.