Abrasive wear behaviour of B4C particle reinforced Al2024 MMCs

In this study, the effects of volume fraction and particle size of boron carbide on the abrasive wear properties of B₄C particle reinforced aluminium alloy composites have been studied. For this purpose, a block-on-disc abrasion test apparatus was utilized where the samples slid against the abrasive suspension mixture at room conditions. The volume loss, specific wear rate and roughness of the samples have been evaluated. The effects of sliding time, particle content and particle size of B₄C particles on the abrasive wear properties of the composites have been investigated. The dominant wear mechanisms were identified using scanning electron microscopy. The results showed that the specific wear rate of composites decreased with increasing particle volume fraction. Furthermore, the specific wear rate decreased with increasing the size of particle for the composites containing the same amount of B₄C. Hence, it is deduced that aluminium alloy composites reinforced with larger B₄C particles are more effective against the abrasive suspension mixture than those reinforced with smaller B₄C particles.     

Analysis of dry sliding friction and wear behaviour of AA6351–SiC–B4C composites using grey relational analysis

Abstract

This paper describes the multifactor based experiments that are applied to investigate the dry sliding wear system of aluminium matrix alloy (AA6351) with 5 wt-% silicon carbide (SiC), 5 wt-% and 10 wt-% of boron carbide (B₄C) reinforced metal matrix composites (MMCs). Stir casting route was adopted to prepare the composites and the tribological experiments were carried out on pin-on-disc type wear machine. The effects of parameters like applied load, sliding velocity, wt-% of B₄C on the dry sliding wear and frictional coefficient of aluminium MMCs using grey relational analysis (GRA) are reported. The orthogonal array with L9 layout and analysis of variance were used to investigate the influence of the parameters. It is observed that the dry sliding friction and wear behaviour of the composites are influenced by the applied load, sliding velocity and wt-% of B₄C with a contribution of 60·82%, 21·72% and 14·28% respectively. The optimal design parameters were found by grey relational grade and a good agreement was observed for 95% level of confidence.     

Wear behavior of electroless Ni–P–B4C composite coatings

In this research, the wear of electroless Ni–P and Ni–P–B₄C composite coatings was reviewed. Auto catalytic reduction of Ni in nickel sulfate and sodium hypophosphate bath including suspended B₄C particles with different concentration was used to create composite coatings with 12, 18, 25 and 33 vol.% of B₄C particles. Coatings 35 μm thick were heat treated at 400 °C for one hour in an argon atmosphere and the wear resistance and friction coefficient of heat-treated samples were determined by block-on-ring tests. All wear tests were carried out at 24 °C, 35% moisture, 0.164 m/s sliding speed and about 1000 m sliding distance. Graphs show that an electroless Ni–P–B₄C composite coating with 25 vol.% of B₄C had the best wear resistance against a CK45 steel counterface.     

Corrosive Wear and Mechanical Properties of Ni/Al2O3 Micro- and Nanoparticulates-Reinforced Coatings on Ti-6Al-4V Alloy

Nanocomposite coatings can endow a plated surface with various properties such as wear resistance, high-temperature corrosion protection, oxidation resistance, and self-lubrication. This work studies the corrosion and corrosive wear resistance of electroplated nickel nanocomposite coatings on Ti-6Al-4V alloy in a Hank's solution, adding various concentrations of an Al₂O₃ powder in plating solution, with particle diameters of 20–30 nm and 1 μm for comparisons. The experimental results showed that the content of Al₂O₃ incorporated into the electroplated nickel composite coating increased with the concentration of Al₂O₃ powder in the electroplating solution, and increasing the surface hardness, corrosion, and corrosive wear resistance of electroplated nickel micro- and nanocomposite coatings caused smearing of the nodule boundary and elimination of voids in the deposits. The Al₂O₃ nanoparticulates were embedded and distributed more uniformly than the Al₂O₃ microparticulates in the nickel matrix after a heat treatment of 400°C, producing a more continuous and dense coated composite layer on the Ti-6Al-4V substrate. This phenomenon is responsible for the Ni/Al₂O₃ composite coating with superior surface hardness, providing high corrosion resistance and corrosive wear protection to the Ti-6Al-4V alloy substrate in Hank's solution.     

Fabrication In Situ TiB<Subscript>2</Subscript>–TiC–Al<Subscript>2</Subscript>O<Subscript>3</Subscript> Multiple Ceramic Particles Reinforced Fe-Based Composite Coatings by Gas Tungsten Arc Welding

A Fe-based composite coating reinforced by multiple TiB₂–TiC–Al₂O₃ ceramic particles was developed by gas tungsten arc welding (GTAW) melting process. Mixture of aluminum (Al), boron carbide (B₄C), and titanium dioxide (TiO₂) powders was used as precursors, and as a consequence TiB₂–TiC–Al₂O₃ multiple ceramic particles were in situ synthesized during GTAW melting process. Microstructural investigations showed that TiB₂ particles exhibit a blocky morphology, TiC particles are of flower-like shape, and the Al₂O₃ particles exist as small black dots and located in the core of reinforced particles. The hardness and wear resistance of the coatings increased drastically in comparison with that of the substrate.     

Tribological Behavior of MoSi2 and Its Composites in Sliding Against Ni-Based Alloys

In this paper, MoSi₂ and its composites were fabricated by hot pressing method. The roles of the second phase as mechanical and tribological components were studied. The results showed that B₄C and ZrO₂ particulates could be used for the strengthening and toughening of MoSi₂ respectively. The tribological behaviors of MoSi₂ and its composites sliding against Ni–Cr alloy and Ni–Cr–S alloy at room temperature and 600 °C were investigated on a tribometer with a pin-on-disk configuration. MoSi₂–SiC exhibited the best tribological performance. The wear behaviors of MoSi₂ and its composites were well correlated with their toughening mechanisms in sliding against Ni–Cr alloy at room temperature. Due to the introduction of chromium sulfides, the formation and removal process of the transferred layers at 600 °C controlled the wear mechanism of MoSi₂ and its composites. The tribo-oxidation was an important factor favorable to wear reduction.     

Dry sliding wear mechanism for P/M austenitic stainless steels and their composites containing Al2O3 and Y2O3 particles

Austenitic stainless steels are used in applications demanding general corrosion resistance at room or moderate operating temperatures. However, their use is often limited by the relative softness of these materials and their suceptibility to wear and galling. The present investigation deals with the dry sliding wear behaviour of two P/M austenitic stainless steels (AISI 304L and 316L) and their composites containing two different ceramic particles (Al₂O₃ and Y₂O₃) and two different sintering activators (BN and B₂Cr). Unlubricated pin-on-disc wear tests were carried out. Wear mechanisms were analysed by means of scanning electron microscopy and X-ray diffraction. A plastic deformation and particle detachment wear mechanism was revealed. Plasticity during sliding induced an austenite to martensite transformation. The presence of ceramic particles (Al₂O₃ and Y₂O₃) and sintering activators (B₂Cr, BN) improved significantly the wear resistance (especially the combination Al₂O₃ and B₂Cr). Ceramic particles limited plastic deformation while sintering activators decreased final porosity.     

Wear Behavior of (TiB2–TiC)–Ni/TiAl/Ti Gradient Materials Prepared by the FAPAS Process

(TiB₂–TiC)–Ni/TiAl/Ti functionally gradient materials were prepared by field-activated pressure-assisted synthesis processes. (TiB₂–TiC)–Ni composite ceramic, the top layer of the functional gradient materials, was prepared in situ by the combustion synthesis process using Ti and B₄C powders as raw materials. Scanning electron microscope (SEM) images of the ceramic layer revealed that the TiB₂ and TiC particles in the composite were fine and homogeneously dispersed in the Ni matrix. The friction and wear properties of the (TiB₂–TiC)–Ni ceramic were evaluated by sliding against a GCr15 disk at temperatures from ambient up to 400 °C. The experimental results showed that the friction coefficient of the (TiB₂–TiC)–Ni ceramic decreased with the increasing testing temperature, load, and sliding speed. However, the loss rate decreased at higher temperature and increased at higher load and higher sliding speed. The wear mechanisms of (TiB₂–TiC)–Ni ceramic mainly depend upon thermal oxidation at higher temperature, load, and sliding speed. The worn topography and phase component of the worn surfaces were analyzed using SEM, energy dispersive spectroscopy, and X-ray diffraction. The oxide films of Fe₂O₃, TiO₂, and B₂O₃ formed during the friction process play an important role in lubrication, which results in a smaller friction coefficient.     

Environmental scanning electron microscopy studies of diffusion mechanism of boron particle combustion

This investigation was performed to resolve long-term contradicting theories regarding the mechanisms which govern the species diffusion across the liquid B₂O₃ layer covering a single boron particle during the combustion of boron. An environmental scanning electron microscope (ElectroScan E-3) was used to observe the liquefaction characteristics of the boron oxide layer and to examine boron dissolution and species diffusion processes in real time. Using a hot stage, crystalline boron particles were heated from 25 to 950°C in O₂, H₂O, or Ar environments. Pure B₂O₃ particles were also heated in an O₂ environment and examined. In situ observations showed that the diffusion of dissolved boron into molten B₂O₃₍₁₎ is much more dominant at elevated temperatures than the diffusion of gaseous O₂ through the B₂O₃₍₁₎ layer. Dissolution of solid boron into the boron oxide layer caused the liquefaction of boron particles at relatively low temperatures (940°C). The chemical composition of liquid boron oxide, coated on the surface of boron particles, was identified as a polymeric vitreous (BO)_n complex through the reaction between dissolved boron and molten B₂O₃₍₁₎.     

Analytical,numerical and experimental approach for design and development of optimal die profile for the cold extrusion of B4C DRMM Al 6061 composite billet into hexagonal section

Aluminium based matrix composites with boron carbide as particle reinforcement called Discontinuous reinforced metal matrix composites (DRMMs) possess high specific strength, high elastic modulus, good wear resistance, damping capacity and thermal stability. But during the development of DRMM composites, compression process like extrusion is an advisable secondary process for homogenous structure. This research work investigates the metal flow behavior of Al-B₄C based DRMM composite through six different die profiles namely third order polynomial, fourth order polynomial, cosine, elliptical, hyperbolic and conical geometry. Extrusion load, stress and strain distribution, and metal flow for above said die profiles are predicted by using analytical approach upper bound technique and compared with finite element method. Cosine and third order polynomial profiles are found to be most optimal in terms of homogenous and minimal extrusion load requirement. To validate the results, specially made Al-B₄C composite through stir casting route was extruded from round to hexagon through an exclusively fabricated cosine die. Results observed from the experiment have good agreement with both analytical and numerical.

     

Advancement and characterization of Al-Mg-Si alloy using reinforcing materials of Fe2O3 and B4C composite produced by stir casting method

The modifications of Al6061-T6 metal matrix composites is an extraordinary enthusiasm of recent pertinence for lesser weight materials with high value of tensile strength, hardness and wear protection, which can be widely used in automotive and aircraft design. In this paper, we investigate the impacts of the reinforced Al6061 composite with 5 wt% of Fe₂O₃ in addition to 2 %, 4 %, 6 % weight of B₄C being made-up by stir casting technique. In this research, Al6061 composites have analyzed by its physical and mechanical properties like as density, hardness, impact strength, ultimate tensile and compressive strength, and an optical microscope is utilized to assess the metallurgical properties such as microstructure with different wt% of reinforcement of Al6061 composite. The microstructure of newly prepared composites was shown a regular spreading of reinforcements in the matrix by an optical microscope and also the muscular bonding between the matrix and reinforcements were demonstrated by SEM analysis. It is further identifying that, microstructure uniformity and therefore the tensile strength of the metal composites was enhanced with increasing the fraction of Fe₂O₃ and B₄C particles without any decrement in elongation.

     

Dry sliding wear properties of unhybrid and hybrid Al alloy based nanocomposites

Abstract

Nanosize B₄C and/or MoS₂ particles reinforced AA2219 alloy composites were prepared using the stir casting process. The wear properties were evaluated for several speed (3.14–5.65 m s^?1), load (10–50 N) and distance (0–2500 m) conditions. The nanoparticles dispersion, density, wear resistance, morphology of the worn surface and loose wear debris were discussed in detail. The wear resistance improvement results by nanoparticle addition correspond well with the hardness. Between the nanocomposites, hybrid composites show significantly higher wear resistance for all load, speed and sliding distance conditions. The better wear resistance is attributed to the matrix strengthening by nanoparticles and the lubricant-rich tribolayer controlled wear in the hybrid composites. The intensity of abrasive, oxidation and delamination wear mechanisms decide the wear rate at any particular wear testing condition.     

Experimental investigation and optimization of EDM process parameters for machining of aluminum boron carbide (Al–B4C) composite

This study investigates the effect of electric discharge machining (EDM) process parameters [current, pulse-on time (T_on), pulse-off time (T_off) and electrode material] on material removal rate (MRR), electrode wear rate (EWR) and surface roughness (SR) during machining of aluminum boron carbide (Al–B₄C) composite. This article also summarizes a brief literature review related to aluminum metal matrix composites (Al-MMCs) based on different process and response parameters, work and tool material along with their sizes, dielectric fluid and different optimization techniques used. The MMC used in the present work is stir casted using 5% (wt) B₄C particles of 50 micron size in Al 6061 metal matrix. Taguchi technique is used for the design of experiments (L₉-orthogonal array), while the experimental results are analyzed using analysis of variance (ANOVA). Response table for average value of MRR, EWR and SR shows that current is the most significant factor for MRR and SR, while electrode material is most important for EWR. ANOVA also confirms similar results. It is also observed that the optimum level of process parameters for maximum MRR is A₃B₁C₃D₃, for minimum EWR is A₁B₂C₃D₁, and for SR is A₁B₃C₃D₃.     

A comparison of the microstructure of silicon nitride-silicon carbide composites made with and without deoxidized starting material

Two different types of silicon carbide (SiC) matrix composites, with either 10 wt% or 20 wt% silicon nitride (Si₃N₄) reinforcement, were fabricated to investigate the effect of pretreatment on the resulting composite micro-structure. The first type of composite was prepared from as-received α-SiC and α-Si₃N₄ powders, while the second type was prepared from powder compacts that had been deoxidized to eliminate surface silica on the powder particles. The composites were hot isostatically pressed in tantalum cans at 2373 K for 1h under a pressure of 200 MPa. Density measurements showed that full theoretical density was achieved for the composites prepared from the as-received powders, while much lower densities were obtained for the composites prepared from the deoxidized green compacts. Almost all of the α-SiC transformed into β-SiC, and almost all the α-Si₃N₄ transformed into α-Si₃N₄ in the composites made from the as-received powders, while in the composites made from the deoxidized material the α-SiC remained untransformed and both α-Si₃N₄ and β-Si₃N₄ phases were present in significant quantities. High-resolution transmission electron microscopy and Fresnel fringe imaging were used to identify the grain boundary and interphase boundary structure. Most interfaces were found to be covered with ? 1 nm thick amorphous intergranular films in the composites prepared from as-received powders, whereas most interfaces were found to be free of such amorphous intergranular films in the composites prepared from the deoxidized material. Taken together, the presence of intergranular films at the interfaces and the results from density measurements are consistent with the densification and reverse α → β-SiC transformation taking place in the composites made from as-received powders by a liquid-phase sintering route. An incomplete liquid-phase sintering mechanism is also able to explain the microstructure observed in the composites made from the deoxidized material.     

Fabrication of two-layered Al-B4C composites by conventional hot pressing uuder nitrogen atmosphere and their characterization

In this study, we describe the conventional hot pressing (CHP) of layered Al-B₄C composites and their characterization. The matrix alloy A1-5 wt.%Cu was prepared from elemental powder mixtures. The metal and B₄C powders were mixed to produce either Al-Cu-10vol.%B₄C or Al-Cu-30vol.%B₄C combinations. Then, these powder mixtures were stacked as layers in the hot pressing die to form a two-layered composite. Hot pressing was carried out under nitrogen atmosphere to produce 30×40×5 mm specimens. Microstructural features and age hardening characteristics of composites were determined by specimens cut longitudinally. The flexural strength of both layered composites and their monolithic counterparts were investigated via three point bending tests. In the case of layered specimens of both 10vol.%B₄C and 30vol.%B₄C containing layers were loaded for three-point test. The results show that a homogeneous distribution of B₄C particles in the matrix alloy which is free of pores, can be obtained by CHP method. The ageing behavior of the composites was found to be influenced by the reinforced materials, i.e. higher hardness values were reached in 8 hrs for the composites than that for the matrix alloy. Flexural strength test showed that two-layered composites exhibited improved damage tolerance depending on layer arrangement. Microstructural investigation of the fracture surfaces of the bending specimens was performed by means of scanning electron microscope (SEM). While layer with lower reinforcement content exhibited large plastic deformation under loading, the other with higher reinforcement content exhibited less plastic deformation.     

Synergetic effect of BN for the electrical conductivity of CNT/PAN composite fiber

Carbon nanotube (CNT) fillers in composite materials improve electrical conductivity, thermal stability, and mechanical properties. Boron nitride (BN) is an insulating material that is also thermally stable. Therefore, CNT and hexagonal boron nitride (hBN) fillers have been used to obtain composite materials’ high electrical conductivity. In this study, CNT-hBN/polyacrylonitrile (PAN) fibers were spun using simple wet-spinning and the effect of hBN on the electrical conductivity of the CNT-hBN/PAN composite was investigated. Contrary to predictions, as the content of the insulating material, BN, increased up to 15 wt%, the electrical resistance of the composite fiber decreased.

     

Wear prevention in molds used to mold boron filled elastomers

An investigation was conducted to identify surface coatings which would improve the wear characteristics of compression molds used to mold contoured parts from elastomers filled with crystalline boron particles. An analysis was made of the mode of wear present on the surfaces of a production mold, followed by selection and modification of a capillary rheometer as the test device. Test specimens were coated by electroplating, electroless plating, plasma spraying, chemical vapor deposition, sputtering and a fused salt process. Testing was conducted under conditions simulating those encountered in the production molding operation.Techniques used in evaluating the results included optical microscopy, scanning electron microscopy, transmission electron microscopy and surface profilometry. The results are expressed as a ratio of volumetric wear of the tested coating to that of unprotected mold steel.Results indicate that titanium diboride (TiB₂) applied by chemical vapor deposition provides wear resistance superior to plasma sprayed aluminum oxide mixed with titanium dioxide, plasma sprayed chromium oxide, electrodeposited chromium, electroless nickel containing synthetic diamond powder, chemical vapor deposited tungsten carbide (W/W₂C), aluminum oxide and aluminum oxide over chromium carbide. Sputtered titanium diboride was also superior to these coatings and to sputtered titanium carbide and boron carbide.     

Abrasion of Steel by Ceramic Coatings: Comparison of RF-DLC to Sputtered B4C

The abrasion rates of steel balls sliding against a very smooth diamond-like carbon (DLC) coating and a rough boron carbide (B₄C) coating are compared. The initial abrasiveness of the B₄C coating is about 2 orders of magnitude greater than that of the DLC coating. Both coatings exhibit a rapid decrease in their abrasiveness with sliding distance, but the details of the abrasion kinetics of these coatings are quite different. The abrasiveness of B₄C falls according to a simple power law, while the abrasiveness of the DLC remains constant for a duration that depends on the load and then switches rather suddenly to zero. An explanation for this different behavior is proposed. During the abrasion process the asperities on the B₄C are smoothed to a startling extent.     

Existence of Good Bonding between Coated B4C Reinforcement and Al Matrix via Semisolid Techniques: Enhancement of Wear Resistance and Mechanical Properties

An Al 6061 alloy matrix reinforced with the coated B₄C particles was used for the present study. The cohesion of the reinforcing ceramic particles is poor at temperatures near the melting point of aluminum and leads to inferior mechanical and tribological properties of developed aluminum matrix composites with nonuniform distribution of the reinforcement. The main reason for coating the particles is to improve the bond between the reinforcement and molten alloy and thus to eliminate interfacial reactions. The great enhancement in strength values of the composites in this study can be ascribed to the effective load-bearing capacity of disintegrated B₄C particles that are adherently bonded to the matrix alloy. Homogeneity and reduction in the particle size of B₄C during the extrusion process is evidenced in the microstructural studies.