Delineating brittle-phase embrittlement and ductile-phase toughening in Nb-based in-situ composites

The fracture toughness of Nb-based in-situ composites typically decreases with increasing volume fractions of hard intermetallic phases, despite the presence of a ductile niobium solid-solution phase in the microstructure. For composites with a continuous intermetallic matrix, the fracture toughness can be more than double that of the monolithic intermetallics, but is still low in absolute terms, indicating that the solid-solution phase is not very effective in inducing ductile-phase toughening. The lack of enhancement of the fracture resistance appears to arise from an embrittlement effect instigated by the brittle phases in the microstructure, whose nondeformability results in a high plastic constraint acting on the ductile phase. In this article, an analytical model is developed for treating both brittle-phase embrittlement and ductile-phase toughening in terms of constituent properties and microstructural variables. The model is then used to (1) delineate brittle-phase embrittlement and ductile-phase toughening in Nb-based in-situ composites, and (2) design fracture-resistant in-situ composites based on Nb-Ti-Cr, Nb-Ti-Al, and Nb-Ti-Si systems.     

The fracture toughness of niobium-based,in situ composites

The fracture resistance of Nb-Cr-Ti alloys orin situ composites of three different compositions, Cr₂Nb, and a Nb-10Siin situ composite was studied at ambient temperature. The crack-tip deformation and fracture behaviors were characterized using near-tip measurement techniques and fractographic analyses. The relevant fracture and toughening mechanisms were identified and related to the microstructure. Despite fracture by a combination of cleavage and slip band decohesion, the Nb solid-solution alloy exhibited a resistance-curve behavior with a relatively high toughness and local ductility. The source of toughness was modeled and explained in terms of a cracking process that involved alternate slip band decohesion and cleavage. Thein situ composites, on the other hand, exhibited cleavage fracture but considerably lower toughness with little or no resistance-curve behaviors. The difference in the fracture behavior appears to arise from two factors: (1) the presence of a high constraint in the Nb solid-solution matrix in thein situ composites, and (2) the lack of plastic flow associated with cleavage of the constrained Nb solid-solution matrix.     

Ductile-phase toughening in V-V3Si in situ composites

This article describes the room-temperature fracture behavior of ductile-phase-toughened V-V₃Si in situ composites that were produced by arc melting (AM), cold-crucible induction melting (IM), and cold-crucible directional solidification (DS). Composites were produced containing a wide range of microstructures, interstitial impurity contents, and volume fractions of the ductile V-Si solid solution phase, denoted (V). The fracture toughness of these composites generally increases as the volume fraction of (V) increases, but is strongly influenced by the microstructure, the mechanical properties of the component phases, and the crystallographic orientation of the (V) phase with respect to the maximum principal stress direction. For eutectic composites that have a (V) volume fraction of about 50 pct, the fracture toughness increases with decreasing “effective” interstitial impurity concentration, [I]=[N]+1.33 [O]+9 [H]. As [I] decreases from 1400 ppm (AM) to 400 ppm (IM), the fracture toughness of the eutectic composites increases from 10 to 20 MPa √m. Further, the fracture toughness of the DS eutectic composites is greater when the crack propagation direction is perpendicular, rather than parallel, to the composite growth direction. These results are discussed in light of conventional ductile-phase bridging theories, which alone cannot fully explain the fracture toughness of V-Si in situ composites.     

原位合成TiB2对B4C/2024Al合金复合材料组织与力学性能的影响

在B4C粉末中加入5%高纯TiO2,经过压制和烧结制备B4C-TiB2陶瓷预制体,然后在氩气气氛中1 200℃下浸渗2024铝合金制得B4C-TiB2/Al合金复合材料。对该复合材料进行力学性能测试、X射线衍射分析、显微组织观察和断口分析。结果表明:该复合材料主要由B4C,Al,Al3BC和AlB2相组成,原位合成的TiB2使B4C/Al合金复合材料的抗弯强度和断裂韧性显著提高,分别达到361 MPa和7.49 MPa m1/2,增幅分别为14.6%和11.5%,但密度变化很小。原位合成TiB2使B4C/Al合金复合材料的抗弯强度和断裂韧性提高主要来源于金属铝塑性变形的裂纹桥接机制、TiB2细化晶粒及微裂纹引起的主裂纹偏转分叉机制。     

Finite-element method simulation of effects of microstructure, stress state, and interface strength on flow localization and constraint development in Nb/Cr2Nb in situ composites

The effects of volume fraction of particles, stress state, and interface strength on the yield strength, flow localization, plastic constraint, and damage development in Nb/Cr₂Nb in situ composites were investigated by the finite-element method (FEM). The microstructure of the in situ composite was represented in terms of a unit rectangular or square cell containing Cr₂Nb particles embedded within a solid-solution-alloy matrix. The hard particles were considered to be elastic and isotropic, while the matrix was elastic-plastic, obeying the Ramberg-Osgood constitutive relation. The FEM model was utilized to compute the composite strength, local hydrostatic stress, and plastic strain distributions as functions of volume fraction of particles, stress state, and interface strength. The results were used to elucidate the influence of volume fracture of particles, stress state, and interface property on the development of plastic constraint and damage in Nb/Cr₂Nb composites.     

Fracture toughness and fatigue crack growth in rapidly quenched Nb-Cr-Ti In situ composites

In situ composites based on the Nb-Cr-Ti ternary system were processed by rapid solidification in order to reduce the size of the reinforcing intermetallic phase. Two-phase microstructures with small Cr₂Nb particles in a Nb(Cr, Ti) solid solution alloy matrix were produced for several compositions that previous work showed to produce high toughness composites in cast materials. The fracture and fatigue behaviors of these composites were characterized at ambient temperature. The results indicate that the fracture resistance increases with a decreasing volume of Cr₂Nb particles. Fracture toughnesses of the rapidly solidified materials with their smaller particle sizes were lower than for conventionally processed composites with larger particles of the intermetallic compound. The fatigue crack growth rate curves exhibit steep slopes and a low critical stress intensity factor at fracture. The lack of fracture and fatigue resistance is attributed to the contiguity of the intermetallic particles and the absence of plastic flow in the Nb solid solution matrix. The matrix alloy appears to be embrittled by (1) the rapid solidification processing that prevented plastic relaxation of residual stresses, (2) a high oxygen content, and (3) the constraint caused by the hard Cr₂Nb particles.     

The effects on fracture toughness of ductile-phase composition and morphology in Nb-Cr-Ti and Nb-Siin situ composites

Niobium-chromium alloys, both single and two phase, were alloyed with titanium in order to enhance fracture toughness and fatigue crack growth resistance. The selection of titanium as an alloying element and the relationship of electronic bonding to toughness are examined. The results indicated that toughness increased with a decreasing number of D +s electrons. Titanium was found to increase the toughness of solid-solution Nb-Cr alloys from ≈8 to 87 MPa√m, while for the twophase “insitu composites,” toughness was increased from ≈5 to 20 MPa√m, although this is less than expected. Fracture toughness of the composites correlated nonlinearly with the volume fraction of the phases. The evidence suggests that the toughness of the composites is decreased due to fracture of the intermetallic particles and constraint on matrix deformation imposed by the intermetallic. Fracture characteristics of the Nb-Cr-Ti materials are compared to those of Nb-Cr and Nb-Si materials.     

Some observations of the influence of δ-ferrite content on the hardness,galling resistance,and fracture toughness of selected commercially available iron-based hardfacing alloys

Iron-based weld hardfacing deposits are used to provide a wear-resistant surface for a structural base material. Iron-based hardfacing alloys that are resistant to corrosion in oxygenated aqueous environments contain high levels of chromium and carbon, which results in a dendritic microstructure with a high volume fraction of interdendrite carbides which provide the needed wear resistance. The ferrite content of the dendrites depends on the nickel content and base composition of the iron-based hardfacing alloy. The amount of ferrite in the dendrites is shown to have a significant influence on the hardness and galling wear resistance, as determined using ASTM G98 methods. Fracture-toughness (K _IC) testing in accordance with ASTM E399 methods was used to quantify the damage tolerance of various iron-based hardfacing alloys. Fractographic and microstructure examinations were used to determine the influence of microstructure on the wear resistance and fracture toughness of the iron-based hardfacing alloys. A crack-bridging toughening model was shown to describe the influence of ferrite content on the fracture toughness. A higher ferrite content in the dendrites of an iron-based hardfacing alloy reduces the tendency for plastic stretching and necking of the dendrites, which results in improved wear resistance, high hardness, and lower fracture-toughness values. A NOREM 02 hardfacing alloy has the most-optimum ferrite content, which results in the most-desired balance of galling resistance and high K _IC values.     

Effects of microstructure on the fracture toughness of Ti3Al-based titanium aluminides

The influence of microstructure on the fracture toughness of Ti-23A1-9Nb-2Mo-1Zr-1.2Si (at. pct) and Ti-23A1-11Nb-0.9Si (at. pct) Ti₃Al-based alloys has been investigated. Basket-weave microstructures comprising different volume fractions of α ₂ and retained β phases were produced by systematic heat treatments. Besides the volume fraction of the retained β phase, the average size of the β laths has also been used to characterize these microstructures. The toughness of both alloys was examined at room temperature, and the brittle transgranular fracture modes were found to be controlled by microstructure. However, the toughness is not determined solely by the volume fraction of the retained β phase, and a linear relationship has been obtained between the fracture toughness and the average size of the retained β laths. It appears therefore that the toughness of Ti₃Al-based alloys at room temperature is controlled primarily by the width of retained β laths rather than by the retained β volume fraction.     

Fracture toughness, fracture morphology, and crack-tip plastic zone of a Zr-based bulk amorphous alloy

The elastic constants, fracture toughness, fracture morphology, and crack-tip plastic zone of a bulk amorphous alloy (bulk metallic glass), with the composition Zr-10Al-5Ti-17.9Cu-14.6Ni (at. pct), were investigated. The room-temperature fracture toughness reached values as high as 69 MPa&mrm. However, it showed considerable scatter, which is, at least in part, due to microcrystalline regions in the castings. Controlled crack propagation could not be obtained in chevron-notched specimens. The fracture-surface morphologies of chevron-notched specimens varied as the crack advanced, and this effect is probably related to differences in the crack propagation rate. Controlled fracture resulting in featureless fracture surfaces was observed during in-situ transmission electron microscope (TEM) fracture experiments. The plastic zone of a fatigue-precracked bulk flexure specimen was examined in situ in an atomic-force microscope (AFM). Shear displacements up to 2 &gmm were found. The AFM observations did not reveal any cracks associated with the shear steps. Sectioning of shear steps using a focused ion beam (FIB) with a diameter of 5 nm also did not reveal any cracks.     

Fracture toughness of discontinuously reinforced Al-4Cu-1.5Mg/TiB2 composites

The effect of particle size, particle volume fraction, and matrix microstructure on the fracture initiation toughness of a discontinuously reinforced aluminum composite was examined. The composites were Al-4 wt pct Cu-1.5 wt pct Mg reinforced with 0 to 15 vol pct of TiB₂ having an average particle diameter of 1.3 or 0.3μm producedin situ by the XD process. The room-temperature plane-strain toughness measured using compact tension specimens ranged from 19 to 25 MPa . Toughness was adversely affected by increases in TiB₂ volume fraction. The fracture toughness of all composites was affected by changes in the matrix microstructure produced by aging. The response of the composites to artificial aging deviates from that of the matrix. Fractography revealed that these composites failed in a ductile manner, with voids initiating at the reinforcing TiB₂ particles. The experimentally measured plane-strain toughness properties of Al-4Cu-l .5Mg composites with well-dispersed, 1.3-μm TiB² reinforcements agree with the Rice and Johnson model.     

Correlation of microstructure and fracture toughness in high-chromium white iron hardfacing alloys

A correlation is made of microstructure and fracture toughness in hypereutectic high-chromium white iron hardfacing alloys. In order to investigate the matrix effect of these alloys, in particular, four different matrices such as pearlite, austenite, and a mixture of pearlite and austenite were employed by changing the ratio of Mn/Si, while the total volume fraction of carbides was fixed. The hardfacing alloys were deposited twice on a mild steel plate by the self-shielding flux-cored arc-welding method. Fracture toughness was increased by increasing the volume fraction of austenite in the matrix, whereas hardness and abrasion resistance were nearly constant.In situ observation of the fracture process showed that cracks initiated at large primary carbides tended to be blocked at the austenitic matrix. This suggested that fracture toughness was controlled mainly by the amount of austenite in the matrix, thereby yielding the better toughness in the hardfacing alloy having the austenitic matrix. Considering both abrasion resistance and fracture toughness, therefore, the austenitic matrix was preferred for the high-chromium white iron hardfacing alloys.     

Fracture of Ti-Al<Subscript>3</Subscript>Ti metal-intermetallic laminate composites: Effects of lamination on resistance-curve behavior

The fracture toughness and resistance-curve (R-curve) behavior of Ti-Al₃Ti metal-intermetallic laminate (MIL) composites have been studied in the crack-divider orientation, by examining the effect of ductile-laminate-layer thickness and volume fraction. The MIL composites were fabricated in open air by a novel one-step process, and the final structure consists of alternating layers of ductile Ti and brittle Al₃Ti. Such a laminate architecture in conjunction with a relatively low volume fraction of tougher Ti (18 to 40 pct) was seen to augment the fracture toughness of the inherently brittle intermetallic by over an order of magnitude. Additionally, as a result of their low density, MIL composites exhibit a specific fracture toughness (K/ρ) on par with tougher but relatively denser ductile metals such as high-strength steel. Such vast improvements may be rationalized through the toughening provided by the ductile Ti layers. Specifically, toughening was obtained through plastically stretching the intact ductile Ti layers that formed bridging zones in the crack wake, thus reducing the crack driving force. Such toughening resulted in R-curve behavior, and the toughness values increased with an increase in the volume percentage of Ti. Weight-function methods were used to model the bridging behavior, and they indicated that large bridging zones (∼2 to 3 mm) were responsible for the observed increase in toughness. The role of large-scale bridging (LSB) conditions on the resistance curves is explored, and steady-state toughness (K _SS ) values are estimated using small-scale bridging (SSB) approximations. A new approach to gage the potential of laminate composites in terms of their true fracture-toughness values as determined from a cyclic crack-growth fatigue test is proposed, wherein small-scale specimens can be utilized to obtain fracture-toughness values.     

Microstructure,Thermal, Thermo-mechanical and Fracture Analyses of Hybrid AA2024-SiC Alloy Composites

This research work aims to investigate the inter-correlation between microstructure, thermal (thermal conductivity, thermo-gravimetric analysis), thermo-mechanical (dynamic mechanical analysis) and fracture characteristics of hybrid AA2024-SiC alloy composites fabricated via semi-automatic stir-casting process, as per standard industrial practice. Silicon Carbide (SiC) particulates of varying amount (0–6 wt%; @ step of 2%) were used to reinforce master batch of AA2024 wrought alloy, Silicon Nitride (Si3N4) and graphite particulates. The thermal conductivity and storage-modulus magnitudes of alloy composites have shown diminishing trend with hard SiC reinforcing phase, while material stability, viscous modulus, damping factor and fracture toughness have shown significant improvement. Uniform dispersion and better interfacial adhesion between matrix–reinforcement were observed from metallographic examination. The XRD analysis identified the different phases of the hybrid alloy composites. The trends in variations of physical, mechanical and tribological properties were supported by microstructure analysis, thermal analysis, thermo-mechanical analysis and fracture analysis.     

Importance of slip mode for dispersion-hardened β-titanium alloys

The mechanical properties of Ti-7 Mo-7 Al and Ti-7 Mo-16 Al (in at. pct) were correlated to the microstructure. The mechanical properties of the alloy with low aluminum content, consisting of α+ β phases, were dependent on the size of the α particles. Although the α phase is softer than the β phase, the small α particles, upon plastic deformation of the alloy, functioned as typical hard agents in a dispersion-hardened system and the volume fraction of the particles controlled the macroscopic ductility. A rapid strain-hardening behavior of the small α particles seemed to be responsible for this effect. Large α particles behaved like soft, incoherent particles, the volume fraction having little effect on the inherent ductility of the alloy. The two phase (β+ Ti₃Al) microstructure of the alloy with high aluminum content resulting from high temperature aging to 900°C exhibited a yield stress of 130 ksi and an elongation to fracture of 5 pct. The ductility of this microstructure was controlled by the volume fraction of the Ti₃Al particles inducing homogeneous slip. The favorable ductility properties of the microstructures with low Ti₃Al volume fraction were lost if the slip mode was changed from homogeneous slip to planar slip. Formerly Staff Member, Materials Research Center, Allied Chemical Corp., Morristown, N. J.     

Fracture in equiaxed two phase alloys: part ii. fracture in alloys with isolated plastic particles

A model, describing fracture of two phase equiaxed alloys containing isolated plastic particles within an elastically deforming matrix, has been developed. The model relates fracture toughness parameters to the microstructure and mechanical characteristics of the individual phases. The model utilizes the concepts of a process zone and crack closing forces in the process zone along with recent developments in the fracture mechanics of toughened ceramics. One adjustable parameter, either the extent of the process zone or the effective “gauge length” of plastic particles within the process zone, is used in the analysis. The values of these parameters, as deduced from experimental fracture mechanics studies in Co-CoAl alloys, are reasonable in their magnitude and depend on alloy microstructure in the manner predicted from the analysis. M. A. PRZYSTUPA, formerly Graduate Research Assistant, Department of Metallurgical Engineering, Michigan Technological University     

<Emphasis Type="Italic">In-situ</Emphasis> three-dimensional microstructural investigation of solidification of an Al-Cu alloy by ultrafast x-ray microtomography

This article presents the first results of a new experimental technique developed to investigate the evolution of the morphology of the solid and liquid phases during the solidification of a metallic alloy. It consists of ultrafast X-ray microtomography observations of a solidifying aluminum-copper alloy carried out at ESRF. These experiments allow investigating in-situ the formation of the casting microstructure and of the evolution of the morphology of the solid and the liquid phases. It allows also the in-situ determination of the solidification path, of the variation of the copper content in both the liquid and solid phases, and of some other characteristic parameters of the microstructure. Provided that some forthcoming technical improvements on the experimental setup are performed, more quantitative results can be obtained as well as better image quality and resolution.     

Microstructure and mechanical behavior of Cr-Cr2Hfin situ intermetallic composites

A detailed investigation of the effects of microstructural changes on the mechanical behavior of twoin situ intermetallic composites with Cr and Cr₂Hf phases in the Cr-Hf system was performed. The nominal compositions (at. pct) of the alloys were Cr-5.6Hf (hypoeutectic) and Cr-13Hf (eutectic). The study included evaluations of strength, ductility, and fracture toughness as a function of temperature and creep behavior. Two microstructures in each alloy were obtained by heat treatments at 1250 ‡C (fine microstructure) and 1500 ‡C (coarse microstructure). A decrease in elastic strength (stress at the onset of inelastic response in the load-deflection curve) with the coarsening of the microstructures was noted for both alloys below 1000 ‡C. The Cr-13Hf alloy retained strength to a higher test temperature, relative to Cr-5.6Hf alloy, under both microstructural conditions. The alloys showed no evidence of ductility at room temperature. However, in the coarse microstructure of the Cr-5.6Hf alloy, the primary Cr exhibited ductility at and above 200 ‡C; ductility in primary Cr could be seen only at and above 1000 ‡C for the fine microstructure. In other words, the temperature at which ductility was first observed decreased from about 1000 ‡C to about 200 ‡C due to high-temperature heat treatment in this alloy. Both microstructures of Cr-5.6Hf alloy showed a significant increase in fracture toughness with increasing test temperature. However, the increases in fracture toughness with temperature for the Cr-13Hf alloy microstructures were relatively small. Both alloys showed about four orders of magnitude reduction in steady-state creep rates relative to pure Cr at 1200 ‡C. The results are analyzed in the light of deformation characteristics and fracture micromechanisms. The effects of microstructural factors, such as the size and continuity of phases, solubility levels of Hf as well as interstitial elements in Cr, on the observed mechanical behavior are discussed. Formerly Research Scientist, Materials and Processes, UES, Inc.     

Characterization of Damage Evolution in SiC Particle Reinforced Al Alloy Matrix Composites by <Emphasis Type="Italic">In-Situ</Emphasis> X-Ray Synchrotron Tomography

We carried out a detailed investigation of the damage behavior of SiC particle reinforced 2080 Al alloy matrix composites by in-situ X-ray synchrotron tomography. We studied the tensile damage behavior of a peak-aged aluminum matrix composite. The main damage mode was SiC particle fracture with a very small contribution from void growth. The onset of damage takes place very close to the ultimate tensile strength of the composite. Particle fracture damage is stochastic in nature and is confined to a small distance from the fracture plane. Minimal void growth is observed, primarily at pre-existing microscopic voids from processing. Microstructure-based simulations, based on two-dimensional (2-D) images from the tomography data sets, show the importance of particle distribution and morphology on the evolution of plastic strain and damage in the composite.