The mechanical behaviour of interpenetrating phase composites — III: resin-impregnated porous stainless steel

Powder metallurgy (P/M) derived porous metals that have been impregnated with a polymer resin to create fully dense composites are examples of interpenetrating phase composites (IPCs), in which each phase forms a completely interconnected network. In this paper, we describe an experimental and modelling investigation of the mechanical properties of resin-impregnated P/M derived porous 316L stainless steel composites of various volume fractions, with a view to gaining a better understanding of the mechanical properties of IPCs. In comparison with a similar investigation of 420 stainless/bronze IPCs, properties of the 316L stainless/resin IPCs are less well represented by non-linear finite element analysis based on a unit cell model with periodic boundary conditions. This is attributed to the more irregular microstructure of the 316L/resin IPCs, greater uncertainty in the properties of the constituent materials, and larger differences between constituent properties. Considering only mechanical properties, the 316L stainless/resin combination does not appear to take advantage of the interpenetrating phase morphology, since the resin does not possess a superior property to contribute to the composite as a whole.     

The mechanical behaviour of interpenetrating phase composites – II: a case study of a three-dimensionally printed material

Interpenetrating phase composites (IPCs) – composites in which each phase forms a completely interconnected network – are becoming an important class of materials as the result of the development of a number of new techniques for producing composites with interpenetrating microstructures. In this paper, the mechanical properties of two-phase IPCs are modelled. Finite element analysis is used to investigate elastic, strength, and thermal expansion properties of IPCs. The numerical results are compared with the properties of composites with non-interpenetrating microstructures. For the specific microstructures investigated, it is found that a composite with an interpenetrating microstructure can possess enhanced thermo-mechanical properties. The enhanced properties may result more from the contiguity of the phase with more advantageous properties than from the interpenetrating microstructure.     

The model for fracture toughness

It is pointed out that the distribution introduced by Neville [1] (for modeling fracture toughness to failures) is contained by at least two families of distributions known since the 1940s. Some elementary statistical properties of these families are discussed. Six data sets on fracture toughness are used to demonstrate that these families are much better models for fracture toughness than the one introduced by Neville [1].     

Development of cleavage fracture toughness locus considering constraint effects

In this paper, the higher order terms in the crack tip stress fields are investigated macroscopically for more realistic assessment of structural material behaviors. For reactor pressure vessel material of A533B ferritic steel, effects of crack size and temperature have been evaluated using 3-point SENB specimens through a series of finite element analyses, tensile tests and fracture toughness tests. The T-stress, Q-parameter andq-parameter as well as theK andj-integral are calculated and mutual relationships are investigated also. Based on the evaluation, it has proven that the effect of crack size from standard length (a/W=0.53) to shallow length(a/W=0.11) is remarkable whilst the effect of temperature from - 20°C to-60°C is negligible. Finally, the cleavage fracture toughness loci as a function of the promising Q-parameter orq-parameter are developed using specific test results as well as finite element analysis results, which can be applicable for structural integrity evaluation considering con-straint effects.     

Effects of substrate materials on fracture toughness measurement in adhesive joints

To understand the effects of substrate materials on the fracture behavior of adhesive joints, experimental studies and finite element analyses have both been conducted for double-cantilever-beams (DCB) with aluminum and steel substrates at different bond thickness (h). Numerical results show that the region dominated by the crack singularity is much smaller than by the bond thickness. Very small plastic deformation may hence violate the requirements for small-scale yielding where the crack-tip field can be characterized uniquely by the stress intensity factor. Both critical strain energy release rate and J-integral for the joints with steel substrate are lower than those for the joints with aluminum substrate. Compared to the critical strain energy release rate, the critical J-integral is less sensitive to the substrate material if small plastic deformation occurs before cohesive failure takes place through the adhesive layer. For the joints with aluminum substrate, the fracture toughness initially increases and then decreases with bond thickness. Elastic–plastic crack-tip analysis indicates that at the same level of loading, a higher opening stress is observed in the joint with a smaller bond thickness. A self-similar stress field can be obtained by the normalised loading parameter, J/hσ₀.     

Effect of microwave heat treating processing on frictional behaviour of aluminium alloy 2900 composites

The sliding wear behaviour of microwave processed, SiC_p and Al₂O_3p reinforced aluminium alloy 2900 and 2024 metal matrix composites prepared by powder metallurgy method was investigated in a pin on disc system. The objective is to determine the effects of novel alloying elements of AA 2900, ceramic addition and microwave aging process on the strength to tribological properties. This composite is evaluated to be an effective replacement for conventionally available AA 2024 composites in brake applications. Compared to conventional heat treating processes, microwave processing used for heat treating the samples is observed to be novel method in improving the strength–microstructural–tribological properties. AA 2900 with 6 wt-% Al₂O₃ exhibited good strength to microstructure relationship with excellent wear characteristics compared to AA 2024 composites which are governed by alloying elements in AA 2900. 2 H aged AA 2900 with 6 wt-% Al₂O₃ sample exhibited good frictional coefficient values with good density and strength characteristics. Hence, it is observed that alloying elements in AA 2900 and microwave processing have enhanced the strength to tribological behaviour where the property enhancement is achieved only through ceramic reinforcements.     

Three-parameter approach for elastic–plastic fracture of the semi-elliptical surface crack under tension

Systematic three-dimensional elastic–plastic finite element analyses are carried out for a semi-elliptical surface crack in plates under tension. Various aspect ratios (a/c) of three-dimensional fields are analyzed near the semi-elliptical surface crack front. It is shown that the developed J–Q annulus can effectively describe the influence of the in-plane stress parameters as the radial distances (r/(J/σ₀)) are relatively small, while the approach can hardly characterize it very well with the increase of r/(J/σ₀) and strain hardening exponent n. In order to characterize the important stress parameters well, such as the equivalent stress σ_e, the hydrostatic stress σ_m and the stress triaxiality R_σ, the three-parameter J–Q_T–T_z approach is proposed based on the numerical analysis as well as a critical discussion on the previous studies. By introducing the out-of-plane stress constraint factor T_z and the Q_T term, which is determined by matching the finite element analysis results, the J–Q_T–T_z solution can predict the corresponding three-dimensional stress state parameters and the equivalent strain effectively in the whole plastic zone. Furthermore, it is exciting to find that the values of J-integral are independent of n under small-scale yielding condition when the stress-free boundary conditions at the side and back surfaces of the plate have negligible effect on the stress state along the crack front, and the normalized J tends to a same value when φ equals about 31.5° for different a/c and n. Finally, the empirical formula of T_z and the stress components are provided to predict the stress state parameters effectively.     

Dry wear and friction properties of an A356/SiC foam interpenetrating phase composite

The dry sliding wear and friction behaviors of A356 aluminum alloy and a hybrid composite of A356 aluminum alloy and silicon carbide foam in the form of an interpenetrating phase composite were evaluated using a ball-on-disk apparatus at ambient conditions. The stationary 6.35 mm alumina ball produced a wear track (scar) diameter of 7 mm on the rotating specimen surface. Three different loads; 5 N, 10 N and 20 N were applied at a constant sliding speed of 33 mm/s for both materials. Wear tracks were characterized with a scanning electron microscope and measured with an optical surface profilometer. In general, this novel A356/SiC foam composite reduced the friction coefficient and wear rate from that of the base alloy for all loading conditions. In addition, as the load increased, the friction coefficient and wear rate decreased for both materials. The results indicate the composite could be used in light-weight applications where moderate strength and wear properties are needed.     

Estimation of fully plastic crack tip stresses from equilibrium of least upper bound circular arcs

This paper presents a simple method to estimate fully plastic crack tip stresses based on the equilibrium condition of the least upper bounds for plane strain deformation fields consisting of rigid-body rotation across a circular arc extending from a crack tip across the remaining ligament. The method is applied to deep, single-edge-cracked specimens under combined bending and tension. For various bending-to-tension ratios, the limit loads and crack tip stresses are estimated from the present method and compared with results from finite element limit analyses. The present method gives impressive results.     

Wear and fracture toughness of partially stabilized zirconia ceramics under dry friction against steel

The wear of two ceramic materials containing partially stabilized zirconia is studied under unlubricated friction against steel. The first material, with ZrO₂ and 3 mol % Y₂O₃, was obtained by cold isostatic pressing and sintering. The second material, comprising ZrO₂ and 4 mol % Y₂O₃, was fabricated by additional hot isostatic pressing. The samples of both materials were fabricated with high and low values of fracture toughness. The samples with high fracture toughness are found to wear more intensively. This fact can be explained by surface micro-cracking during braking as a result of phase transformations.     

Effect of reinforcement size and volume fraction on the abrasive wear behaviour of AA7075 Al/SiCp P/M composites—A statistical analysis

In the present study, a new mathematical model was developed to predict the abrasive wear rate of AA7075 aluminum alloy matrix composites reinforced with SiC particles. Five factors, five levels, central composite, rotable design matrix was used to optimise the required number of experiments. The model was developed by response surface method. Analysis of variance technique was applied to check the validity of the model. Student's t-test was utilised to find out the significant factors. The effect of volume percentage of reinforcement, reinforcement size, applied load, sliding speed and abrasive size on abrasive wear behaviour was analysed in detail.     

Finite element analysis considering fracture strain of sheath material and die lubricant in extrusion process of Al/Cu clad composites and its experimental investigation

Clad composite materials consist of stacks of different materials. During the extrusion process of clad composites, fracture of the sheath or core materials frequently occurs because of the discontinuity of deformation caused due to the differences in the flow stress of the sheath material and core material. In order to predict fracture of the sheath material with oxygen-free high conductivity copper, the theory of ductile fracture has been applied. The effect of lubrication behavior on fracture of core material has been investigated. A technique to predict the fracture strain rate has been proposed. The calculated interface bonding force between the core material and the sheath material has been used to assist in die design for the indirect and direct extrusion processes.     

Optical characteristics of thin film coating and measurement of its thickness

Theoretical analysis of the optical characteristics of thin film coatings was carried out. The relations of refractive index, phase change and film thickness were studied. As a result, a new optical method of measuring thickness of thin metallic coatings was developed. Further, the technique can also be used to find the refractive index of the thin film and the phase change of the light beam owing to being reflected from the coating. It is shown that the new method is very accurate for measuring the thin coating thickness. A specimen coating was tested with a polarised laser beam and the measured phase change falls between the reasonable range of 0 and π.     

Influence of secondary phases on the tribological response of electro-discharge machined zirconia-based composites against WC-Co cemented carbide

Three ceramic composite grades, consisting of a ZrO₂ matrix and 40 vol.% WC, TiC_0.5N_0.5 or TiN phase, were completely self-developed by hot pressing powder mixtures of yttria-stabilised zirconia (Y-TZP) and distinctive WC, TiC_0.5N_0.5 or TiN powder sources. The friction and wear characteristics of the zirconia-based composites against WC-Co cemented carbide were investigated by performing dry reciprocating sliding experiments on a pin-on-plate tribometer under various normal contact forces. The generated wear was quantified using surface scanning topography. Post-mortem obtained wear volumes were correlated to real-time recorded wear depth. The ZrO₂-40 vol.% WC grade displayed more favorable tribological properties compared to the other grades with equal secondary phase content. The worn surfaces and the wear debris were analysed by scanning electron microscopy (SEM) and energy dispersive X-ray analysis (EDX), revealing several wear mechanisms such as polishing, abrasion and wear debris layer formation, mainly depending on the imposed contact load and the material composition.     

Novel photoactive aggregates of rhodamine 6G: dequenched and quasi-stable aggregates induced by a dewetting process

Self-organized rhodamine 6G particles prepared by wetting/dewetting process of an ethanol solution on a hydrophilic glass surface exhibits fluorescence without quenching, showing a sharp linewidth of 2nm with a large redshift, which indicates an existence of dye aggregates, similar to J-aggregates, inside the particle. Polarized evanescent field excitation showed that the dye molecule's transition moment along the pi-conjugation was oriented unidirectionally within particles and parallel to the substrate surface. This deduced dye orientation showed correlation between adjacent, but separated, particles and pointed roughly 45 degrees off the dewetting direction. In contrast, the particles of another pi-conjugated NK1420 dye, J-aggregates of which grows easily from an oversaturated solution, showed dye orientation along the dewetting direction preferably, still indicating the effect of self-organization, however based on a different mechanism. An annealing procedure revealed that both aggregates are in quasi-stable states, which is consistent with the rapidness of the dewetting process that may lead to crystallization in nonequilibrium.     

Synthesis and evaluation of mechanical and high temperature tribological properties of in-situ Al-TiC composites

In situ Al-TiC (5, 10 and 15 wt%) composites were produced by using a reaction mixture of K₂TiF₆ and graphite powder with molten metal. The effect of ceramic particulate addition on the high temperature sliding wear resistance of the composites was studied. The sliding wear tests were conducted at room temperature, 120 and 200 °C. The wear rate increases with the increase in applied load and decreases with increase in the weight percentage of TiC. Both monolithic and composites were able to withstand thermal softening effects due to the formation of oxidative protective transfer layer.     

Erosive wear behaviour of weld hardfacing high chromium cast irons: effect of erodent particles

Five commercial hardfacing high chromium cast iron alloys were deposited by flux cored arc-welding method. The solid particle erosion studies were carried out using air blast type erosion test rig with 125–150 μm cement clinker, 125–150 μm blast furnace sinter, 100–150 μm silica sand and 125–150 μm alumina particles at a velocity of 50 m s⁻¹ and at impingement angles of 15–90°. The observed erosion rates were rationalised in terms of relative hardness of erodent particles and ability of erodent particle to cause gross fracture of the carbides. The dependence of erosion rate on impingement angle was found to be quite weak for hardfacing high chromium cast iron alloys. However, significant differences were observed in the ranking of the alloys when eroded with different erodent particles. The presence of large volume fraction of carbides proved to be beneficial to the erosion resistance when the erodent particle were softer than the carbides. With silica sand particles at normal impact and with alumina particles large volume fraction of carbides proved detrimental to the erosion resistance. The operating erosion mechanisms involved small-scale chipping, edge effect, indentation and fracture and fatigue.     

Effect of nanoparticles on the tribological behaviour of short carbon fibre reinforced poly(etherimide) composites

The tribological behaviour of nano-TiO₂ particle filled polyetherimide (PEI) composites, reinforced additionally with short carbon fibre (SCF) and lubricated internally with graphite flakes, was investigated. The wear tests were conducted on a pin-on-disc apparatus, using composite pins against polished steel counterparts under dry sliding conditions, different contact pressures and various sliding velocities. It was found that the conventional fillers, i.e. SCF and graphite flakes, could remarkably improve both the wear resistance and the load-carrying capacity. With the addition of nano-TiO₂, the frictional coefficient and the contact temperature of the composite were further reduced, especially under high pv (the product of the normal pressure, p, and the sliding velocity, v) conditions. Based on microscopic observations of worn surfaces and transfer films on the counterparts, possible wear mechanisms were discussed.     

The Influence of Anchoring-Group Structure on the Lubricating Properties of Brush-Forming Graft Copolymers in an Aqueous Medium

We have compared the lubricating properties of two different PEG-grafted, polycationic, brush-forming copolymers to gain a deeper understanding of the role of the polyionic backbone in the lubricating behavior of such materials, when used as additives in aqueous lubricant systems. Previously, poly(l-lysine)-graft-poly(ethylene glycol) (PLL-g-PEG) has been shown to adsorb onto oxide surfaces from aqueous solution and substantially lower frictional forces. Poly(allylamine)-graft-poly(ethylene glycol) (PAAm-g-PEG), which also has a polycationic backbone, has been synthesized in several different architectures, and its performance investigated via adsorption tests, rolling- and sliding-contact tribometry, and the surface forces apparatus. These tests show a clear reduction of friction forces with PAAm-g-PEG compared to water alone. However, when compared with PLL-g-PEG, while PAAm-g-PEG copolymers did not adsorb to the same extent or exhibit as high a lubricity in sliding geometry, they showed a similar lubricating effect under rolling conditions. The difference in the chemical structure of the backbones, especially the flexibility of the anchoring groups, appears to significantly influence both the extent and kinetics of polymer adsorption, which in turn influences lubrication behavior.

Effects of strain rate and temperature on fracture strength of ceramic/metal joint brazed with Ti-Ag-Cu alloy

Ceramics are significantly used in many industrial applications due to their excellent mechanical and thermal properties such as high temperature strength, low density, high hardness, low thermal expansion, and good corrosion resistive properties, while their disadvantages are brittleness, poor formability and high manufacturing cost. To combine advantages of ceramics with those of metals, they are often used together as one composite component, which necessiates reliable joining methods between metal and ceramic. Direct brazing using an active filler metal has been found to be a reliable and simple technique, producing strong and reliable joints. In this study, the fracture characteristics of Si₃N₄ ceramic joined to ANSI 304L stainless steel with a Ti-Ag-Cu filler and a Cu (0.25–0.3 mm) interlayer are investigated as a function of strain rate and temperature. In order to evaluate a local strain a couple of strain gages are pasted at the ceramic and metal sides near joint interface. As a result the 4-point bending strength and the deflection of interlayer increased at room temperature with increasing strain rate. However bending strength decreased with temperature while deflection of interlayer was almost same. The fracture shapes were classified into three groups ; cracks grow into the metal-brazing filler line, the ceramic-brazing filler line or the ceramic inside.