Microstructure and mechanical properties of in situ Al–Mg2Si composites

Abstract

In situ metal matrix composites (MMCs) with Mg₂Si particulate reinforcement have been developed recently as ultralight materials. In this paper, a brief overview of the physical and mechanical properties of Mg₂Si and the current status of research on Mg₂Si reinforced MMCs is presented, followed by more detailed information on recent progress in the research group of the present authors. The effects of element additions and processing parameters on the microstructure of the composites obtained by gravity casting are discussed, together with some mechanical property data.     

Selective laser melting of in situ TiN–Ti5Si3 composites with RE–Si–Fe addition: comparative study

Abstract

A comparative study was conducted to investigate the influence of rare earth (RE)–Si–Fe addition on the microstructures and tribological properties of in situ TiN–Ti₅Si₃ composites prepared by selective laser melting (SLM). With the addition of 3 wt-% RE–Si–Fe, the shape of in situ TiN reinforcing particles became rounded and smoothened, the particle size was refined and the dispersion state was homogenised. Relative to TiN–Ti₅Si₃ composites without RE addition, the average friction coefficient of SLM processed RE containing composites decreased from 0·85 to 0·55, and the resultant wear rate decreased from 3·79×10^?4 to 2·65×10^?4 mm³ N^?1m^?1. Metallurgical functions of the RE elements in improving the SLM processability and the resultant wear performance of in situ composites were elucidated.     

Tensile and fatigue behaviour of Ni–Ni3Si eutectic in situ composites

A Ni–Ni₃Si composite was fabricated via a eutectic reaction (Ni–Ni₃Si) using a rapidly cooled directional solidification technique at a solidification rate of 40?μm?s^?1. The composite consisted of approximately 62.2% Ni–Si solid solution and 37.8% Ni–Ni₃Si eutectic phase in volume. Four-point bend fatigue tests were carried out on the composite. The fatigue strength of the alloy was measured to be 520?MPa (maximum cyclic stress). It was found that the fatigue cracks were preferably initiated in the Ni–Ni₃Si eutectic phase, and that the Ni matrix was fractured in a cleavage fashion. It was probably attributed to the high level of supersaturated Si in the Ni matrix, which led to inducing the embrittlement of the Ni matrix.     

Microstructure and tensile properties of graded Al–Mg2 Si in situ composites fabricated by centrifugal casting

Abstract

Al–Mg₂ Si in situ composite tubes were fabricated by a centrifugal casting process. The microstructure and tensile strength of the composite tubes were examined revealing an inhomogeneous distribution of Mg₂ Si particles along the radial direction. Adjacent to the rapidly cooled area, near the outer periphery, in situ particles were forced inwards leaving behind a particle free region in the middle part of the tubes. Increasing Mg₂ Si weight percentage in the aluminium matrix induced dendrite formation in the rapidly cooled area and the width of the particle free region in the middle part of the cylinder wall decreased. The particle distribution gradient in the inner region also decreased with increasing Mg₂ Si content. The width of the particle free region and the particle distribution gradient were both influenced by the gradually varying viscosity of the liquid alloy as it solidified. The tensile strength of the centrifugally cast tubes increased from inner to outer periphery. High volume fractions of Mg₂ Si particles of between 50 and 70 vol.-% reduced the strength of the composites.     

Microstructure evolution and interfacial reaction of TiAl–Si alloy solidified in alumina crucible

The microstructure evolution of Ti–43Al–3Si (at-%) alloy solidified in alumina crucible was investigated by directional solidification technology. After directional solidification, the microstructure of the alloy is consisted of γ-TiAl, α₂-Ti₃Al, ξ-Ti₅Si₃ phases and Al₂O₃ particles. There are three morphologies of ξ phases formed in the alloy, namely, long rod-like, cluster-like with eutectic morphology, and needle-like shape. The volume fraction of ξ phases decreases with increasing growth rates. Al₂O₃ particles broke from the crucible and enter into the melt by the thermal physical erosion. Al₂O₃ particles enrich in the liquid phase with the moving of solid-liquid interface, and are captured or entrapped by dendrites during solidification. The Al₂O₃ particles mainly distributed in the interdendritic region, and some particles exist in dendrites.     

Effect of hot extrusion on wear properties of Al–15 wt.% Mg2Si in situ metal matrix composites

Al–15 wt.% Mg₂Si composites were prepared by in situ casting and characterized in wear tests. Previous to the extrusion of specimens at 470 °C – varying extrusion ratio (7.4, 14.1 and 25), the as-cast composites were homogenized at 500 °C for 5 h, followed by slow furnace cooling. The microstructure, hardness and sliding wear behavior were characterized for both, the as-cast and hot extruded composites. Results show that increasing the extrusion ratio causes a significant improvement in hardness and wear resistance. This is ascribed to the observed decrease in average size and better distribution of Mg₂Si particles, in tandem with a remarkable decrease in porosity percentages, which goes from 5.63 in the as-cast condition, to 0.47 at the extrusion ratio of 25. It was found that abrasion is the dominant wear mechanism in all extruded composites, whilst a combination of adhesion and delamination appears to be the governing mechanism for as-cast composites.     

Damping behaviour and mechanical properties of rapidly solidified Al–Fe–Mo–Si/Al alloys

In order to develop a new high damping aluminium alloy with strength and toughness for advanced aircraft structure application, rapidly solidified (RS) Al–Fe–Mo–Si/Al alloys were synthesized. The damping behaviour, mechanical properties and microstructures of the alloys were studied. Results showed that the damping capacities of RS Al–Fe–Mo–Si/10–15% Al alloys are stable between 7.0–10.0×10-3 at room temperature, which almost reach the high damping threshold, 10.0×10-3. At lower frequency (0.1–10 Hz) the damping capacity is decidely frequency and temperture dependent above 50°C, with lowest frequency and highest temperature resulting in the highest less factor. It was noted that mechanical properties of the Al–Fe–Mo–Si/10–15% Al alloys are both excellent at room temperature (b=536–564 MPa, =7.2–11.4%) and at elevated temperature (250°C: b=295–324 MPa). Analysis of microstructures reveal that the damping capacity arises from deformation of the pure Al areas, and strength at elevated temperature from the dispersion strengthening of intermetallic phase. © 1998 Chapman & Hall     

Microstructure and properties of Sip/Al–Si surface composites prepared by ultrasonic method

Primary Si particles reinforced Al–Si surface composites (Si_p/Al–Si surface composites) were prepared by means of ultrasonic equipment with a special horn crucible. The microstructure and properties of the surface composites were investigated using optical microscope, scanning electron microscopy (SEM), hardness meter and friction and wear tester. The results show that when Al–12%Si alloy was treated by ultrasonic, Si element was easy to move up because of the decrease of the viscosity of the melt, and the alloy composition at the top of the melt became hypereutectic. So, a mass of primary Si particles formed in this place. The thickness of the surface composite layer in the surface composites decreased with increasing the ultrasonic input power. The average size of the primary Si particles in the surface composite layer was larger than that of Al–Si alloy untreated by the ultrasonic and increased with increasing ultrasonic input power. The top layer hardness of Si_p/Al–Si surface composites is higher than that of Al–Si alloy without ultrasonic treatment and increased with increasing ultrasonic input power. The friction coefficients of the top layers of the surface composites are lower than that untreated by ultrasonic. The friction coefficient decreased with increasing ultrasonic input power. With the increase of the applied load, the friction coefficient of the top layer of the surface composites increased. The wear mass loss of Si_p/Al–Si surface composites is lower than that Al–Si alloy without ultrasonic treatment. The wear resistance of the surface composites was improved with increasing ultrasonic input power.     

Strength of β-sialon/Si3N4 layered composites

The strength of layered composites consisting of -sialon and Si3N4 layers, which were prepared by hot pressing, was investigated. The strength increased as the thickness of the sialon (outer layer) decreased, and reached almost the same level of Si3N4 (inner layer) when the sialon thickness was 250–300 m. No specific fracture morphologies were recognized around the interface of sialon and Si3N4. The aluminium concentration changed sharply around the interface, while the yttrium tended to diffuse deeper than aluminium. This tendency was remarkable in the samples hot-pressed at higher temperature (1900°C). The existence of compressive residual stress in the surface sialon layer was revealed and the residual stress increased as the sialon thickness decreased down to 250–300 m. The increase of strength with the decrease of sialon thickness was discussed based on the mechanical calculations in which the residual stress was considered. This calculation approximately agreed with the results of the samples hot-pressed at lower temperature (1800°C). However, the strength of the samples hot-pressed at 1900°C was much higher than the prediction in the thin range of the sialon thickness. The deep diffusion of yttrium into the sialon layers was thought to be one of the causes of this unpredictable effect.     

Microstructure and mechanical properties of TiC/Ti–6Al–4V composites processed by in situ casting route

Abstract

TiC/Ti–6Al–4V composites containing various volume fractions of TiC were produced by induction skull melting and common casting utilising in situ reaction between titanium and carbon powder. The microstructure and room tensile properties of as cast and heat treated TiC/Ti–6Al–4V composites were investigated. Bar-like or small globular eutectic TiC were found in 5 vol.-%TiC/Ti–6Al–4V composite, whereas the equiaxed or dendritic primary TiC particles were found to be the main reinforcements in 10 and 15 vol.-%TiC/Ti–6Al–4V composites. The as cast TiC/Ti–6Al–4V composites have shown higher strength but lower ductility than those of monolithic Ti–6Al–4V alloy. The shape and fracture of TiC particles can strongly influence the fracture and failure of the composites, and so the ultimate tensile strengths and elongations of as cast composites reduce with the increase in volume fraction of TiC. TiC particles appear to be spheroidised, and titanium precipitation can be found within large TiC particles after heat treatment at 1050°C for 8 h, which can promote the resistance to fracture of composites. Therefore, the elongations of the composites increase significantly, and the ultimate tensile strengths also have marginal increase especially for the 10 and 15 vol.-%TiC/Ti–6Al–4V composites after heat treatment.     

Development of Al 6063–TiB2 in situ composites

In situ TiB₂ reinforced Al 6063 composites have been successfully synthesized through the chemical reaction between Al–10%Ti and Al–3%B master alloys in the Al 6063 alloy using liquid metallurgy route. The amount of TiB₂ formed in the composite is estimated using gravimetric analysis. Mechanical properties in terms of microhardness, ultimate tensile strength and modulus of elasticity have been improved by 21%, 47% and 65% respectively in comparison with matrix alloy. Further, ductility in terms of percentage elongation of the composites was found to increase by about 368% when compared with the matrix alloy. The improvement in ductility may be associated with the grain refinement of the composite with an increase in the content of Al–3%B master alloy.     

Microstructure and mechanical properties of in situ formed TiC-reinforced Ti–6Al–4V matrix composites

Carbon nanotubes were blended into a Ti–6Al–4V matrix to synthesize titanium carbide (TiC) in situ, via spark plasma sintering. The microstructure and mechanical properties of both the monolithic Ti–6Al–4V alloys and the TiC/Ti–6Al–4V composites were studied to evaluate the strengthening effects of TiC on the Ti–6Al–4V matrix. The morphologies obtained by scanning electronic microscopy and optical microscopy indicated that the grain size of both the Ti–6Al–4V alloy and the TiC/Ti–6Al–4V composite decreased with increasing planetary ball-milling (PBM) speed, leading to an increase in the hardness of the investigated materials. The compressive yield strength of the monolithic Ti–6Al–4V alloys and the TiC/Ti–6Al–4V composites initially increased and then decreased with increasing PBM speed. The strengthening and fracture mechanisms were studied.     

Synthesis and high temperature oxidation of Mo–Si–B–O pseudo in situ composites

In this paper, the new concept of ‘pseudo in situ composites’ is introduced into artificial composites for ultra-high temperature applications, composed of five phases, Mo, Mo₃Si, Mo₅Si₃, Mo₅SiB₂ and SiO₂. Among these phases, Mo and Mo₅Si₃ are not thermodynamically stable with each other, but they are locally equilibrated in the composites due to the formation of Mo₃Si as their reactant. Using the spark plasma sintering (SPS) technique, the Mo–Si–B–O pseudo in situ composites are successfully synthesized from Mo₃Si/Mo₅Si₃/Mo₅SiB₂ in situ composite powder, Mo and/or SiO₂ powders. The consolidated compacts are sound and fully dense, indicating that the SPS is a promising technique to synthesize the Mo–Si–B–O pseudo in situ composites. High temperature oxidation properties of the composites were examined up to 1673 K. The temperature range is divided into three with respect to the oxidation behavior; i.e. (I) below 1000 K, (II) between 1000 and 1400 K, and (III) above 1400 K. In the range II, the oxidation resistance of the composites is significantly improved by SiO₂ addition. In the range III, the oxidation resistance of the composites is good enough even at 1673 K in spite of the existence of Mo, displaying high potential for ultra-high temperature applications.     

Influence of tool geometries and process variables on friction stir butt welding of Al–4.5%Cu/TiC in situ metal matrix composites

Present work describes friction stir welding of in-house produced and hot rolled Al–4.5%Cu/TiC in situ metal matrix composites by using hardened bimetallic tool with varying shoulder surface geometries and other process variables. Joining of the said composite using friction stir welding process has been seen to provide beneficial effects such as grain refinement of the matrix and subsequent redistribution and refinement of reinforcements. A predictive model has also been developed to estimate the weld properties such as tensile strength and ductility with respect to the tool geometry used and input process variables. The X-ray diffraction analysis results of Al–4.5%Cu/TiC butt welds indicated formation of CuAl₂O₄ and CuAl₂ to some extent in the stir zone. Fractography of the weld samples revealed dimpled ductile nature of fracture. Through multi response optimization of the welding parameters and tool geometry, weld strength of 89% that of the base material was achieved.     

Microstructure–properties relationship in ceramic–elastomer composites with 3D connectivity of phases

The ceramic–elastomer composites with 3D phase connectivity were tested under compressive loads. Such composites exhibit high initial strength and stiffness with the ability to sustain large deformations. Samples of the composites were made of porous SiO₂ ceramic matrix infiltrated by polyurethane elastomer. The ceramic matrix preforms used differed in the porosity and three different composite microstructures have been obtained. Selected parameters of microstructure composites were evaluated using image analysis. The compressive strength and capacity for energy absorption are characterized under various strain rates (0.001–235 s⁻¹). It was found that stress–strain characteristic depends on the strain rate and the specific interface area (Sv). Pore size and the specific interface area have a strong effect on the compressive strength of composites and these parameters can be used for tailoring their mechanical properties. The acoustic emission was applied to identify stages in the process of microstructure damage during compression. The interpretation of damage stages was proposed, which also explains the character of the stress–strain curves.     

Microstructure and mechanical properties of in situ TiC and Nd2O3 particles reinforced Ti–4.5 wt.%Si alloy composites

(TiC + Nd₂O₃)/Ti–4.5 wt.%Si composites were in situ synthesized by a non-consumable arc-melting technology. The phases in the composites were identified by X-ray diffraction. Microstructures of the composites were observed by optical microscope and scanning electron microscope. The composite contains four phases: TiC, Nd₂O₃, Ti₅Si₃ and Ti. The TiC and Nd₂O₃ particles with dendritic and near-equiaxed shapes are well distributed in Ti–4.5 wt.%Si alloy matrix, and the fine Nd₂O₃ particles exist in the network Ti + Ti₅Si₃ eutectic cells and Ti matrix of the composites. The hardness and compressive strength of the composites are markedly higher than that of Ti–4.5 wt.%Si alloy. When the TiC content is fixed as 10 wt.% in the composites, the hardness is enhanced as the Nd₂O₃ content increases from 8 wt.% to 13 wt.%, but the compressive strength peaks at the Nd₂O₃ content of 8 wt.%.