Temperature effect on fracture behaviour of an alumina particulate-reinforced 6061-aluminium composite

The effect of temperature on the fracture behaviour of a peak-aged alumina particulate 6061 aluminium composite was studied in the range of 25 to 180° C. The fracture toughness was found to be independent of test temperature. The role of the reinforcement phase was examined in detail at 180° C, and compared to observations at room temperature, by using an interrupted test methodology. Ductile fracture occurred at all temperatures. At room temperature the fractured particles acted as void nucleation sites and at 180° C both debonded and fractured particles were responsible for void nucleation. Large particles were found to be susceptible to fracture and nucleate microvoids earlier than small particles. A decrease in the range and size of the reinforcement phase would increase the fracture resistance for this MMC material.On leave at the Department of Mechanical Engineering, Hong Kong University of Science and Technology, Clear Water Bay, Kowloon, Hong Kong.     

The microstructure and elevated temperature strength of tungsten-titanium carbide composite

A new tungsten matrix composite containing 30 vol% titanium carbide particles (W-TiC) produced by sintering under 20 MPa pressure at 2000°C in a vacuum has been developed in order to improve the elevated temperature strength of tungsten. Flexural strength tests of the W-TiC composite in the temperature range 20–1200°C showed that the strength was significantly increased by the presence of TiC particles. The flexural strength at 1000°C was 1155 MPa, which was much higher than that at 20°C (770 MPa). Microstructural observations showed that a interdiffusion zone was produced at the W matrix-TiC particle interface, and a strong bond was formed between TiC and W, which was very beneficial to the elevated temperature mechanical properties. The mechanisms of fracture at 20°C and 1000°C were investigated. The fracture at 20°C was brittle. There was a growth-coalescence process for the initial cracks during the fracture process of the W-TiC composite at 1000°C, and the W matrix exhibited ductile tearing. The excellent elevated temperature strength of W-TiC composite was attributed to the brittle-ductile transition in the W matrix, which allows more effective strengthening from TiC particles.     

Microstructure and mechanical properties of aluminum alloy matrix composites reinforced with Fe-based metallic glass particles

Fe-based metallic glass (FMG) particles reinforced Al-2024 matrix composites were fabricated by using the powder metallurgy method successfully. Mechanical alloying result in nanostructured Al-2024 matrix with a grain size of about 30 nm together with a good distribution of the FMG particles in the Al matrix. The consolidation of the composites was performed at a temperature in the super-cooled liquid region of the FMG particles, where the FMG particles act as a soft liquid-like binder, resulting in composites with low or zero porosity. The microstructure and mechanical properties of the composites were investigated by X-ray diffraction (XRD), scanning electron microscopy (SEM), transmission electron microscopy (TEM) and compression test. The yield and fracture strength of the composites are 403 MPa and 660 MPa, respectively, while retaining a considerable fracture deformation of about 12%. The strengthening mechanism is associated with the grain refinement of the matrix and uniform distribution of the FMG particles.     

Characterization of microstructural damage during plastic strain of a particulate-reinforced metal matrix composite at elevated temperature

The evolution of damage in a SiC-reinforced 2618 AI alloy during plastic strain has been investigated by elastic modulus reduction and direct observations of the microstructure at room temperature and temperatures up to 220 °C. Particle fracture increases as a function of strain at all temperatures but the total number of fractured particles at any given strain is lower at higher test temperatures. The dependence of fracture on particle size and aspect ratio was recorded. Normalized elastic modulus measurements decrease as a function of strain at the same rate for tests at 25,110 and 220 °C with an anomalous set of measurements at 165 °C showing a reduced damage rate. There is no universal correlation between the number of damaged particles and reduced modulus with each test temperature showing a different relation. This indicates the different temperature dependence of void nucleation and subsequent growth. The results are used to interpret different models of load sharing between reinforcement and matrix during straining.[/p]     

Nanoparticle-induced enhancement in fracture toughness of highly loaded epoxy composites over a wide temperature range

The fracture toughness of an epoxy molding compound (EMC) has been enhanced over a wide temperature range by the addition of a very low volume fraction of silica nanoparticles to the EMC filled with micro-silica particles, which induces macroscopic crack deflection and plastic deformation in front of the crack tip. To evaluate the fracture toughness (G _IC) of these materials, the single edge notched bending (SENB) test was performed for a wide range of temperatures (from ambient temperature to 230°C). The fracture toughness of the nano-silica filled EMCs was found to be improved in this temperature range by as much as a factor of two. Investigation of the fracture surfaces revealed that the micro-silica particles are covered with deformed matrix materials, which implies that the silica nanoparticles induced the crack to move into the interface between the micro-silica particles. Fractography results suggest that the silica nanoparticles act as surface modifiers of the micro-silica particles, which results in crack deflection and plastic deformation.     

Thermo-mechanical performance of an ablative/ceramic composite hybrid thermal protection structure for re-entry applications

Hybrid thermal protection systems for aerospace applications based on ablative material (ASTERM™) and ceramic matrix composite (SICARBON™) have been investigated. The ablative material and the ceramic matrix composite were joined using graphite and zirconia–zirconium silicate based commercial high temperature adhesives. The thermo-mechanical performance of the structures was assessed from room temperature up to 900 °C. In all the joints there is a decrease of shear strength with the increase of temperature. Analysis of the fractured surfaces showed that above 150 °C the predominant mode of fracture is cohesive failure in the bonding layer. The joints fabricated with the zirconia–zirconium silicate based adhesive present the best performance and they have the potential to be used as hybrid thermal protection systems for aerospace applications in the temperature range 700–900 °C.     

AIM 核壳增韧剂/ PVC 树脂共混体系性能

采用自制的丙烯酸丁酯接枝甲基丙烯酸甲酯核壳结构增韧剂( PBA-g-PMMA, AIM) 与聚氯乙烯( PVC) 树脂熔融共混, 制备了AIM/ PVC 共混物。研究了增韧剂粒子在PVC 中的分散和空洞化、AIM/ PVC 共混物的断裂与脆韧转变。结果表明, 球形的增韧剂粒子能够在PVC 树脂中均匀分散并对PVC 有很好的增韧作用, 在PVC 树脂中加入质量分数为615 %AIM 时, 冲击样条以韧性方式断裂; 样条冲击断面周围应力发白区域内产生了空洞。提出AIM 增韧PVC 的机理是橡胶粒子的空洞化与塑料基体剪切屈服协同作用。      

Crack resistance behavior of particulate reinforced composites at various test speeds and temperatures

In this study, the fracture behavior and characteristics of particulate-reinforced composite materials were evaluated by performing wedge splitting tests. The crack resistance of the materials was evaluated using the crack tip opening displacement and crack tip opening angle. The composites were tested under various temperatures and test speeds. The digital image correlation method was used to analyze the strain field at the crack tip. The fracture surface under test conditions was observed using a scanning electron microscope. The test results showed that the fracture energy increased with decreasing temperature, and the crack resistance increased with increasing test speed. The crack tip opening angle is divided into an unstable region and stable region. The critical crack tip opening angle can be defined as the fracture mechanics parameter measured in a stable region. The surface strain fields obtained by digital image correlation method are distributed in the range from 1.5 % to 4.5 % at the initiation of the crack. A crack grows with dewetting phenomenon at the temperature range from 60 °C to −40 °C, and the crack propagates with fracture of ammonium perchlorate oxidizer particles at the glass transition temperature of −70 °C.     

Microstructure, tensile deformation and fracture behaviour of aluminium alloy 7055

The microstructure, tensile deformation and fracture behaviour of aluminium alloy 7055 were studied. Detailed optical and electron microscopy observations were made to analyse the as-received microstructure of the alloy. Detailed transmission electron microscopy observations revealed the principal strengthening precipitates to be the hexagonal disc-shaped η′ phase of size 2 mm×20 mm and fully coherent with the aluminium alloy matrix, the presence of spheroidal dispersoids, equilibrium grain-boundary η precipitates and narrow precipitate-free zones adjacent to grain-boundary regions. It is shown that microstructural characteristics have a profound influence on tensile deformation and fracture behaviour. Tensile test results reveal the alloy to have uniform strength and ductility in the longitudinal and transverse orientations. Strength marginally decreased with an increase in test temperature but with a concomitant improvement in elongation and reduction in area. No change in macroscopic fracture mode was observed with sample orientation. Fracture, on a microscopic scale, was predominantly ductile comprising microvoid nucleation, growth and coalescence. The tensile deformation and fracture process are discussed in the light of the competing influences of intrinsic microstructural effects, matrix deformation characteristics, test temperature and grain-boundary failure. This revised version was published online in November 2006 with corrections to the Cover Date.     

Microstructure and mechanical behavior of die casting AZ91D-Fly ash cenosphere composites

The feasibility of incorporating fly ash cenospheres in die cast magnesium alloy has been demonstrated. The effects of fly ash cenosphere additions on the microstructure and some of the salient physical and mechanical properties of magnesium alloy (AZ91D) metal matrix composites were investigated. The control AZ91D alloy and associated composites, containing 5, 10, and 15 wt.% of fly ash cenospheres (added), were synthesized using a die casting technique. A microstructural comparison showed that microstructural refinement – occurred due to the fly ash additions and became more pronounced with an increase in the percentage of the fly ash added. The metal matrix areas nearer to the fly ash particles exhibited a greater degree of refinement than was observed in the areas further away from these particles. Both filled and unfilled fly ash cenospheres, and porosity were observed in the composite microstructures. The composite specimen densities decreased and the coefficient of thermal expansion did not change significantly as the volume percent of fly ash was increased within the range investigated. The hardness values of the composite specimens exhibited an increase in proportion to the increase in percentage of added fly ash. The tensile strength of the composites also increased as the concentration of fly ash cenospheres was increased. In contrast, the Young’s modulus of these composite samples, as measured by non-destructive pulse-echo method, decreased as the percentage of fly ash in the composite was increased. SEM micrographs of the tensile fracture surfaces showed broken cenospheres on the fracture surface and evidence of ‘pull outs’, where fly ash particles were previously embedded in the matrix. Compression testing results showed that the presence of 5 wt.% cenospheres decreased the compressive strength and compressive yield strength of the composite relative to that of the AZ91D matrix alloy. Surprisingly, a significant change in compression strength was not observed for the composites with 10 and 15 wt.% cenospheres in comparison to the AZ91D matrix alloy. In contrast to the tensile tests, no cenosphere remnants were observed on the compressive test fracture surface of the composites. This observation suggests that the fracture of the composite was initiated within the AZ91D matrix by normal void nucleation and growth, followed by crack propagation through the matrix, avoiding any of the cenospheres, leading to composite fracture of the matrix.     

Hot tensile properties and microstructural evolution of as cast NiTi and NiTiCu shape memory alloys

Hot tensile properties of as cast NiTi and NiTiCu shape memory alloys were investigated by hot tensile test at temperature range of 700–1100 °C using the strain rate of 0.1 s⁻¹. The NiTi alloy exhibited a maximum hot ductility at temperature range of 750–1000 °C, while the NiTiCu alloy showed it at temperature range of 800–1000 °C. It was found that at temperatures less than 750 °C, diffusion-assisted deformation mechanism was inactive leading to semi-brittle type of failure and limited ductility in both alloys. Also it was found that at temperature range of 800–1000 °C, dynamic recrystallization is dominant leading to high ductility. Likewise, the fracture surface of the specimens presenting the maximum hot ductility showed an ideal type of ductile rupture in which they gradually pulled out to a fine point. On the other hand, the decline in ductility occurred at the temperatures above 1000 °C was attributed to the liquid phase formation leading to interdendritic and intergranular type of fracture.     

Fracture and flexural characterization of SiCw/SiC composites at room and elevated temperatures

The fracture and flexural behaviour of monolithic SiC and SiC-whisker reinforced SiC composites (SiC_w/SiC) has been investigated at room and elevated temperatures. Flexure and fracture tests were conducted in a four-point beam configuration at 23 °C, 800 °C and 1200 °C to study the effects of whisker reinforcements especially in respect of mechanical and thermal stability at high energy environments. Flexural strengths and fracture toughness data within the test temperature range are presented in graphical as well as in Weibull form, and experimental observations are analysed and discussed. Increase in flexural strength as well as in fracture toughness has been observed with the whisker reinforcement. However, it was found that the trend discontinues after a certain range of temperature. Post-failure analyses have been performed with the scanning electron microscope (SEM). Formation of glass phase has been observed at the whisker/matrix interface and the crack growth was found to be shifting from intergranular to transgranular with the rise in temperature. Effects of whisker reinforcement and the degradation of flexural and fracture properties at elevated temperature are investigated. Ultrasonic velocity measurements have been performed through the thickness of the untested as well as fractured specimen, and the variation in the sonic wave velocity is discussed in this paper.     

Strength and fracture toughness of nano and micron-silica particles bidispersed epoxy composites: evaluated by fragility parameter

In this study, we discuss the composition effect of 240 nm and 1.56 μm-silica particles on strength and fracture toughness by examining two parameters, fragility and glass transition temperature, that were derived from the thermo-viscoelasticity measurements. Experimental results showed that the composites had a lower fragility with higher strength and fracture toughness as the content of nanoparticles was increased regardless of glass transition temperature. The improvement in mechanical properties from adding nanoparticles was definitely explained by the fragility represented the heterogeneity in polymer matrix, and this was related to the interaction between particles and matrix. The fragility was found to be an effective parameter for evaluating strength and fracture toughness of epoxy composite containing a bidispersion of nano and micron-silica particles.     

Finite-element modeling of initial matrix failure in CFRP under static transverse tensile load

The failure of transversely loaded unidirectional CFRP has been investigated by the use of mechanical and thermo-mechanical test methods and finite-element analysis. The case considered here is characterized by a high interfacial strength between fiber and matrix, so that matrix failure governs the fracture process of the composite. On the basis of the experimental results, the parabolic and other failure criteria were applied to the FE calculations. The failure dependence of the resin on the actual stress state could be described. Furthermore, the influence of thermal residual stresses on the initial matrix failure has been investigated, and the actual stiffnesses and thermal expansion changes of the epoxy resins and the composites as a function of temperature have been determined experimentally. The results of the mechanical and thermo-mechanical tests performed on the pure resins and on the composites were incorporated into a finite-element analysis and compared with the transverse tensile properties of the composite laminates. In the FE analysis, the local fiber-volume fraction was varied over a wide range in order to investigate its influence on the thermal residual stresses and transverse composite strength. The results could explain the low strain to failure of transverse laminates under tensile loading.     

Tensile fracture behavior of aging hardened Mg-1Ca and Mg-1Ca-1Zn alloys

The tensile properties and fracture characteristics of the peak-aged Mg-1.0 wt.% Ca and Mg-1.0 wt.% Ca-1.0 wt.% Zn alloys, have been investigated in the temperature range 295-450 K. In this temperature range the tensile strength of the Mg-1Ca alloy linearly diminishes by 20%. However the drop in the tensile strength for the Mg-1Ca-1Zn alloy is smaller. The results indicate that the precipitates formed in the Mg-1Ca-1Zn alloy retain their strengthening potential up to ~ 450 K. Microstructure observations using scanning electron microscopy revealed that the failure mode for both alloys is transgranular combined with intergranular rupture, irrespective of the treatment and test temperature. The fractography analyses showed that the transgranular fracture changed from quasi-cleavage to dimple rupture with increasing temperature.     

Processing-microstructure relationships in compocast magnesium/SiC

Compocasting experiments were conducted to investigate the feasibility of the process as applied to the AZ91 D magnesium alloy-SiC particles system. Processing-macro/ microstructure relationships were examined. Three temperature-time processing sequences were investigated: stirring temperature maintained above liquidus; stirring temperature in the semi-solid temperature range; and lastly, an imposed temperature rise above the liquidus after stirring in the mushy zone. Stirring temperature and particle size significantly affect spatial particle distribution and porosity level. The easy incorporation and even dispersion of particles in the matrix suggest good wetting of SiC particles by the magnesium matrix. Impact fracture surfaces show strong bonding at the particle/matrix interface. A reaction takes place at the matrix/particle interface whilst stirring at temperatures above the liquidus. Reaction products have been identified. Finally, the mechanical properties of a compocast ingot which was extruded have been studied and are reported. This work clearly points out that there is a preferred procedure to follow during compocasting to obtain an optimum microstructure. The procedure is to add the reinforcing materials to the semi-solid alloy followed by stirring above the liquidus temperature.     

温度和应变率对原位合成钛基复合材料动态压缩性能及破坏机制的影响

使用分离式Hopkinson压杆（SHPB）系统,在温度293~973 K、应变率6 000~10 000 s-1下,对原位合成TiC颗粒和TiB晶须混合增强钛基复合材料（TMCs）的动态压缩性能进行了研究。试验结果表明:在373~573 K、673~773 K和873~973 K范围内TMCs流变应力随温度的增加而显著减小;在较低温度（低于373 K）和较低应变率（6 000~8 000 s-1）下,TMCs呈现小幅的应变率硬化特征,而在较高温度（573 K及以上）时各应变率下TMCs均存在应变率软化特征,且温度越高材料应变率软化效应越明显。材料失效/断裂机制分析表明:应变率软化机制主要是绝热软化及其产生的绝热剪切带（ABS）中微裂纹的形成和扩展的综合作用;在较高的应变率和较大应变下ABS中会产生微裂纹,温度较低时TMCs塑性不足以抑制或阻碍微裂纹的扩展,从而导致TMCs在宏观上迅速破坏;材料破坏时以钛合金基体塑性断裂为主,但在局部伴随部分增强相脆性断裂。      

Microscale experimental investigation of failure mechanisms in off-axis woven laminates at elevated temperatures

Off-axis woven laminates fabricated from carbon fiber and a high glass transition temperature thermosetting resin were subjected to tensile static and fatigue loading at temperatures ranging from room temperature up to 205 °C. The damage mechanism prevalent to these specimens was investigated by post-mortem examination using a scanning electron microscope. During most of their life fatigue specimens had accumulated minimal damage which consisted of matrix cracks, transverse bundle cracks and intra-ply delamination. Just before failure fiber bundles began to straighten out and rotate towards the loading direction. This behavior led to large elongation and necking of the specimens before fracture. Overall, the matrix-dominated material behavior and fiber reorientation due to the off-axis configuration had a far greater influence on the fracture morphology than the gradual accumulation of damage due to fatigue loading. It was also found that damage formation was strongly influenced by the type of applied loading and the test temperature.     

Fracture behaviour of hybrid glass matrix composites: thermal ageing effects

The thermal aging of a glass matrix composite reinforced by short carbon fibres as well as by ZrO₂ particles (hybrid composite) was investigated at temperatures in the range 500–700 °C for exposure durations of 24 h in air. The mechanical properties of as-received and aged samples were evaluated at room temperature by using the three-point flexure chevron notch technique. The fracture toughness values of as-received specimens were in the range 2.6–6.4 MPa m^1/2. Fracture toughness was affected by the thermal aging conditions. For thermal aging at temperatures <700 °C, degradation of fibre–matrix interfaces occurred and therefore the apparent fracture toughness and flaw tolerant resistance decreased. For the most severe ageing conditions tested (700 °C/24 h), fracture toughness values dropped to 0.4 MPa m^1/2. Significant degradation of the material was detected for this aging condition, mainly characterised by porosity formation in the matrix as a result of softening of the glass and oxidation of the carbon fibres.     

Effect of isothermal extrusion parameters on mechanical properties of Al-Si eutectic alloy

In this paper, mechanical properties of a deformed Al-Si eutectic alloy processed by isothermal extrusion at temperature from 573 K to 773 K with reduction ratio from 25% to 85% were investigated at ambient temperature. The results showed that a banded structure composed of matrix region and accumulation region of second phase particles was formed and a few cracks were generated in particles and evolved to voids among particles. The tensile strength of test specimens ranged from 250 MPa to 400 MPa and was directly related with temperature from 623 K to 773 K. The elongation of test specimens ranged from 2.8% to 13.1%, and had a peak value at 673 K under each section reduction ratio. A reduction in elongation occurred at section reduction ratio larger than 75% because of particle bands splitting aluminum matrix severely. The effect of temperature on mechanical properties was more significant than that of section reduction ratio. Excellent balance between strength and ductility can be obtained by extrusion at temperature 623-723 K and section reduction ratio 40-70%.