SEM/AFM studies of cementitious binder modified by MWCNT and nano-sized Fe needles

Several compositions of cement paste samples containing multiwalled carbon nanotubes were produced using a small-size vacuum mixer. The mixes had water-to-binder ratios of 0.25 and 0.3. Sulfate resistant cement has been used. The multiwalled carbon nanotubes were introduced as a water suspension with added surfactant admixtures. The used surfactant acted as plasticizing agents for the cement paste and as dispersant for the multiwalled carbon nanotubes. A set of beams was produced to determine the compressive and flexural strengths. The scanning electron microscope and atomic force microscope studies of fractured and polished samples showed a good dispersion of multiwalled carbon nanotubes in the cement matrix. The studies revealed also sliding of multiwalled carbon nanotubes from the matrix in tension which indicates their weak bond with cement matrix. In addition to multiwalled carbon nanotubes also steel wires covered with ferrite needles were investigated to determine the bond strength between the matrix and the steel wire. These later samples consisted of 15-mm-high cylinders of cement paste with vertically cast-in steel wires. As reference, plain steel wires were cast, too. The bond strength between steel wires covered with nano-sized Fe needles appeared to be lower in comparison with the reference wires. The scanning electron microscope studies of fractured samples indicated on brittle nature of Fe needles resulting in shear-caused breakage of the bond to the matrix.     

INFLUENCE OF AXISYMMETRIC DEFORMATION PROCESSING METHODS ON THE MECHANICAL PROPERTIES OF Cu-Nb COMPOSITES

It has been shown that deformation processed Cu-19% Nb alloys with good strength and electrical conductivity can be developed in sizes that are useful for engineering applications. Mot extrusion of bundled sub-elemental Cu-19% Nb wires followed by cold drawing to make a composite wire of diameter equal to that of the initial sub-elemental wires resulted in a 67% increase in the ultimate tensile stress. However, on subsequent cold drawing of this composite wire the strength increased at a slower rate than that obtained on continuing cold drawing of the sub-elemental wire and the strength differential decreased. In addition, after cold drawing to equivalent diameters the electrical conductivity of the composite wire was less than that of the sub-elemental wire. These results indicate that while high strengths and good electrical conductivities can be produced in larger size deformation processed Cu-Nb composites by a process of bundling, extrusion and cold drawing of sub-elemental wires, there appears to be a limit to the amount of subsequent cold drawing feasible before the benefit in properties ceases.     

Production of stainless steel wire-reinforced aluminium composite sheet by explosive compaction

Composite sheet material has been produced by explosively compacting stacks of alternately placed stainless steel wire meshes and aluminium foils. It was found that stacks could be satisfactorily bonded by using an aluminium driver plate which was prevented from bonding to the stack by interposing a polythene sheet. Stacks containing six or seven layers of mesh and having a wire volume fraction of up to 0.24 could be bonded when the driver plate kinetic energy exceeded 120 J cm^–2. It is concluded that the bonding mechanism involves cold pressure welding of the matrix metal by extrusion through the mesh apertures, and the aperture size is a controlling factor in bonding. No evidence was found of strong bonding between the wires and the matrix. In the production of larger sizes of composite sheet, (300 mm×500 mm), blistering and tearing occurred due to the presence of excess air in the stack, a consequence of bowing of the foils by the springy and curved pieces of mesh. This difficulty was overcome by enclosing the stack in a polythene envelope, which was evacuated before detonation of the charge, so that the stack was compressed by atmospheric pressure. Tests have shown that tensile and fatigue properties of the composites compare favourably with other aluminium matrix composites and with high strength aluminium alloys.     

Variation in flexural properties of photo-pultruded composite archwires: analyses of round and rectangular profiles

Prototype continuous, unidirectional, fiber-reinforced composite archwires were manufactured into round and rectangular profiles utilizing a photo-pultrusion process. Both 0.022 inch (0.56 mm) diameter and 0.021 × 0.028 inch (0.53 × 0.71 mm) rectangular composites were formed utilizing commercially available S2-glass® reinforcement within a polymeric matrix. Reinforcement was varied according to the number, denier and twists per inch (TPI) of four S2-glass® yarns to volume levels of 32–74% for round and 41–61% for rectangular profiles. Cross-sectional geometry was evaluated via light microscopy to determine loading characteristics; whereas two flexural properties (the elastic moduli and flexural strengths) were determined by 3-point bending tests. Morphological evaluation of samples revealed that as the TPI increased from 1 to 8, the yarns were more separated from one another and distributed more peripherally within a profile. For round and rectangular profiles utilizing 1 TPI fibers, moduli increased with fiber content approaching theoretical values. For round profiles utilizing 1 TPI and 4 TPI fibers, flexural strengths increased until the loading geometry was optimized. In contrast, the flexural strengths of composites that were pultruded with 8 TPI fibers were not improved at any loading level. Doubling the denier of the yarn, without altering the loading, increased both the moduli and flexural strengths in rectangular samples; whereas, the increases observed in round samples were not statistically significant. At optimal loading the maximum mean moduli and strengths equaled 53.6 ± 2.0 and 1.36 ± 0.17 (GPa) for round wire and equaled 45.7 ± 0.8 and 1.40 ± 0.05 (GPa) for rectangular wires, respectively. These moduli were midway between that of martensitic NiTi (33.4 GPa) and beta-titanium (72.4 GPa), and produced about one-quarter the force of a stainless steel wire per unit of activation. Values of strengths placed this composite material in the range of published values for beta-titanium wires (1.3–1.5 GPa). © 2000 Kluwer Academic Publishers     

低碳钢高速线材的表面缺陷及冷镦开裂原因分析

采用扫描电镜和能谱仪对低碳冷镦用高速线材表面缺陷进行了分析，同时对轧制中间料的缺陷和成品冷镦标准件开裂样品进行对照分析。结果表明，浇注和连铸过程的夹渣残留在坯料中极易在后序的加工中使成品表面产生裂纹，最终引起了冷镦开裂。     

Strategic reinforcement of hybrid carbon fibre-reinforced polymer composites

A secondary fibre has been used to improve the impact properties of carbon fibre-reinforced composites. Steel wires possessing similar elastic properties to Type III carbon fibres have been added strategically to the composite cross-section. This has resulted in a 100% improvement in the fracture energy provided that the wires were placed in close proximity to the compressive or impacted face. Such a result is achieved with small increases in longitudinal and interlaminar shear strength. Only minor changes in specific properties occurred through the introduction of the high-density wires. The increase in fracture energy occurs because of the elimination of a compressive failure mode, believed to be brought about by the steel wires increasing the resistance to buckling at the impacted face. Hence, more energy-intensive processes, such as multiple delamination, fibre and wire pull out, are permitted to take place over larger areas of the fracture face.     

Reinforcement of Hadfield steel matrix by oriented high‐chromium cast iron bars

To attain a wear‐resistant material compatible with high hardness and high toughness, Hadfield steel matrix was reinforced by oriented high chromium cast iron bars, through inserting high chromium alloys flux‐cored welding wires into Hadfield steel melt at 1500 ± 10 °C. The obtained composites were investigated by XRD, SEM, micro‐hardness, three‐body abrasion wear and impact toughness testers. The results show that the alloy powders inside the flux‐cored welding wires can be melted by the heat capacity of Hadfield steel melt and in situ solidified into high chromium cast iron bar reinforcements tightly embedded in the matrix. The micro‐hardness of reinforcements of the water‐quenched composite is about four times higher than that of the matrix. The impact toughness of the water‐quenched composite is higher than that of the as‐cast composite and lower than that of Hadfield steel, and its fracture mechanism is very complicated and refers to brittle and ductile mixture fracture mode. The excellent impact toughness and better wear resistance of the water‐quenched composite are attributed to combine fully the advantages and avoid the drawbacks of both Hadfield steel and high chromium cast iron. Additionally, in industrial application, the pulverizer plate produced by this composite, has also better wear resistance compared to the reference Hadfield steel pulverizer plate.     

碳化物特性对Ni3Al基表面强化复合材料组织与性能的影响

将真空常压烧结的方法制得的Cr3C2-Ni-Al和WC-Ni-Al复合焊丝氩弧堆焊于碳钢表面时,利用氩弧物理热和Ni-Al反应热,促使碳化物硬质颗粒与自生成的Ni3Al金属间化合物基体复合.XRD分析表明,在堆焊过程中两种焊丝中的Ni,Al均化合反应生成Ni3Al金属间化合物.微观组织与硬度试验表明,受各自物理特性(密度、熔点)的影响,两种碳化物硬质相在Ni3Al基体中分布均匀程度不同,其强化效果也迥异:WC仍以原始的大颗粒形态偏聚于焊层层间界面处,而起不到弥散强化作用;Cr3C2则发生分解,并反应析出条块状的Cr7C3相,均匀分布于Ni3Al基体中,很好地强化了基体材料.Cr7C3/Ni3Al复合材料的室、高温硬度远高于传统高温耐磨材料stellite合金.该合金有望成为一种新型的高温耐磨表面强化材料.     

Neuartige Faserverbunddrähte für die Leistungselektronik

Novel fibre reinforced wires for power electronics The use of power electronics within the scope of mechatronic applications as well as the increasing integration of components lead to increased requirements concerning their mechanical and thermal reliability. Today contact making in power electronics is mostly done by aluminum thick wire bonding. This process is highly productive, however the life time of power electronic components is meanwhile predominantly limited by the durability of these wire bonds. The thermal mismatch between the wire material and the connected components is one cause. A new starting point, in order to improve the reliability, is the application of new fibre reinforced metal matrix composite (MMC) wires with increased reliability under thermo‐mechanical stress. In the context of a research project MMC bond wires of different material combinations and arrangements were manufactured. Aluminum wires with copper fiber reinforcement as well as Copper wires containing FeNi36 fibre reinforcement have successfully be drawn to a final diameter of 300 μm. The fibre reinforcements should reduce the coefficient of thermal expansion and improve the mechanical strength. By aluminium copper MMC the electrical conductivity is increased as well. Measurements of the produced MMC wires confirmed these expectations. The manufacturing of the MMC took place on the basis of wire material of different diameters. These wires were stacked in capsules in different arrangements and material combinations. Subsequently, the capsules were either hot‐isostatically pressed or directly extruded. In such a way produced composites have been manufactured by rotary swaging and wire drawing into bond wires and after that tested.     

Silicon carbide (NicalonTM) fibre-reinforced borosilicate glass composites: mechanical properties

The objective of this study was to assess the applicability of an extrinsic carbon coating to tailor the interface in a unidirectional NicalonTM–borosilicate glass composite for maximum strength. Three unidirectional NicalonTM fibre-reinforced borosilicate glass composites were fabricated with different interfaces by using (1) uncoated (2) 25 nm thick carbon-coated and (3) 140 nm thick carbon coated Nicalon fibres. The tensile behaviours of the three systems differed significantly. Damage developments during tensile loading were recorded by a replica technique. Fibre–matrix interfacial frictional stresses were measured. A shear lag model was used to quantitatively relate the interfacial properties, damage and elastic modulus. Tensile specimen design was varied to obtain desirable failure mode. Tensile strengths of NicalonTM fibres in all three types of composites were measured by the fracture mirror method. Weibull analysis of the fibre strength data was performed. Fibre strength data obtained from the fracture mirror method were compared with strength data obtained by single fibre tensile testing of as-received fibres and fibres extracted from the composites. The fibre strength data were used in various composite strength models to predict strengths. Nicalon–borosilicate glass composites with ultimate tensile strength values as high as 585 MPa were produced using extrinsic carbon coatings on the fibres. Fibre strength measurements indicated fibre strength degradation during processing. Fracture mirror analysis gave higher fibre strengths than extracted single fibre tensile testing for all three types of composites. The fibre bundle model gave reasonable composite ultimate tensile strength predictions using fracture mirror based fibre strength data. Characterization and analysis suggest that the full reinforcing potential of the fibres was not realized and the composite strength can be further increased by optimizing the fibre coating thickness and processing parameters. The use of microcrack density measurements, indentation–frictional stress measurements and shear lag modelling have been demonstrated for assessing whether the full reinforcing and toughening potential of the fibres has been realized. This revised version was published online in November 2006 with corrections to the Cover Date.     

Exceeding average rule of mixtures stiffness in composite materials with interconnected fibres as reinforcement

Abstract

In the present study, a galvanised iron wire mesh structure of two different types was used to reinforce aluminium alloy 1050. The composite was synthesised using conventional casting followed by hot extrusion. Microstructural characterisation of the composite specimens showed good interfacial integrity between the matrix and the reinforcement wire. Thermomechanical analysis demonstrated that the average coefficient of thermal expansion of the composites was decreased below the values predicted by theoretical models. Tensile tests conducted on the composite specimens revealed that the average elastic modulus of the composites exceeded the rule of mixtures predictions. The average values of 0.2 yield strength and ultimate tensile strength of the composites were found to be higher than those of the monolithic aluminium alloy irrespective of a low volume fraction 0.049 of reinforcement. This unusual variation in the properties clearly reflects the uniqueness of using interconnected wires as reinforcement in the metallic matrix. An attempt is made in the present study to rationalise particularly the tensile behaviour, especially the stiffness of the composite material, according to the type of reinforcement preform in the aluminium alloy matrix.     

Study of the martensitic transformation in NiTi–epoxy smart composite and its effect on the overall behavior

In this work, the effect of wire phase transformation on the overall thermo-mechanical behavior of NiTi–epoxy composites has been investigated. The shape memory wire received in as drawn condition was subjected to three heat treatments which results to different transformation characteristics. Composite specimens were manufactured by casting followed by curing and post curing process. The mechanical behavior of samples has been determined using standard tensile test. The effect of wire volume fraction and test temperature was investigated as well.It is found that the martensitic transformation occurring in the wire affects the mechanical behavior of the composite specimens. In this way, using the wire with higher transformation stress improves the composite tensile strength. This is achieved either by increasing the test temperature or by using the wires heat treated at lower temperatures. From the experimental results, the martensitic transformation can change the debonding mode. It seems that on the constraint of matrix, the transformation occurs simultaneously at several points in wires that result in regular debonded/undebonded pattern.     

The cracking of composites consisting of discontinuous ductile fibres in a brittle matrix — effect of fibre orientation

The effect of the orientation of metal wires on the opening of a crack in a brittle-matrix composite has been studied. The force arising from the plastic bending of a wire which is weakly bonded to the matrix and which crosses the matrix crack at an angleθ to the crack face normal has been measured in model resin-wire composites and good agreement is found with a simple theory based on the calculation of the force needed to produce a plastic hinge in a cantilever beam. The force passes through a maximum at a small crack opening, of the order of one wire diameter, and decreases with further crack opening. The The largest force is obtained for a value ofθ of approximately 45°. For wires whose length approaches the critical length, the force and the total work of fracture arising from the bending of the wire are small compared to the values arising from the interfacial shear stress resisting pull-out; the contributions due to bending and interfacial shear stress are of comparable magnitudes for wires which are approximately one-fifth of the critical length.     

Studies on the development of aluminium alloy–mild steel reinforced composite

With a view to developing a new metal–metal cast composite material as a possible substitute for ferrous materials in wear resistant applications, Al alloy (LM11) is reinforced with mild steel (ms) wires and it is heat treated to get ‘reaction interface’ (RI). Microhardness, tensile properties and wear characteristics of the matrix, as-cast and heat treated composites have been determined. While microhardness of the composite showed variation from 150 to 45 VHN across the interface in the as-cast composite, annealed (500–525°C) composite showed a microhardness of 350–420 VHN at the interface indicating the effectiveness of the heat treatment. It is seen that the % improvement in wear resistance increased with increase in number of wires when embedded in the aluminium alloy matrix. Further imrpovement of about 30% was observed when heat treated at 500°C for 15 h. These results have been discussed in terms of wetting between ms wires and the matrix, particularly the increase of hardness and tensile strength to the formation of ‘reaction interface’ due to annealing. The width of the interface increased with annealing time and temperature and the kinetics of reaction followed logarithmic and parabolic growth rate. The activation energy for the formation of intermetallics constituting the reaction interface is found to be 20.7 KJ mol⁻¹. From the measured hardness and ultimate tensile strength of the constituents and composites an empirical relation was deduced.     

High temperature interfacial studies in aluminium-stainless steel composites

Interfacial shear strengths in single wire aluminium-stainless steel composites have been measured by the pull-out test, both at room temperature and high temperatures, as a function of annealing temperatures up to 823 K and times up to 24 h. The post-exposure interfacial shear strengths measured at room temperature have been found to be inversely proportional to the square root of the interfacial compound layer thickness. A tentative mechanism to explain this relationship has been proposed in terms of matrix-compound layer debonding. The growth of the compound layer during high-temperature exposure is accompanied by an increase in its microhardness, presumably resulting from a concurrent precipitation of intermetallics. The interfacial shear strength has been found to be independent of stainless steel wire diameter.     

Debonding initiation in a NiTi shape memory wire–epoxy matrix composite. Influence of martensitic transformation

The effect of martensitic transformation on the debonding initiation in single shape memory NiTi wire–epoxy matrix composite was studied. Three different heat treatment cycles were performed in order to obtain wires with different transformation characteristics. The composite samples were prepared using NiTi wires and steel wire for comparison. The single-wire specimens were subjected to the pull-out test. The in situ observations of the interfacial debonding and sliding behaviour during the test were carried out.     

Microstructure and mechanical properties of Hadfield steel matrix composite reinforced with oriented high-chromium cast iron bars

To obtain a compatible material of high hardness and high toughness, Hadfield steel matrix was reinforced by oriented high-chromium cast iron bars. The mechanical behaviors of the as-cast and water-quenched composites were comparatively studied with a Hadfield steel substrate. The experimental results showed that the alloy powders inside the flux-cored welding wires could be melted by the heat capacity of Hadfield steel melt and became high-chromium cast iron bars. The impact toughness of the water-quenched composite was higher than that of the as-cast composite and lower than that of the Hadfield steel. The wear rate of the water-quenched composite was 1.23 mg/h m² at 0.3 kg and 2.93 mg/h m² at 1.2 kg, which was lower compared with those of the as-cast composite and Hadfield steel. The impact toughness and wear resistance of the water-quenched composite were related not only to the combining actions of the Hadfield steel matrix and high-chromium cast iron bars but also to the effect of heat treatment. The wear behavior of the water-quenched composite was industrially tested as pulverizer plate.     

金属复合线材成形工艺的研究开发概况

金属复合线具有广阔的开发与应用前景。目前巳开发的产品有铜包钢线、铝包钢线、铜包铝线以及纤维增强金属复合线等。从电镀法到连续挤压包覆、反向凝固等，生产技术不断进步。开发高效、低能耗、短流程的先进工艺是复合线材制备工艺的重要发展方向。综述了金属复合线材成形工艺的研究开发概况。     

Adaptive composites incorporating shape memory alloy wires Part I Probing the internal stress and temperature distributions with a laser Raman sensor

Hybrid composite laminates consisting of an epoxy resin reinforced by aramid fibres and incorporating SMA wire actuators have been produced. The residual thermal stresses of the composites were determined with the technique of laser Raman spectroscopy and the generated compressive loads during SMA activation were quantified. The results obtained indicate that the SMA wires can be effectively used as actuating elements whereas the aramid fibres can be exploited as independent thermal and mechanical sensors.     

Pass schedule of wire drawing process to prevent delamination for high strength steel cord wire

The high-speed drawing of high carbon content steel wires is usually conducted at room temperature employing a number of passes or reductions through several dies. In the multipass drawing process, the temperature rise at each pass affects the mechanical properties of the final product (such as its bending and torsion properties, and its tensile strength). This temperature rise during deformation encourages delamination in the wire, which has a deleterious influence on the torsional properties and durability of the wire. In this study, we investigated the delamination of wires using torsion tests and evaluated the wire temperature during drawing. Our data shows that one of the main reasons for delamination was an excessive rise in wire temperature. Based on our experimental results, in order to prevent delamination due to an excessive rise in wire temperature, a new isothermal pass schedule that could control the wire temperature was designed. The pass redesign for the conventional high carbon (0.75 wt%C) steel cord wire drawing process with delamination was carried out by using the isothermal pass schedule to control the wire temperature. In order to verify the effectiveness of the proposed method, wire drawing and torsion test were conducted. From the results of experiments, it was possible to produce high carbon steel cord wire without delamination.