Mechanical properties and fracture of Al–15 vol.-%B4C based metal matrix composites

The present work was performed on three aluminium metal matrix composites (MMCs) containing 15 vol.-%B₄C particles. The matrix in two of these materials is pure aluminium, whereas the matrix of the third material was an experimental 6063 aluminium alloy. All composites were homogenised at elevated temperatures for 48 h before being quenched in warm water. The quenched samples were aged in the range of 25–400°C for 10 h, at each temperature. Hardness and tensile tests performed on the aged MMCs show that the presence of Zr (with or without Ti) resulted in a noticeable hardening due to the precipitation of a Zr rich phase. Maximum strengthening was obtained from the 6063 based MMC due to the precipitation of Mg₂Si phase particles. The present technique used to produce the MMCs examined proved capable of manufacturing composites with a uniform distribution of B₄C in the matrix with a strong degree of matrix/particle bonding. When the MMC samples were deformed to failure, the B₄C was fractured transgranularly without debonding from the matrix. The addition of Zr and Ti resulted in the formation of protective layers around the B₄C particles that were retained after fracture; these protective layers were not affected by the B₄C particle size (0·15–20 μm). Stacking faults were commonly observed in fractured Al 6063/B₄C/15p samples. The precipitation of zirconium–titanium compounds during aging contributed to the composite strength.     

Ti 元素对B4C/Al复合材料力学性能的改善作用研究

B₄C/Al复合材料是目前最理想的中子吸收材料,广泛用于乏燃料储存。本文利用液态搅拌法制备B₄C/Al复合材料,通过添加Ti元素,探讨了界面反应对材料的界面结构和力学性能的影响。研究发现,Ti元素通过参与界面反应,改变了界面结构,在B₄C颗粒表面形成了紧密结合的纳米TiB₂界面层;Ti的添加消除了界面微裂纹、微孔、分离等缺陷。随着界面反应程度的加强,材料强度提高,尤其反应脱落的纳米TiB₂颗粒作为原位第二强化相进一步增强基体。B₄C/Al复合材料断裂过程表现为韧窝延性断裂;TiB₂界面层增强了B₄C颗粒与基体的结合,断裂行为从B₄C-Al界面脱落转变为B₄C颗粒断裂;但过渡的界面反应会形成微韧窝,引起材料延伸率下降。     

Effect of weight percentage and particle size of B4C reinforcement on physical and mechanical properties of powder metallurgy Al2024-B4C composites

In this study, Al2024-B₄C composites containing 0, 5, 10 and 20 wt% of B₄C particles with two different particle sizes (d₅₀=49 μm and d₅₀=5 μm) as reinforcement material were produced by a mechanical alloying method. Two new particle distribution models based on the size of reinforcement materials was developed. The microstructure of the Al2024-B₄C composites was investigated using a scanning electron microscope. The effects of reinforcement particle size and weight percentage (wt%) on the physical and mechanical properties of the Al2024-B₄C composites were determined by measuring the density, hardness and tensile strength values. The results showed that more homogenous dispersion of B₄C powders was obtained in the Al2024 matrix using the mechanical alloying technique according to the conventional powder metallurgy method. Measurement of the density and hardness properties of the composites showed that density values decreased and hardness values increased with an increase in the weight fraction of reinforcement. Moreover, it was found that the effect of reinforcement size and reinforcement content (wt%) on the homogeneous distribution of B₄C particles is as important as the effect of milling time.     

Phase identification of Al–B4C ceramic composites synthesized by reaction hot-press sintering

A series of boron carbide (B₄C) matrix composites with different contents of Al, were synthesized by reaction hot-press sintering with milled B₄C and pure metallic Al powder at 1600 °C for 1 h. X-ray diffraction (XRD), scanning electron microscope (SEM) and transmission electron microscopy (TEM) were used to identify the phase constituent of the milled powders and the composites. The results have shown that parts of B₄C and Al particles were oxidized to boron oxide (B₂O₃) and alumina (Al₂O₃) during the milling. Thermit reaction occurred and B₂O₃ was reverted during hot-press sintering. A ternary phase of Al boron carbide (Al₈B₄C₇) was found in the composites, and the B₄C transformed to a rich boron phase (B_6.5C) because of the superfluous boron in the system.     

Comparison of wear behaviour of LM13 Al−Si alloy based composites reinforced with synthetic (B4C) and natural (ilmenite) ceramic particles

Dry sliding wear behaviour of stir-cast aluminium matrix composites (AMCs) containing LM13 alloy as matrix and ceramic particles as reinforcement was investigated. Two different ceramic particle reinforcements were used separately: synthetic ceramic particles (B₄C), and natural ceramic particles (ilmenite). Optical micrographs showed uniform dispersion of reinforced particles in the matrix material. Reinforced particles refined the grain size of eutectic silicon and changed its morphology to globular type. B₄C reinforced composites (BRCs) showed maximum improvement in hardness of AMCs. Ilmenite reinforced composites (IRCs) showed maximum reduction in coefficient of friction values due to strong matrix−reinforcement interfacial bonding caused by the formation of interfacial compounds. Dry sliding wear behaviour of composites was significantly improved as compared to base alloy. The low density and high hardness of B₄C particles resulted in high dislocation density around filler particles in BRCs. On the other hand, the low thermal conductivity of ilmenite particles resulted in early oxidation and formation of a tribo-layer on surface of IRCs. So, both types of reinforcements led to the improvement in wear properties of AMCs, though the mechanisms involved were very different. Thus, the low-cost ilmenite particles can be used as alternative fillers to the high-cost B₄C particles for processing of wear resistant composites.     

Surface damage during transient thermal load of 50% thickness reduced W-2% (Vol.) Y2O3 sheet with different recrystallization volume fraction

Thermal shock damage of tungsten as a plasma facing material (PFM) depends on thermal shock power density level, duration and repeated time, and microstructure of the sample. The recrystallization process will degrade the mechanical property of material and thus change the its thermal shock resistance. The effects of recrystallization volume fraction on thermal shock response of W-Y₂O₃ under different power density levels (0.22–0.44 GW/m²) has been systematically studied. Electron beam pulse of duration of 1 ms with 100 recycles was used to simulate the transient thermal load of fusion device. The changes of morphology, distance, depth, width of crack and surface roughness on the rolling direction-normal direction (RD-ND) surfaces of W-Y₂O₃ samples with different recrystallization volume fraction were investigated. The results showed that recrystallization process have significant influence on the thermal shock resistance of W-Y₂O₃ samples. For the rolled sample, crack depth, width and surface roughness increased with the increased of power density level while crack distance decreased. The partially and fully recrystallized samples showed significant wider crack networks and severe surface modification.     

Production of High-Strength Al/Al2O3/WC Composite by Accumulative Roll Bonding

In this study, Al/Al₂O₃/WC composites were fabricated via the accumulative roll bonding (ARB) process. Furthermore, the microstructure evolution, mechanical properties, and deformation texture of the composite samples were reported. The results illustrated that when the number of cycles was increased, the distribution of particles in the aluminum matrix improved, and the particles became finer. The microstructure of the fabricated composites after eight cycles of the ARB process showed an excellent distribution of reinforcement particles in the aluminum matrix. Elongated ultrafine grains were formed in the ARB-processed specimens of the Al/Al₂O₃/WC composite. It was observed that as the strain increased with the number of cycles, the tensile strength, microhardness, and elongation of produced composites increased as well. The results indicated that after ARB process, the overall texture intensity increases and a different-strong texture develops. The main textural component is the Rotated Cube component.     

The heterophase interface character distribution of physical vapor-deposited and accumulative roll-bonded Cu-Nb multilayer composites

We present a method for characterizing the full five parameter heterophase interface character distributions (HICD) using two-dimensional electron back-scatter diffraction (EBSD) images. We apply the HICD method to determine the orientation relationships and three-dimensional normal vectors of Cu-Nb interfaces in both physical vapor-deposited (PVD) pure Cu-Nb (4 μm individual layer thickness) and accumulative roll-bonded (ARB) alloyed Cu-Nb multilayer composites (200-600 nm layer thickness). The HICD analysis shows that {1 1 2}_Cu planes are most preferentially and frequently bonded with {1 1 2}_Nb planes with Kurdjumov-Sachs and Nishiyama-Wasserman misorientations in the ARB alloyed Cu-Nb multilayers. These interfaces differ from the {1 1 1}_Cu||{1 1 0}_Nb interfaces predominantly found in the PVD pure Cu-Nb multilayered thin films. Also, pure tilt type interfaces with a [1 1 1]/30° misorientation and {1 1 0}_Cu planes bonded to {1 1 2}_Nb planes were found in ARB alloyed Cu-Nb multilayers. In the ARB material the observed Cu-Nb interfaces differ from what would be obtained from random pairings of the Cu and Nb orientations in terms of the relative intensities (in multiples of random distribution) and shapes of the interface normal peaks, which indicates that these interfaces were preferentially selected during the high strain ARB process. The measured ARB textures along the interface also differ from the theoretical rolling textures for each bulk single phase metal, suggesting that during ARB layer refinement these interfaces have some influence on slip activity by constraining grain deformation or through the kinetics of dislocation-interface interactions.     

Microstructural and mechanical behavior of blended powder semisolid formed Al7075/B4C composites under different experimental conditions

This work aimed to fabricate B₄C reinforced aluminum matrix composites via blended powder semisolid forming that is an implementation of the benefits of semisolid forming to the powder metallurgy. Al7075 elements were incrementally added to ethanol solution under mechanical mixing. Al7075 constituents and B₄C particles were blended in a high energy ball mill. Cold compacted Al7075/B₄C blends were pressed at semisolid state. The effects of the size of the matrix (20, 45 and 63 μm), reinforcing volume fraction (5%, 10% and 20%) and semisolid compaction pressure (50 and 100 MPa) on the morphology, microstructure, density, hardness, compression and bending strength were thoroughly analyzed. Experimental results revealed that the highest microstructural uniformity was achieved when large B₄C particles (45 μm) were distributed within the small particles (20 μm) of the matrix phase. Composites with matrix particles larger than reinforcing phase indicated agglomerations in loadings more than 10% (volume fraction). Agglomerated regions resisted against penetration of the liquid phase to the pores and lowered the density and strength of these composites. Composites with 20 μm Al7075 and 20% (volume fraction) 45 μm B₄C powder pressed under 100 MPa exhibited the highest values of hardness (HV 190) and compressive strength (336 MPa).     

Characterization of (TiB + TiC)/TC4 in situ titanium matrix composites prepared by laser direct deposition

Preliminary characterization of microstructure and mechanical properties of (TiB + TiC)/TC4 in situ titanium matrix composites prepared by laser direct deposition is reported in this paper. The results indicate that in situ reaction occurred during laser direct deposition of coaxially fed mixed powders from TC4 and B₄C. Reinforcements of TiB and TiC with a fraction of about 25 vol.% were formed with feeding 5 wt.% B₄C. The morphology of TiB tended to be needle-like and prismatic, while TiC appeared as granular. Small amount of un-reacted B₄C with reduced size remained within the composites. A thin skull of reaction product formed around the un-reacted B₄C weakened its interface bonding with the titanium alloy matrix, resulting in less outstanding properties of the composites.     

Improved Thermal Performance of Diamond-Copper Composites with Boron Carbide Coating

B₄C-coated diamond (diamond@B₄C) particles are used to improve the interfacial bonding and thermal properties of diamond/Cu composites. Scanning electron microscopy, x-ray diffraction, and x-ray photoelectron spectroscopy were applied to characterize the formed B₄C coating on diamond particles. It is found that the B₄C coating strongly improves the interfacial bonding between the Cu matrix and diamond particles. The resulting diamond@B₄C/Cu composites show high thermal conductivity of 665 W/mK and low coefficient of thermal expansion of 7.5 × 10^?6/K at 60% diamond volume fraction, which are significantly superior to those of the composites with uncoated diamond particles. The experimental thermal conductivity is also theoretically analyzed to account for the thermal resistance at the diamond@B₄C-Cu interface boundary.     

Influence of B4C coating on graphitization for diamond/WC-Fe-Ni composite

Diamond/WC-Fe-Ni composite is a potential composition for impregnated diamond drill bits. It is necessary to avoid the graphitization of the diamond from Fe and Ni under the powder metallurgy process. Boron carbide (B₄C) was coated on diamond, and diamond/WC-Fe-Ni composites were consolidated by hot pressing at different temperatures. The influences of sintering temperature and interfacial structure on bending strength and wear behavior were investigated. The bending strength for diamond/WC-Fe-Ni composite was dependent on matrix densification and interfacial graphitization. Un-coated diamond was eroded by Fe-Ni matrix and partially converted to graphite during the sintering process at all sintering temperatures. In opposite, B₄C coating was beneficial to matrix densification at a lower sintering temperature, and delayed the appearance of graphitization to around 1300 °C. Therefore, the diamond/WC-Fe-Ni composites with B₄C coating exhibited larger bending strength and better wear behavior at a relative low sintering temperature.     

In-Situ (TiB+TiC) particulate reinforced titanium matrix composites: Effect of B4C size and content

This study investigated the microstructure and tensile behavior of (TiB+TiC) reinforced titanium matrix composites (TMCs) using an in-situ reaction between Ti and B₄C. Different B4C sizes (1,500 and 150 μm) and contents (0.94, 1.88 and 3.76 mass%) were added to pure Ti to produce 5, 10, and 20 vol% (TiB+TiC) reinforced TMCs. In-situ synthesized TiB and TiC reinforcements prepared with 150 μm B₄C were very fine, and were distributed more homogeneously than the 1,500 μm B₄C. As the TiB and TiC contents increased, the tensile strength increased and the ductility decreased compared to unreinforced pure Ti. The improvements in the tensile strength of TMCs were obtained by load transfer strengthening and an alpha-Ti matrix grain reduction of 9–26%. In addition, the TMCs produced using 150 μm B₄C showed a greater tensile elongation of approximately 61–117%, with a slightly improved strength compared to that with 1,500 μm B₄C. The tensile elongation of TMCs obtained with 150 μm B₄C was enhanced because the coarse reinforcements produced by 1,500 μm B₄C were more easily and frequently cracked at the fracture surface.     

Effect of the B<Subscript>4</Subscript>C content on the structure and thermal expansion coefficient of the Al–5% Cu alloy-based metal-matrix composite material

The Al–5% Cu alloy-based metal-matrix composite materials reinforced with 5-μm B₄C particles have been produced using mechanical mixing-in method. A process of addition of the B₄C particles into the melt has been developed. A homogeneous distribution of the B₄C reinforcing particles in the metal-matrix composite matrix was obtained. Using X-ray diffraction analysis, the formation of Al₃BC and AlB₂ phases has been revealed at the interphase matrix/particle boundary, which indicates a good interaction in the phases. With increasing B₄C content in the matrix alloy, an insignificant increase in the porosity (from 1 to 3.1%) occurs. The average linear thermal-expansion coefficient is reduced from 24.5 to 22.6 × 10^–6 K^–1 in the temperature range of 20–100°C.     

Characterisation of welded joints produced by FSW in AA 1100–B4C metal matrix composites

Abstract

The feasibility of friction stir welding for joining AA 1100 based metal matrix composites reinforced with B₄C particulate is studied for 16 and 30%B₄C volume concentrations. For both composites, friction stir welding has a significant influence on the particle size distribution and the matrix grain size. For the 16% composite, the average particle size decreases after welding by ～20% and the grain size from 15 to 5 μm as measured in the weld nugget. Tensile testing of welded joints showed up to 100% joint efficiency for both annealed AA 1100–16%B₄C and AA 1100–30%B₄C composite materials. However, if the ultimate tensile strength values of all the studied composites are similar at ～130 MPa, then the weld ductility is higher for the annealed materials. Furthermore, it was observed that varying the welding speed between 100 and 275 mm min^?1 does not influence the tensile properties and the particle size distribution in the nugget.     

Densification and compressive strength ofin-situ processed Ti/TiB composites by powder metallurgy

In the present study, the densification of Ti/TiB composites, the growth behavior ofin-situ formed TiB reinforcement, the effects of processing variables — such as reactant powder (TiB₂, B₄C), sintering temperature and time — on the microstructures and the mechanical properties ofin-situ processed Ti/TiB composites have been investigated. Mixtures of TiB₂ or B₄C powder with pure titanium powder were compacted and presintered at 700°C for 1 hr followed by sintering at 900, 1000, 1100, 1200, and 1300°C, respectively, for 3hrs. Some specimens were sintered at 1000°C for various times in order to study the formation behavior of TiB reinforcementin-situ formed within the pure Ti matrix. TiB reinforcements were formed through different mechanisms, such as the formation of fine TiB and the formation of coarse TiB by Ostwald ripening or the coalescence of fine TiB. There was no crystallographic relationship between TiB reinforcement and the matrix. There were voids at the interface between the TiB reinforcement and the Ti matrix due to the preferential growth of coarse TiB without a particular crystallographic relationship with pure Ti matrix and the surface energy between the Ti matrix and TiB reinforcements. Therefore, the densification of Ti/TiB₂ compacts was hindered by the preferential growth of coarse TiB reinforcements. The mechanical properties ofin-situ processed composites were evaluated by measuring the compressive yield strength at ambient and high temperatures. The compressive yield strength of thein situ processed composites was higher than that of the Ti-6A1-4V alloy. It was also found that the compressive yield strength of the composite made from TiB₂ reactant powder was higher than that of the composite made from B₄C at the same volume fraction of reinforcement. A crack path examination suggested that the bonding nature of interface between matrix and reinforcement made from TiB₂ reactant powder was better than that made from B₄C.     

Processing,microstructure and mechanical properties of HfB2-ZrB2-SiC composites: Effect of B4C and carbon nanotube reinforcements

The fully dense HfB₂-ZrB₂-SiC composites were processed using spark plasma sintering (SPS) at 1850 °C. The effect of reinforcements (B₄C and CNT) on the densification as well as mechanical properties were investigated and compared (with monolithic) in the present study. The study showed that the addition of B₄C and CNT were not only beneficial for the densification but also towards enhancing the mechanical properties (hardness, elastic modulus, and fracture toughness) of HfB₂-ZrB₂-SiC composites. The augmentation in the mechanical properties establish the synergy between solid solution formation (with the equimolar composition of HfB₂/ZrB₂) and the reinforcements (SiC, B₄C, and CNT). The highest increase in the indentation fracture toughness with the reinforcements of B₄C as well as CNT is >3 times (~13.8 MPam^0.5 when it is 3–4 MPam^0.5 for monolithic ZrB₂/HfB₂) on HfB₂-ZrB₂-SiC composites, which is attributed to the crack deflection and pull-out mechanisms. An increase in the analytically quantified interfacial compressive residual stresses in the composites during SPS processing with the synergistic addition of reinforcements (SiC, B₄C, and CNT) and its effect on the indentation fracture toughness has also been addressed.     

In situ synthesized (ZrB2 + ZrC) hybrid short fibers reinforced Zr matrix composites for nuclear applications

In the present work, novel zirconium matrix composites reinforced with ZrB₂ or (ZrB₂ + ZrC) hybrid short fibers were designed and prepared for the first time, through the reaction from Zr, B and B₄C with non-consumable vacuum arc melting. The result shows that the ZrB₂ particles grow in large short-fiber shape while the ZrC particles grow in thin short-fiber shape or near equiaxed shape. The morphological characters are related to their crystal structure and growth mechanism. Homogeneous distribution of both two in situ reinforcements can be found in the as-cast composites. As both the Zr matrix and the in situ reinforcements have good nuclear and mechanical properties, these Zr matrix composites are considered to be good candidates for applied as reactor core components.     

Mechanical Properties of Squeeze-Cast A356 Composites Reinforced With B4C Particulates

In this study, different volume fractions of B₄C particles were incorporated into the aluminum alloy by a mechanical stirrer, and squeeze-cast A356 matrix composites reinforced with B₄C particles were fabricated. Microstructural characterization revealed that the B₄C particles were distributed among the dendrite branches, leaving the dendrite branches as particle-free regions in the material. It also showed that the grain size of aluminum composite is smaller than that of monolithic aluminum. X-ray diffraction studies also confirmed the existence of boron carbide and some other reaction products such as AlB₂ and Al₃BC in the composite samples. It was observed that the amount of porosity increases with increasing volume fraction of composites. The porosity level increased, since the contact surface area was increased. Tensile behavior and the hardness values of the unreinforced alloy and composites were evaluated. The strain-hardening behavior and elongation to fracture of the composite materials appeared very different from those of the unreinforced Al alloy. It was noted that the elastic constant, strain-hardening and the ultimate tensile strength (UTS) of the MMCs are higher than those of the unreinforced Al alloy and increase with increasing B₄C content. The elongation to fracture of the composite materials was found very low, and no necking phenomenon was observed before fracture. The tensile fracture surface of the composite samples was indicative of particle cracking, interface debonding, and deformation constraint in the matrix and revealed the brittle mode of fracture.     

Synthesis and characterization of WB2-WB3-B4C hard composites

WB₂-WB₃-B₄C composites were fabricated from powder mixtures of W and B₁₃C₂ by DC arc melting. XRD analysis illustrated that W has reacted with B₁₃C₂ and resulted in the formation of WB₂-WB₃-B₄C composites. Vickers hardness of 55.7 ± 8.5 (load 0.49 N) and 34.2 ± 1.1 GPa (load 4.9 N) with corresponding Young's modulus of 575 GPa were observed for the as-synthesized composites. SEM and XPS results revealed that the composites consist of WB₂, WB₃, B₄C, elemental boron and carbon. Raman spectra confirmed that B₄C and carbon coexist in the composites. The harden mechanism of the as-synthesized composites including solid-solution hardening and dispersion hardening were analyzed in detail.