Aluminium based composites strengthened with metallic amorphous phase or ceramic (Al2O3) particles

Two methods were used to obtain amorphous aluminium alloy powder: gas atomization and melt spinning. The sprayed powder contained only a small amount of the amorphous phase and therefore bulk composites were prepared by hot pressing of aluminium powder with the 10% addition of ball milled melt spun ribbons of the Al₈₄Ni₆V₅Zr₅ alloy (numbers indicate at.%). The properties were compared with those of a composite containing a 10% addition of Al₂O₃ ceramic particles. Additionally, a composite based on 2618A Al alloy was prepared with the addition of the Al₈₄Ni₆V₅Zr₅ powder from the ribbons used as the strengthening phase. X-ray studies confirmed the presence of the amorphous phase with a small amount of aluminium solid solution in the melt spun ribbons. Differential Scanning Calorimetry (DSC) studies showed the start of the crystallization process of the amorphous ribbons at 437 °C. The composite samples were obtained in the process of uniaxial hot pressing in a vacuum at 380 °C, below the crystallization temperature of the amorphous phase. A uniform distribution of both metallic and ceramic strengthening phases was observed in the composites. The hardness of all the prepared composites was comparable and amounted to approximately 50 HV for those with the Al matrix and 120 HV for the ones with the 2618A alloy matrix. The composites showed a higher yield stress than the hot pressed aluminium or 2618A alloy. Scanning Electron Microscopy (SEM) studies after compression tests revealed that the propagation of cracks in the composites strengthened with the amorphous phase shows a different character than these with ceramic particles. In the composite strengthened with the Al₂O₃ particles cracks have the tendency to propagate at the interfaces of Al/ceramic particles more often than at the amorphous/Al interfaces.     

Limiting the development of Al4C3 to prevent degradation of Al/SiCp composites processed by pressureless infiltration

The presence of Al₄C₃ in Al/SiC composites may activate degradation of the material by its interaction with water; even moisture may cause its environmental degradation. It has been demonstrated that incorporation of 6 vol% SiO₂ powders into SiC_p preforms before processing by pressureless infiltration prevents formation of Al₄C₃. Analysis by electron back-scattered diffraction confirms that regardless of its crystal structure (α-quartz or α-cristobalite), SiO₂ completely reacts to form MgAl₂O₄. The metal/composite interface microstructure condition of the specimens processed under the most severe conditions (1100 °C for 60 min), four months later confirms the effectiveness of the SiO₂ powders.     

Doping of iron phosphate glasses with Al2O3, SiO2 or B2O3 for improved thermal stability

The effects of doping 60 P₂O₅–40 Fe₂O₃ (mol%) glasses with 5–10 mol% SiO₂, Al₂O₃ or B₂O₃ on their thermal stability, iron environments and redox were investigated. Thermal stability improved markedly with 5% dopant addition in the order Al₂O₃ > SiO₂ > B₂O₃ ≫ base glass. Solubility of pro rata additions when melted at 1150 °C was 5–10% SiO₂, <5% Al₂O₃, and >10% B₂O₃. It was possible to dissolve 5% Al₂O₃ by replacing Fe₂O₃. These additions generally had little effect on dilatometric measurements and iron environments, however the Fe²⁺/ΣFe redox ratio increased in the order base glass < Al₂O₃ < SiO₂ < B₂O₃. This behaviour was broadly consistent with the effects of glass basicity. The increased thermal stability of these glasses may improve their suitability for applications such as waste immobilisation or sealing.     

Improvement of yield strength of LM24 alloy

In this study, Al₂O₃ particles were employed to improve the microstructure of LM24 and therefore, to increase the yield strength and tensile strength of this kind of alloy. In situ Al₂O₃ particles were obtained by direct reaction between oxygen and Al melt at 750–800 °C. Microstructure examination shows that the size of in situ formed Al₂O₃ particles was about 1–2 μm, and interestingly, with addition of in situ Al₂O₃ particles, the coarse primary Si phase was disappeared completely. More important, the yield strength and the tensile strength of Al₂O₃/LM24 are increased by 52 MPa, 16 MPa than that of LM24 alloy with 0.1% Sb addition. The value of 181 MPa and 315 MPa is for yield strength and tensile strength of Al₂O₃/LM24 respectively. Besides, the yield strength and tensile strength are 180 MPa and 314 MPa respectively for Al₂O₃/LM24 alloy after remelting and casting. This verifies that the improvement of mechanical properties of such kind of material possesses stability and reliability.     

Net-shape forming of bi-continuous Al2O3/Al composite by displacement reaction

Displacement reaction constitutes a novel and specialized reaction-induced processing technique which allows the fabrication of a composite in net-shape. Composite containing α-Al₂O₃ and Al, in which both the phases are continuous, were formed by a displacement reaction between silica shapes and molten aluminium isothermally at temperatures between 1173 and 1573 K. Soaking periods varied between 0.2 and 48 h at each of these peak temperatures. The course of reaction was followed by microstructure evaluation of the products as observed at different time intervals of reaction processing. These specimens were analysed for phase evolution by XRD, extent of reaction and microstructure by optical microscopy and composition profile across the reaction zone by electron probe microanalyzer (EPMA). The product obtained on completion of reaction consisted of 74% α-Al₂O₃ and 26% Al (Si) by volume, and the phase were co-continuous. Grain size of % α-Al₂O₃ increased with an increase in forming temperature. The remarkable features of this forming technique are that the product has the same shape as that of the silica preform and it undergoes an isotropic linear shrinkage of barely over 1%. The formation of the composite and the microstructure evolution are discussed. Some properties of the product are presented.     

Low-temperature diffusion brazing of actively metallized Al2O3 ceramic tube and 5A05 aluminum alloy

A low-temperature ceramic–metal joining technique was successfully developed to produce a vacuum-tight Al₂O₃ ceramic and 5A05 aluminum alloy joint, with leak rates of less than 1.0 × 10^− 9 Pa∙m³/s. This involved two steps: active metallization of the Al₂O₃ ceramic surface using Ag–Cu–TiH₂–B composite filler, followed by diffusion brazing of metallized Al₂O₃ ceramic and 5A05 alloy at 530 °C. The microstructure, interfacial reactions and mechanical properties of the actively metallized Al₂O₃ ceramic and diffusion-brazed Al₂O₃/5A05 joint were investigated. The joint properties were determined by the formation of a continuous Ti₃Cu₃O reaction layer adjacent to Al₂O₃ ceramic, in situ synthesized TiB whiskers in the brazing seam, and dissolution thickness of 5A05 alloy. The maximum shear strength of the bonded joints reached 70 MPa, while fracture propagated in the Al₂O₃ substrate, with a bowed crack path. A model for quantitatively evaluating the dissolution thickness of 5A05 aluminum alloy during diffusion brazing process was established.     

Improving the mechanical properties of Al2O3/Ni laminated composites by adding Ni particles in Al2O3 layers

The (Al₂O₃ + Ni) composite, (Al₂O₃ + Ni)/Ni and Al₂O₃/(Al₂O₃ + Ni)/Ni laminated materials were prepared by aqueous tape casting and hot pressing. Results indicated that the (Al₂O₃ + Ni) composite had higher strength and fracture toughness than those of pure Al₂O₃. The fracture toughness of (Al₂O₃ + Ni)/Ni and Al₂O₃/(Al₂O₃ + Ni)/Ni laminated materials was higher than not only those of pure Al₂O₃, but also those of Al₂O₃/Ni laminar with the same layer numbers and thickness ratio. It was found that the toughness of the Al₂O₃/(Al₂O₃ + Ni)/Ni laminated material with five layers and layer thickness ratio = 2 could reach 16.10 MPa m^1/2, which were about 4.6 times of pure Al₂O₃. The strength and toughness of the (Al₂O₃ + Ni)/Ni laminated material with three layers and layer thickness ratio = 2 could reach 417.41 MPa and 12.42 MPa m^1/2. It indicated the material had better mechanical property.     

In-situ fabrication of Al3V/Al2O3 nanocomposite through mechanochemical synthesis and evaluation of its mechanism

In this research, in situ fabrication of Al₃V based nanocomposite and its formation mechanism have been investigated. In order to synthesize Al₃V/Al₂O₃ nanocomposite, a mixture of Al and V₂O₅ powders was subjected to high-energy ball milling and the nanocomposite was produced through a mechanochemical reaction. The produced structure was isothermally heat-treated at 500–600 °C for 0.5–2 h under argon atmosphere. In order to evaluate the structural changes during milling and annealing, the synthesized powders were characterized by X-ray diffraction (XRD). Moreover, the powder morphological changes were studied by scanning electron microscopy (SEM). It was observed that the reaction between Al and V₂O₅ occurred after about 30 min and, the Al₃V and Al₂O₃ were formed in nanocrystalline structure with the continuing mechanical milling. Calculation of adiabatic temperature confirmed that reaction took place in combustion mode. In final stage of milling up to 40 h; it was observed that the Al₃V decomposed to Al and V so that the optimum time of milling to achieve fabrication of nanocomposite was determined to be about 20 h. Calculations based on Miedema’s model verified partial disordering of Al₃V during further milling and annealing of as-milled powder at 600 °C led to the ordering of Al₃V. The crystallite size of Al₃V and Al₂O₃ after annealing at 600 °C for 2 h remained in nanometer scale. So the final product appeared to be stable even after annealing.     

Influence of sol–gel derived Al2O3 film on the oxidation behavior of a Ti3Al based alloy

Al₂O₃ thin films were deposited on a Ti₃Al based alloy (Ti–24Al–14Nb–3V–0.5Mo–0.3Si) by sol–gel processing. Isothermal oxidation at temperatures of 900–1000 °C and cyclic oxidation at 800–900 °C were performed to test their effect on the oxidation behavior of the alloy. Results of the oxidation tests show that the oxidation parabolic rate constants of the alloy were reduced due to the applied thin film. This beneficial effect became weaker after longer oxidation time at 1000 °C. TiO₂ and Al₂O₃ were the main phases formed on the alloy. The thin film could promote the growth of Al₂O₃, causing an increase of the Al₂O₃ content in the composite oxides, sequentially decreased the oxidation rate. Nb/Al enriched as a layer in the alloy adjacent to the oxide/alloy interface in both the coated and uncoated alloy. The coated thin film decreased the thickness of the Nb/Al enrichment layer by reducing the scale growth rate.     

Mechanical properties of rolled A356 based composites reinforced by Cu-coated bimodal ceramic particles

Three kinds of A356 based composites reinforced with 3 wt.% Al₂O₃ (average particle size: 170 μm), 3 wt.% SiC (average particle size: 15 μm), and 3 wt.% of mixed Al₂O₃–SiC powders (a novel composite with equal weights of reinforcement) were fabricated in this study via a two-step approach. This first process step was semi-solid stir casting, which was followed by rolling as the second process step. Electroless deposition of a copper coating onto the reinforcement was used to improve the wettability of the ceramic particles by the molten A356 alloy. From microstructural characterization, it was found that coarse alumina particles were most effective as obstacles for grain growth during solidification. The rolling process broke the otherwise present fine silicon platelets, which were mostly present around the Al₂O₃ particles. The rolling process was also found to cause fracture of silicon particles, improve the distribution of fine SiC particles, and eliminate porosity remaining after the first casting process step. Examination of the mechanical properties of the obtained composites revealed that samples which contained a bimodal ceramic reinforecment of fine SiC and coarse Al₂O₃ particles had the highest strength and hardness.     

Al2O3–FeCrAl composites and functionally graded materials fabricated by reactive hot pressing

Al₂O₃–FeCrAl composites were fabricated by mixing Fe₂O₃, Al and Cr powders and then reactive hot pressing. The high temperature alloy FeCrAl was formed by the reaction of extra Al, Cr and the Fe reduced from Fe₂O₃. The Al₂O₃–FeCrAl composites with various Al₂O₃ fractions were successfully fabricated by the proper addition of extra Fe, Cr, Al or Al₂O₃ powders. A five-layer functionally graded material of YSZ–FeCrAl was fabricated using the Al₂O₃–FeCrAl composites with compositions of 25, 53.2 and 75 vol.% Al₂O₃ as interlayer. The results from XRD analysis, optical microscope observation and thermal cycling test show that the composites fabricated by this method consist of α-Al₂O₃ phase and (Fe, Cr, Al) solid solution. The α-Al₂O₃ grain formed by this in-situ reaction between Fe₂O₃ and Fe is ultrafine and uniform distribution. The three-point bending strength is 305.0 MPa for the composite with 53.2 vol.% Al₂O₃ prepared by the reactive hot pressing, about 20% higher than that of the composite with same composition prepared by ex situ hot pressing method (252.0 MPa). No cracking was found in the functionally graded materials after 10 thermal cycles up to 1000 °C due to the better metal–ceramic bond, continuous in microstructure at interface of FGM and good oxidation resistance component FeCrAl alloy formed in the FGM.     

Effect of Al2O3 layer on improving high-temperature oxidation resistance of siliconized TiAl-based alloy

TiAl-based specimens were siliconized with two different kinds of cementation respectively, one is 23 vol.% Si + 77 vol.% Al₂O₃, and the other is 23 vol.% Si + 77 vol.% ZrO₂. SEM observation showed that a Ti₅Si₃-based layer, in which some Al₂O₃ particles dispersed, formed on the surface after siliconization. Further observation showed that an extra outer Al₂O₃ layer existed on the surface of specimens siliconized with 23 vol.% Si + 77 vol.% Al₂O₃, while no such Al₂O₃ layer was found in specimens siliconized with 23 vol.% Si + 77 vol.% ZrO₂. The cyclic oxidation test performed at 900 °C shows that the oxidation resistance was significantly improved by siliconizing. By comparison, the specimens that siliconized with 23 vol.% Si + 77 vol.% Al₂O₃ exhibits a better oxidation resistance than that with 23 vol.% Si + 77 vol.% ZrO₂. It was deduced that the extra outer Al₂O₃ layer is beneficial to the oxidation resistance of siliconized TiAl-based alloy.     

Thermal and structural characterization of erbium-doped borosilicate fibers with low silica content containing various amounts of P2O5 and Al2O3

We report results on the processing and characterization of different glass preforms and single core fibers within the SiO₂–Na₂O–B₂O₃–Er₂O₃–P₂O₅–Al₂O₃ system. Micro-Raman spectroscopy was used to identify post-draw structural modification. The differences in the micro-Raman spectra recorded on the preform and on the fiber glass were attributed to a change in the structure induced by the drawing process. Changes in the silicate network organization and small scale molecular orientation within the glass matrix are suspected to occur during the fiber drawing process. We found that the extent in the changes between the preform and fiber properties depend on the glass composition. The glass network of the Al-containing fiber is expected to be less sensitive to the drawing process than that of the fiber matrix as the network of this Al-containing fiber is formed by a larger number of Si-BO units in the network and neutral three-coordinated boron compared to the network of the fiber matrix. From the micro-Raman spectra, formation of small crystals is suspected to occur in the P-containing glasses during the fiber drawing process. The resulting fibers were found to have propagation losses at 1330 nm and Er³⁺ absorption between (7 ± 1) and (25 ± 1) dB/m and (36 ± 1) and (47 ± 1) dB/m, respectively, depending on the glass composition.     

Biomimetic apatite coating on biomorphous alumina scaffolds

Highly porous Al₂O₃ scaffolds were prepared from natural cellulosic sponges via pyrolysis and Al-vapour phase infiltration. Subsequent oxidation and sintering in air resulted in porous Al₂O₃ ceramics with an open cellular morphology and a total porosity of 95%. The Al₂O₃-sponges were immersed in highly supersaturated simulated body fluid (5 × SBF) solutions with different Mg²⁺ and HCO³⁻ concentrations. After soaking of the porous Al₂O₃ sponges for 4 days a homogeneous calcium phosphate layer with a thickness of approximately 2 μm and a Ca : P ratio of 1.62 (apatite) was found.     

Effect of stirring on the dissolution of coal fly ash and synthesis of pure-form Na-A and -X zeolites by two-step process

Using the coal fly ash (FA), pure-form Na-A and -X zeolites were synthesized by two-step process. The FA was pretreated in aqueous NaOH solution under stirring condition at 85 °C for 18 h. The amorphous aluminosilicate of FA was dissolved during pretreatment. Increasing the stirring speed accelerated the dissolution of FA and increased Si⁴⁺ and Al³⁺ concentrations in the solution. This fact indicated that the stirring during pretreatment significantly affected on the dissolution of FA. After pretreatment, remaining FA was removed and aqueous NaAlO₂ solution was added to the residual solution to control the molar ratio SiO₂/Al₂O₃ of 0.5–4.5. After aging the resultant at 85 °C for 24 h, white precipitates were generated over the whole SiO₂/Al₂O₃ range. Increment of Si⁴⁺ concentration by stirring during pretreatment increases the yield of the product. At SiO₂/Al₂O₃ = 0.5, the material was identified as Na-A zeolite with a trace amount of hydroxysodalite. A single phase Na-A zeolite was obtained at SiO₂/Al₂O₃ = 1.0. The Na-X zeolite was emerged at SiO₂/Al₂O₃ ? 2.0. At SiO₂/Al₂O₃ = 4.5, a single phase Na-X zeolite was formed. The cation exchange capacity of synthetic single phase Na-A and -X zeolites was respectively 4.78 and 3.88 meq./g.     

Mechanochemical synthesis of Al2O3/Co nanocomposite by aluminothermic reaction

In this work, Al₂O₃/Co nanocomposite was successfully prepared by mechanochemical reaction between Co₃O₄ and Al powders in a planetary high energy ball mill. The mechanism of the reaction was dealt using X-ray diffraction (XRD), differential thermal analysis (DTA), and thermodynamics calculations. It was found that Co₃O₄ reacts with Al through a self-sustaining combustion reaction after an incubation period of 50 min and the reaction between Co₃O₄ and Al involves two steps. First, Co₃O₄ reacts with Al to form CoO and Al₂O₃ at the temperature around melting point of Al, and at higher temperature, CoO reacts with remaining Al to form Co and Al₂O₃. Mechanical activation process decreases the reaction temperature from 1041 °C for as-received Co₃O₄ and Al powder mixture to 869 °C for 45 min milled powders. After annealing of powder milled for 12 h, no phase transformation has been detected. The crystallite sizes of both α-Al₂O₃ and Co remained in nanometeric scale after annealing at 1000 °C for 1 h.     

Infiltrated Cu8Al–Ti alumina composites

The effect of titanium additions on the interface and mechanical properties of infiltrated Cu8 wt%Al–Al₂O₃ composites containing 57 ± 2 vol% ceramic are investigated, exploring two different Al₂O₃ particle types and four different Ti concentrations (0, 0.2, 1, 2 wt%Ti). Addition of 0.2 wt%Ti leads to the development of a thin (5–10 nm) layer enriched in Ti at the interface between Cu alloy and Al₂O₃ particles; this Ti concentration produces the best mechanical properties. With higher Ti-contents Ti₃(Cu, Al)₃O appears; this decreases both the interface and composite strength. Composites reinforced with vapor-grown polygonal alumina particles show superior mechanical properties compared to those reinforced by angular comminuted alumina particles, as has been previously documented for aluminum-based matrices. Micromechanical analysis shows that damage accumulation is more extensive, as is matrix hardening by dislocation emission during composite cooldown, in the present Cu8 wt%Al matrix composites compared with similarly reinforced and processed Al-matrix composites.     

Effect of 10Ce-TZP/Al2O3 nanocomposite particle amount and sintering temperature on the microstructure and mechanical properties of Al/(10Ce-TZP/Al2O3) nanocomposites

A zirconia/alumina nanocomposite stabilized with cerium oxide (Ce-TZP/Al₂O₃ nanocomposite) can be a good substitute as reinforcement in metal matrix composites. In the present study, the effect of the amount of 10Ce-TZP/Al₂O₃ particles on the microstructure and properties of Al/(10Ce-TZP/Al₂O₃) nanocomposites was investigated. For this purpose, aluminum powders with average size of 30 μm were ball-milled with 10Ce-TZP/Al₂O₃ nanocomposite powders (synthesized by aqueous combustion) in varying amounts of 1, 3, 5, 7, and 10 wt.%. Cylindrical-shape samples were prepared by pressing the powders at 600 MPa for 60 min while heating at 400–450 °C. The specimens were then characterized by scanning and transmission electron microscopy (SEM and TEM) in addition to different physical and mechanical testing methods in order to establish the optimal processing conditions. The highest compression strength was obtained in the composite with 7 wt.% (10Ce-TZP/Al₂O₃) sintered at 450 °C.     

Mechanical properties of in-situ toughened Al2O3/Fe3Al

Mechanical properties of in-situ toughened Al₂O₃/Fe₃Al nano-/micro-composites were measured. Effects of Fe₃Al content, sintering temperature and holding time on properties and microstructure of the composites were investigated. The addition of Fe₃Al nano-particles decreased the aspect ratio and grain size of Al₂O₃, and changed the fracture mode of composites. The maximum bending strength and fracture toughness were 832 MPa and 7.96 MPa m^1/2, which were obtained in Al₂O₃/5 wt.% Fe₃Al sintered at 1530 °C and Al₂O₃/10 wt.% Fe₃Al sintered at 1600 °C, respectively. Compared to monolithic alumina, the strength increased by 132% and the toughness increased by 73%. The improvement in the mechanical properties of the composites was attributed to the change in fracture mode from intergranular fracture to transgranular fracture, the “in-situ reinforced effect” arising from the platelet grains of Al₂O₃ matrix, refined microstructure by dispersoids, as well as crack deflection and bridging of intergranular and intragranular Fe₃Al.     

Properties of near- and sub-micrometre Al matrix composites strengthened with nano-scale in-situ Al2O3 aimed for low temperature applications

Mechanical and electrical properties of in-situ Al–Al₂O₃ metal matrix composites (MMCs) fabricated by powder metallurgy approach using different aluminium powders of particle size 0.8–21 µm and purity 99.8–99.996% were examined. Hot working powder consolidation by vacuum hot pressing at 270 °C and direct extrusion at 425 °C and reduction ratio of 7:1 were applied. Subsequently, extruded composite rods with the diameter of 7.5 mm were cold worked by groove rolling and rotary swaging to the wires with the diameter of 1.1 mm. Detailed microstructural characterization of composite materials was carried out. Stress-strain characteristics of composite wires were measured at 77 and 300 K. In addition, resistivity of all wires were measured by four-probe method between 25 and 300 K and eddy current losses at frequency 72 Hz and temperatures between 18 and 77 K. Obtained results clearly showed that properly designed Al–Al₂O₃ MMC materials can be utilized at low temperatures e.g., for the thermal stabilization of superconducting wires.