Thermal conductivity and thermal contact conductance studies on Al2O3/Al–AlN metal matrix composite

Al₂O₃/Al–AlN is a metal matrix composite (MMC) used for making heat sink of electronic devices. This paper presents the detailed investigations carried out on thermal contact resistance across this MMC contact in vacuum at different contact pressures. The experimental results are compared with the theoretical models available in the literature for metallic contacts and they are found to be in good agreement with each other.     

Fracture toughness of microsphere Al2O3–Al particulate metal matrix composites

The fracture toughness and behaviour of COMRAL-85^TM, a 6061 aluminium–magnesium–silicon alloy reinforced with 20 vol% Al₂O₃-based polycrystalline ceramic microspheres, and manufactured by a liquid metallurgy route, have been investigated. Fracture toughness tests were performed using short rod and short bar (chevron-notch) specimens machined from extruded 19 mm diameter rod, heat treated to the T6 condition. The fracture toughness in the R–L orientation was found to be lower than in the C–R or L–R orientations owing to the presence of particle-free bands in the extrusion direction. Short rod tests were also conducted for the R–L orientation on six powder metallurgy composites with particle volume fractions ranging between 5% and 30%. It was found that the fracture toughness decreased progressively with particle volume fraction, but at a decreasing rate. A detailed examination of the fracture behaviour was made for both the liquid metallurgy and powder metallurgy processed composites.     

High cycle fatigue behaviour of microsphere Al2O3–Al particulate metal matrix composites

The high-cycle stress-life (S–N) curve and fatigue crack growth threshold (ΔK_th) behaviour of COMRAL-85^TM, a 6061 aluminium–magnesium–silicon alloy reinforced with 20 vol.% Al₂O₃-based polycrystalline ceramic microspheres, and manufactured by a liquid metallurgy route, have been investigated for a stress ratio of R = −1 (fully reversed loading). Fatigue testing was conducted on both smooth round bar (S–N) specimens and notched round bar (fatigue threshold) specimens. Unreinforced Al 6061-T6 also processed by a liquid metallurgy route and six powder metallurgy processed composites with particle volume fractions ranging between 5% and 30% were also studied. S–N data revealed that the powder metallurgy processed composites generally gave longer fatigue lives than the matrix alloy, whereas COMRAL-85^TM exhibited a reduced fatigue life. The fatigue threshold results were very similar for all the composites, being lower than for Al 6061-T6. Fatigue failure mechanisms were determined from examination of the fracture surfaces and the crack profiles.     

Machinable Al2O3/BN composite ceramics with strong mechanical properties

Al₂O₃/BN composite ceramics with nano-sized BN dispersions ranging from 0 to 30 vol.% were successfully fabricated by hot-pressing α-Al₂O₃ powders with turbostratic BN (t-BN) coating, which was prepared through chemical processes using boric acid and urea. SEM observations revealed that the nano-sized hexagonal BN (h-BN) particulates were homogeneously dispersed within Al₂O₃ grains as well as at grain boundaries. Vickers hardness of materials decreased with an increase in BN content. The fracture toughness was improved but the fracture strength had a small decrease, in comparison to Al₂O₃ monolithic ceramics. The nanocomposite ceramics with BN content more than 20 vol.% exhibited excellent machinability, which could be drilled using conventional hard metal alloy drills. Drilling rates and normal forces demonstrate the ease of machining of these materials. The preliminary information on the relationship between microstructures and properties are provided. The mechanism of material removal is also discussed.     

Refinement of microstructure and improvement of mechanical properties of Al/Al2O3 cast composite by accumulative roll bonding process

Some important problems associated with cast metal matrix composites (MMCs) include non-uniformity of the reinforcement particles, high porosity content, and weak bonding between reinforcement and matrix, which collectively result in low mechanical properties. Accumulative roll bonding (ARB) process was used in this study as a very effective method for refinement of microstructure and improvement of mechanical properties of the cast Al/10 vol.% Al₂O₃ composite. The average particle size of the Al₂O₃ was 3 μm. The results revealed that the microstructure of the composite after eleven cycles of the ARB had an excellent distribution of alumina particles in the aluminum matrix without any noticeable porosity. The results also indicated that the tensile strength and elongation of the composites increased as the number of ARB cycles increased. After eleven ARB cycles tensile strength and elongation values reached 158.1 MPa and 7.8%, which were 2.54 and 2.36 times greater than those of the as-cast MMC, respectively.     

Optimization of cold-sprayed AA2024/Al2O3 metal matrix composites via friction stir processing: Effect of rotation speeds

In this study, friction stir processing (FSP) was employed to modify cold-sprayed (CSed) AA2024/Al₂O₃ metal matrix composites (MMCs). Three different rotation speeds with a constant traverse speed were used for FSP. Microstructural analysis of the FSPed specimens reveals significant Al₂O₃ particle refinement and improved particle distribution over the as-sprayed deposits. After FSP, a microstructural and mechanical gradient MMC through the thickness direction was obtained. Therefore, a hybrid technique combining these two solid-state processes, i.e. CS and FSP, was proposed to produce functionally gradient deposits. The Guinier-Preston-Bagaryatskii zone was dissolved during FSP, while the amounts at different rotation speeds were approximately the same, which is possibly due to the excellent thermal conductivity of the used Cu substrate. Mechanical property tests confirm that FSP can effectively improve the tensile performance and Vickers hardness of CSed AA2024/Al₂O₃ MMCs. The properties can be further enhanced with a larger rotation speed with a maximum increase of 25.9% in ultimate tensile strength and 27.4% in elongation at 1500 rpm. Friction tests show that FSP decreases the wear resistance of CSed MMCs deposits due to the breakup of Al₂O₃ particles. The average values and fluctuations of friction coefficients at different rotation speeds vary significantly.     

Multi-walled carbon nanotubes reinforced Al2O3 nanocomposites: Mechanical properties and interfacial investigations

Well-dispersed multi-walled carbon nanotubes (CNTs) reinforced Al₂O₃ nanocomposites were successfully fabricated by hot-pressing. The resulting promising improvements in fracture toughness, by 94% and 65% with 2 and 5 wt.% CNTs addition respectively, compared with monolithic Al₂O₃, were attributed to the good dispersion of CNTs within the matrix, crack-bridging by CNTs and strong interfacial connections between the CNTs and the matrix. The interfacial phase characteristics between CNTs and Al₂O₃ were investigated via combined techniques. It is believed that a possible aluminium oxy-carbide as the primary interfacial phase was produced via a localized carbothermal reduction process. This interface phase presumably has good chemical compatibility and strong connections with both CNTs and the matrix and led nanocomposites to higher fracture toughness.     

Al2O3-TiC/Al2O3-TiC-CaF2复合叠层陶瓷材料摩擦磨损性能

将Al₂O₃-TiC陶瓷材料与具有固体润滑特性的Al₂O₃-TiC-CaF₂陶瓷材料进行叠层, 通过真空热压烧结制备Al₂O₃-TiC/Al₂O₃-TiC-CaF₂复合叠层陶瓷材料。在环盘式摩擦磨损试验机上进行摩擦磨损实验, 研究该材料在不同载荷、 转速条件下的摩擦系数和磨损率, 分别用SEM及EDS观察材料磨损前后的微观形貌和分析其成分组成, 研究其磨损机制。结果表明: 在相同载荷条件下, Al₂O₃-TiC/Al₂O₃-TiC-CaF₂复合叠层陶瓷材料的摩擦系数和磨损率随着转速的升高而下降, 在相同转速条件下, 其摩擦系数和磨损率随着载荷的增加而下降; Al₂O₃-TiC/Al₂O₃-TiC-CaF₂复合叠层陶瓷材料的磨损机制主要是磨粒磨损和黏着磨损。     

纤维长度和体积分数对Al2O3-SiO2 / Al2Si微屈服行为的影响

以通过浸渗挤压工艺制备的Al₂O₃-SiO₂ / Al₂Si 复合材料为研究对象, 使用配备有精度达10 - 7位移测量装置的Inst ron5569 电子拉伸试验机, 并采用连续加载法, 详细研究了晶化硅酸铝短纤维的体积分数和短纤维长度对铝硅基复合材料微屈服行为的影响规律, 并定性分析了原因。结果表明: 随着晶化硅酸铝短纤维体积分数的逐渐增大, 铝硅基复合材料的微屈服强度逐渐减小, 但其宏观屈服强度和弹性模量却逐渐增大; 随着晶化硅酸铝短纤维长度的逐渐增加, 铝硅基复合材料的微屈服强度逐渐减小, 但其宏观屈服强度却逐渐增大。      

Production of high strength Al-Al2O3 composite by accumulative roll bonding

Recently accumulative roll bonding has been used as a novel method to produce particle reinforced metal matrix composites. In this study, aluminum matrix composite reinforced by submicron particulate alumina was successfully produced and the effects of number of ARB cycles and the amount of alumina content on the microstructure and mechanical properties of composites were investigated. According to the results of tensile tests, it is shown that the yield and tensile strengths of the composite are increased with the number of ARB cycles. Scanning electron microscopy (SEM) reveals that particles have a random and uniform distribution in the matrix by the ARB cycles and a strong mechanical bonding takes place at the interface of particle-matrix. It is also found that the tensile strength of the composite, as a function of alumina content, has a maximum value at 2 vol.%, which is 5.1 times higher than that of the annealed aluminum.     

Structural properties of Al2O3-La2O3 binary oxides prepared by sol-gel

The structural properties of La₂O₃ and Al₂O₃-La₂O₃ binary oxides prepared by sol-gel were studied by XRD, HRTEM and UV-vis. The binary oxides with high lanthana contents show an amorphous structure after calcination at 650 °C. At calcination temperatures higher than 1000 °C there is a phase transformation from the amorphous state to the crystalline LaAlO₃ with a perovskite structure. The structure of La₂O₃ is consistent with the hexagonal system; however, some crystalline microdomains with a monoclinic structure were detected by HRTEM. Islands of La₂O₃ and LaAl₁₁O₁₈ phases were detected at high lanthana concentration in the binary oxide. The modification in the coordination shell of the Al³⁺ cations due to the interaction with La³⁺ cations confirms the formation of phases with a perovskite structure and the presence of islands of the LaAl₁₁O₁₈ phase.     

三维网络Al2O3增强球墨铸铁基复合材料摩擦磨损性能

采用SRV摩擦磨损试验机研究了球墨铸铁及三维网络Al₂O₃增强球墨铸铁基复合材料的干摩擦磨损性能, 测量了球墨铸铁和复合材料在不同摩擦频率及载荷下的摩擦系数和磨损率; 用扫描电镜观察磨损表面形貌, 并分析了三维网络Al₂O₃对复合材料磨损机制的影响。结果表明: 陶瓷与金属基体之间具有良好界面结合的三维网络Al₂O₃/球墨鋳铁复合材料, 其摩擦系数随载荷和摩擦频率的变化保持稳定; 复合材料的耐磨性能远优于球墨铸铁, 而且随着摩擦频率和载荷的增加, 复合材料的抗磨损性能明显提高。这是由于复合材料中陶瓷与金属相之间三维空间结构和良好的界面结合有利于摩擦载荷的传递; 金属基体中的石墨减摩作用保持摩擦系数的稳定; 三维陶瓷骨架在磨损表面形成硬的微突体并起承载作用, 制约了基体的塑性变形和高温软化, 有利于磨损表面氧化膜的留存。     

Effect of liquid-forming additives on the sintering and mechanical properties of Al2O3/3Y-TZP (30 vol.%) composite

Al₂O₃/3Y-TZP (30 vol.%) composite was pressurelessly sintered with addition of TiO₂MnO₂ and/or CaOAl₂O₃SiO₂ glass. It was found that TiO₂MnO₂ addition greatly enhanced the densification of the composite by the formation of a low-viscosity liquid at sintering temperature. In contrast, the high-viscosity liquid formed by CaOAl₂O₃SiO₂ glass improved mechanical properties because of its repressing effect on grain growth. The composite could be obtained at a temperature as low as 1400°C by co-doping with TiO₂MnO₂ and CAS glass. Bending strength of 552±64 MPa and fracture toughness of 6.03±0.22 MPa m^1/2 were obtained with a doping level of 2 wt.% TiO₂MnO₂ and 2 wt.% CAS glass.     

Deformation and damage in Al/Al2O3

Al/Al₂O₃-composites as an example of light weight materials are very interesting for many industrial applications because of a favourable combination of low density and improved mechanical properties. The prediction of the macroscopic mechanical behaviour of these materials related to their microstructure requires the knowledge of damage initiation and crack development under external loading conditions and, if present, residual stresses have to be taken into consideration. Different types of material degradation like particle/matrix-debonding, particle failure and matrix cracking can be observed in these types of metal matrix composites. The aim of the present work is to introduce damage criteria into a FE-microstructural model in order to foresee the degradation process in an Al₂O₃-particle reinforced Al(6061) composite during mechanical loading. Presently, the conventional fabrication route of the Al/Al₂O₃-composite is a metallurgical method with extrusion for homogenisation of the microstructure and final heat treatment to achieve a defined precipitation state. The influence of thermal residual stresses due to cooling down from annealing temperature on the deformation and damage initiation of Al(6061)/10vol%Al₂O₃-composites is investigated through finite element analyses using the experimentally mapped real microstructure as binary data. Especially, the stresses in the ceramic particles which are responsible for particle cracking and the hydrostatic stresses in the Al-matrix making the particle–matrix interface prone to debonding were analysed. The results show the importance of the thermal residual stresses with respect to damage criteria as obtained by micromechanical FE-calculations.     

Comparative study of physical properties of vapor chopped and nonchopped Al2O3 thin films

Aluminium oxide being environmentally stable and having high transmittance is an interesting material for optoelectronics devices. Aluminium oxide thin films have been successfully deposited by hot water oxidation of vacuum evaporated aluminium thin films. The surface morphology, surface roughness, optical transmission, band gap, refractive index and intrinsic stress of Al₂O₃ thin films were studied. The cost effective vapor chopping technique was used. It was observed that, optical transmittance of vapor chopped Al₂O₃ thin film showed higher transmittance than the nonchopped film. The optical band gap of vapor chopped thin film was higher than the nonchopped Al₂O₃, whereas surface roughness and refractive index were lower due to vapor chopping.     

Facile fabrication of SiO2/Al2O3 composite microspheres with a simple electrostatic attraction strategy

SiO₂/Al₂O₃ composite microspheres with SiO₂ core/Al₂O₃ shell structure and high surface area were prepared by depositing Al₂O₃ colloid particles on the surface of monodispersed microporous silica microspheres using a simple electrostatic attraction and heterogeneous nucleation strategy, and then calcined at 600 °C for 4 h. The prepared products were characterized with differential thermal analysis and thermogravimetric analysis (DTA/TG), scanning electron microscopy (SEM), transmission electron microscopy (TEM), nitrogen adsorption and X-ray photoelectron spectroscopy (XPS). It was found that uniform alumina coating could be deposited on the surface of silica microspheres by adjusting the pH values of the reaction solution to an optimal pH value of about 6.0. The specific surface area and pore volume of the SiO₂/Al₂O₃ composite microspheres calcined at 600 °C were 653 m² g⁻¹ and 0.34 ml g⁻¹, respectively.     

电沉积法制备纳米线Cu/ Al2O3 复合材料及其光吸收特性

采用电沉积法成功制备Cu 准一维纳米线及Cu/ Al₂O₃ 纳米复合材料。采用SEM、TEM、XRD 分析技术对纳米线及其组装体系进行了形貌、相结构的观察和表征。紫外2可见光吸收光谱测试表明: Cu/ Al₂O₃ 组装体吸收光谱上仅呈现出一个吸收带边, 无等离子共振吸收峰, 且吸收边相对于阳极氧化铝模板发生了红移。红移主要归结为雷利散射中心的增加, 使消光现象增强所致。      

On structure and mechanical properties of ultrasonically cast Al-2% Al2O3 nanocomposite

An investigation on the structure of an ultrasonically cast nanocomposite of Al with 2 wt.% nano-sized Al₂O₃ (average size ∼10 nm) dispersoids showed that the nanocomposite was consisting of nearly continuous nano-alumina dispersed zones (NDZs) in the vicinity of the grain boundaries encapsulating Al₂O₃ depleted zones (ADZs). The mechanical properties were investigated by nanoindentation and tensile tests. The nano-sized dispersoids caused a marginal increase in the elastic modulus, and a significant increase in the hardness (∼92%), and tensile strength (∼48%). Subsequent cold rolling to achieve a reduction ratio of 2 resulted in an appreciable increase in the hardness due to change in morphology of the microstructure. Estimation of the strength on the basis of inter-particle spacing, which was measured by transmission electron microscopy, could not be accounted for on the basis of Orowan mechanism, and therefore, strengthening mechanisms like local climb and/or cross slip might have a role in this room temperature (0.32T_M) deformation process.     

Study on properties of BaxSmyTi7O20 ceramics with CaO-SiO2-B2O3 glass

The effect of CaO-SiO₂-B₂O₃ (CSB) glass addition on the sintering temperature and dielectric properties of Ba_xSm_yTi₇O₂₀ ceramics has been investigated using X-ray diffraction, scanning electron microscopy and differential thermal analysis. The CSB glass starts to melt at about 970 °C, and a small amount of CSB glass addition to Ba_xSm_yTi₇O₂₀ ceramics can greatly decrease the sintering temperature from about 1350 to about 1260 °C, which is attributed to the formation of liquid phase. It is found that the dielectric properties of Ba_xSm_yTi₇O₂₀ ceramics are dependent on the amount of CSB glass and the microstructures of sintered samples. The product with 5 wt% CSB glass sintered at 1260 °C is optimal in these samples based on the microstructure and the properties of sintering product, when the major phases of this material are BaSm₂Ti₄O₁₂ and BaTi₄O₉. The material possesses excellent dielectric properties: ?_r = 61, tan δ = 1.5 × 10⁻⁴ at 10 GHz, temperature coefficient of dielectric constant is −75 × 10⁻⁶ °C⁻¹.     

Fatigue properties and fracture analysis of a SiC fiber-reinforced titanium matrix composite

Tension–tension fatigue properties of SiC fiber reinforced Ti–6Al–4V matrix composite (SiC_f/Ti–6Al–4V) at room temperature were investigated. Fatigue tests were conducted under a load-controlled mode with a stress ratio 0.1 and a frequency 10 Hz under a maximum applied stress ranging from 600 to 1200 MPa. The relationship between the applied stress and fatigue life was determined and fracture surfaces were examined to study the fatigue damage and fracture failure mechanisms using SEM. The results show that, the fatigue life of the SiC_f/Ti–6Al–4V composite decreases substantially in proportion to the increase in maximum applied stress. Moreover, in the medium and high life range, the relationship between the maximum applied stress and cycles to failure in the semi-logarithmic system could be fitted as a linear equation: S_max/μ = 1.381 − 0.152 × lgN_f. Fractographic analysis revealed that fatigue fracture surfaces consist of a fatigued region and a fast fracture region. The fraction of the fatigued region with respect to the total fracture surface decreases with the increase of the applied maximum stresses.