Investigating effects of process parameters on microstructural and mechanical properties of Al5052/SiC metal matrix composite fabricated via friction stir processing

Friction stir processing (FSP) is a novel process for refinement of microstructure, improvement of material’s mechanical properties and production of surface layer composites. In this investigation via friction stir processing, metal matrix composite (MMC) was fabricated on surface of 5052 aluminum sheets by means of 5 μm and 50 nm SiC particles. Influence of tool rotational speed, traverse speed, number of FSP passes, shift of rotational direction between passes and particle size was studied on distribution of SiC particles in metal matrix, microstructure, microhardness and wear properties of specimens. Optimum of tool rotational and traverse speed for achieving desired powder dispersion in MMC was found. Results show that change of tool rotational direction between FSP passes, increase in number of passes and decrease of SiC particles size enhance hardness and wear properties.     

Preparation and properties of W-SiC/Cu composites by tape casting and hot-pressing sintering

In this study, W-SiC/Cu composites were prepared by tape casting and vacuum hot-pressing sintering. The microstructures and properties of the composites were studied by means of X-ray diffraction, X-ray photoelectron spectroscopy, field emission scanning electron microscopy, Vickers hardness test, bending strength test and coefficient of thermal expansion (CTE) test. The results showed that W₂C, WC and WSi₂ formed in the composites. The effects of SiC particle size on the relative densities, Vickers hardness, bending strength and CTE of composites were investigated. Vickers hardness, bending strength and CTE of the composite with SiC particle size of 6?µm reached the optimal values, which were 445.2?HV, 726.1?MPa, 9.24?ppm?K^?1.     

Optimization of process parameters for friction stir processing (FSP) of Al–TiC in situ composite

Segregation of in situ formed particles at the grain boundaries is a major drawback of in situ composites. In this study, it has been demonstrated that friction stir processing (FSP) can be used as an effective tool to homogenize the particle distribution in Al based in situ composites and FSP processing parameters were optimized for this purpose. An Al-5 wt% TiC composite was processed in situ using K₂TiF₆ and graphite in Al melt and subjected to FSP. Processing parameters for FSP were optimized to get a defect free stir zone and homogenize the particle distribution. It was found that a rotation speed > 800 rpm is needed. A rotation speed of 1000 rpm and a traverse speed of 60 mm/min were found to be an optimum combination. The grain size was also refined in addition to homogenization of the as-cast microstructure. This resulted in significant improvement in the mechanical properties of the processed composite.     

多道次搅拌摩擦加工对SiCP/2A14铝合金复合材料显微组织和力学性能的影响

采用搅拌摩擦加工(FSP)技术对SiC颗粒增强2A14铝合金(SiC_P/2A14)复合材料进行处理,通过金相表征、电子背散射衍射(EBSD)、SEM、硬度测试及力学拉伸实验等分析了多道次搅拌摩擦加工对SiC_P/2A14复合材料微观组织、力学性能及超塑性变形行为的影响。研究表明:经搅拌摩擦加工后,SiC_P/2A14复合材料搅拌区内SiC颗粒分布明显均匀,晶粒细化,其中2道次搅拌摩擦加工的SiC_P/2A14复合材料的晶粒尺寸最小,为3.14 μm。随着搅拌加工道次的增加,SiC_P/2A14复合材料的硬度降低,室温抗拉强度和高温延伸率均先提高后降低,其中2道次搅拌摩擦加工的SiC_P/2A14复合材料的室温抗拉强度为319 MPa,相较于未经FSP处理的SiC_P/2A14复合材料提高了41%,在500℃、应变速率为1.0×10?3 s?1条件下高温延伸率为609%,相较于未经FSP处理的SiC_P/2A14复合材料提高了133%。      

Fabrication of AA6061/Al2O3 nano ceramic particle reinforced composite coating by using friction stir processing

Nano ceramic particle reinforced composite coatings were created by incorporating Al₂O₃ ceramic particles into the surface of AA6061-T6 alloy plate with multiple pass friction stir processing (FSP). Optical microscopy and Micro-Vickers hardness tests were employed to investigate the influence of axial force and the number of FSP pass on the distribution of the ceramic particles and the hardness of the generated nano ceramic particle reinforced composite coating. Results show that the composite coating is as deep as the length of the pin probe. No distinct interface was developed between the coating and the base metal. The composite region becomes greater as the axial force and the number of FSP pass increased. At the same time, the distribution of the ceramic particles became more homogeneous. Nano particles in the coating have no significant effect on the macro-hardness of AA6061-T6 aluminum alloy even in the composite zone due to the softening of matrix material resulted from overaging. Spindle torque of the tool increased with increasing axial force, while it became less variable and smaller in subsequent pass compared to that in the first pass.     

Effect of SiC particle size on the physical and mechanical properties of extruded Al matrix nanocomposites

In this work, the effect of SiC particle size and its amount on both physical and mechanical properties of Al matrix composite were investigated. SiC of particle size 70 nm, 10 μm and 40 μm, and Al powder of particle size 60 μm were used. Composites of Al with 5 and 10 wt.% SiC were fabricated by powder metallurgy technique followed by hot extrusion. Phase composition and microstructure were characterized. Relative density, thermal conductivity, hardness and compression strength were studied. The results showed that the X-ray diffraction (XRD) analysis indicated that the dominant components were Al and SiC. Densification and thermal conductivity of the composites decreased with increasing the amount of SiC and increased with increasing SiC particle size. Scanning electron microscope (SEM) studies showed that the distribution of the reinforced particle was uniform. Increasing the amount of SiC leads to higher hardness and consequently improves the compressive strength of Al–SiC composite. Moreover, as the SiC particle size decreases, hardness and compressive strength increase. The use of fine SiC particles has a similar effect on both hardness and compressive strength.     

Tribological and microstructural evaluation of friction stir processed Al2024 alloy

In this study, a new processing technique, friction stir processing (FSP) was applied to Al2024-T4 as a means to enhance the near-surface material properties. Samples were subjected to FSP using a constant tool rotating rate of 800 rpm and travel speed of 25 mm/min with a tool tilt angle of 3°. Microstructural evolution and tribological behavior of friction stir processed (FSP) Al2024-T4 were investigated. Microstructural characteristics of the samples were investigated by optical microscopy (OM) and scanning electron microscopy (SEM). Evaluations of mechanical properties include micro-hardness and wear resistance. Dry sliding wear tests were applied using a reciprocating wear test. The results showed that FSP was beneficial concerning improvement of hardness and wear resistance. FSP reduced friction coefficient by approximately 30% and wear rate by an order of magnitude.     

On the role of process variables in the friction stir processing of cast aluminum A319 alloy

The surfaces of cast A319 alloy plates of nominal composition (wt.%): Al – 5.2 Si – 2.51 Cu were subjected to single stir Friction Stir Processing (FSP) with a view to decreasing the grain size and porosity level and improving the mechanical properties. Three traverse feed rates and five tool rotational speeds were employed. For certain combinations of the variables, the processed alloy displayed an increase in value of around 50% in tensile strength and 20% in microhardness compared with those of the as-cast alloy. The ductility of the processed alloy had increased by a factor which ranged from 1.5 to 5.Optical and scanning electron microscopy revealed that FSP reduces the size of the second phase particles, which contributes to the improvements in mechanical properties.     

Effect of heat treatment on microstructure and interface of SiC particle reinforced 2124 Al matrix composite

The microstructure and interface between metal matrix and ceramic reinforcement of a composite play an important role in improving its properties. In the present investigation, the interface and intermetallic compound present in the samples were characterized to understand structural stability at an elevated temperature. Aluminum based 2124 alloy with 10 wt.% silicon carbide (SiC) particle reinforced composite was prepared through vortex method and the solid ingot was deformed by hot rolling for better particle distribution. Heat treatment of the composite was carried out at 575 °C with varying holding time from 1 to 48 h followed by water quenching. In this study, the microstructure and interface of the SiC particle reinforced Al based composites have been studied using optical microscopy, scanning electron microscopy (SEM) coupled with energy dispersive X-ray spectroscopy (EDS), electron probe micro-analyzer (EPMA) associated with wavelength dispersive spectroscopy (WDS) and transmission electron microscopy (TEM) to identify the precipitate and intermetallic phases that are formed during heat treatment. The SiC particles are uniformly distributed in the aluminum matrix. The microstructure analyses of Al–SiC composite after heat treatment reveal that a wide range of dispersed phases are formed at grain boundary and surrounding the SiC particles. The energy dispersive X-ray spectroscopy and wavelength dispersive spectroscopy analyses confirm that finely dispersed phases are CuAl₂ and CuMgAl₂ intermetallic and large spherical phases are Fe₂SiAl₈ or Al₁₅(Fe,Mn)₃Si. It is also observed that a continuous layer enriched with Cu and Mg of thickness 50–80 nm is formed at the interface in between Al and SiC particles. EDS analysis also confirms that Cu and Mg are segregated at the interface of the composite while no carbide is identified at the interface.     

Fabrication of 5052Al/Al2O3 nanoceramic particle reinforced composite via friction stir processing route

In this research, microstructure and mechanical properties of 5052Al/Al₂O₃ surface composite fabricated by friction stir processing (FSP) and effect of different FSP pass on these properties were investigated. Two series of samples with and without powder were friction stir processed by one to four passes. Tensile test was used to evaluate mechanical properties of the composites and FSP zones. Also, microstructural observations were carried out using optical and scanning electron microscopes. Results showed that grain size of the stir zone decreased with increasing of FSP pass and the composite fabricated by four passes had submicron mean grain size. Also, increase in the FSP pass caused uniform distribution of Al₂O₃ particles in the matrix and fabrication of nano-composite after four passes with mean cluster size of 70 nm. Tensile test results indicated that tensile and yield strengths were higher and elongation was lower for composites fabricated by three and four passes in comparison to the friction stir processed materials produced without powder in the similar conditions and all FSP samples had higher elongation than base metal. In the best conditions, tensile strength and elongation of base material improved to 118% and 165% in composite fabricated by four passes respectively.     

Investigation on the effect of friction stir processing on the superplastic forming of AZ31B alloy

Superplastic forming has now become conventional for forming complex parts from sheet metals. In many superplastically formed aerospace components, only a selective region undergoes superplastic forming. In those cases, instead of selecting a material exhibiting superplastic properties, a light weight and low cost material can be chosen and its microstructure can be modified locally by the Friction Stir Processing (FSP) technique. In this work, AZ31B magnesium alloy is chosen, and friction stir processing is performed by varying the process parameters, such as tool axial force, tool traversing speed and tool rotational speed. The process parameter that produced equiaxed grains in the stirred zone with a grain size less than 10 μm is selected. With this parameter, single pass FSP, multiple pass FSP without overlapping and multiple pass FSP with overlapping are performed on the AZ31B magnesium alloy sheets and their superplastic behaviour was examined. Also the theoretical modelling was carried out to determine the strain rate sensitivity for the friction stir processed AZ31B magnesium alloy and for the nonprocessed AZ31B magnesium alloy. It is found that the strain rate sensitivity for the friction stir processed component has increased, when compared to the base metal.     

Prediction of mechanical and wear properties of copper surface composites fabricated using friction stir processing

Friction stir processing (FSP) has evolved as a novel solid state method to prepare surface composites. In this work, FSP technique has been successfully applied to prepare copper surface composites reinforced with variety of ceramic particles such as SiC, TiC, B₄C, WC and Al₂O₃. Empirical relationships are developed to predict the effect of FSP parameters on the properties of copper surface composites such as the area of the surface composite, microhardness and wear rate. A central composite rotatable design consisting of four factors and five levels is used to minimize the number of experiments. The factors considered are tool rotational speed, traverse speed, groove width and type of ceramic particle. The effect of those factors on the properties of copper surface composites is analyzed using the developed empirical relationships and explained in this paper taking into account the microstructural characterization of the prepared copper surface composites. B₄C reinforced composites have higher microhardness and lower wear rate.     

Development of AZ91/SiC surface composite by FSP: effect of vibration and process parameters on microstructure and mechanical characteristics

A surface composite layer enhances the mechanical characteristics of a surface while retaining the properties of the base material. Friction stir processing (FSP) is a method for forming surface metal matrix composites (SMMCs) that reinforce a surface with particles. In the current study, a new method entitled friction stir vibration processing (FSVP) was applied to form SMMCs on the surface of AZ91 magnesium alloy with SiC particles as the reinforcing particles. Contrary to FSP, in FSVP, the workpiece was vibrated normal to the processing line while the tool rotated and traversed. The microstructure and mechanical properties of friction stir (FS) and friction stir vibration (FSV) processed specimens were evaluated. Additionally, the effects of vibration frequency and process parameters on different characteristics of FS and FSV processed specimens were studied. The results showed that the stir zone grains for FSV processed specimens were finer than those for FS processed specimens, and the second phase particles (SiC particles) had a more homogenous distribution in the former specimens than in the latter specimens. This was related to the effect of workpiece vibration during FSVP, which increased the material deformation and led to enhanced dynamic recrystallization and the breakdown of agglomerated SiC particles. The results indicated that the stir zone grain size decreased, and the distribution homogeneity of the SiC particles increased as vibration frequency increased. It was also observed that the stir zone grain size increased, and the mechanical properties of the processed specimens decreased as tool rotation speed increased.The full text can be downloaded at https://link.springer.com/content/pdf/10.1007%2Fs40436-019-00288-9.pdf     

Nanomechanical properties of functionally graded composite coatings: Electrodeposited nickel dispersions containing silicon micro- and nanoparticles

Functionally graded composite coatings constitute a class of materials which are mostly used for mechanical and tribological applications. Among these materials, nickel metal deposits with incorporation of SiC particles have excellent mechanical properties due to nickel metal and good tribological properties due to the SiC particles. In this work, nickel coatings containing different sizes of SiC particles, nanoparticles and microparticles (10 nm to 5 μm), were electrodeposited from an additive-free sulfate bath containing nickel ions and SiC particles. The material properties of the coatings were compared to nickel coatings containing microparticles (5 μm). The effect of current density, SiC content in the bath, and electroactive species concentration on the codeposition of SiC were studied. Afterwards, the effect of particle size and codeposition percentage of SiC particles on the nanomechanical properties on the morphology and structure of the electrodeposits were investigated. The coatings were analyzed with scanning electron microscopy (SEM), X-ray diffraction (XRD), nanoidentation and lateral force microscopy (LFM). The Ni–SiC electrocomposites, prepared at optimum conditions, exhibited improved nanomechanical properties in comparison to pure nickel electrodeposits. The improved properties of the composite coatings are associated to structural modifications of the nickel crystallites as well as the morphology of the electrodeposited layers. The improved nanomechanical properties of electrocomposites containing nanosized SiC particles, as compared to electrocomposites containing micron-sized SiC particles, is attributed to the increasing values of the density of embedded SiC particles with decreasing particle size and the mechanism of embedment of the SiC particles.     

Effect of minor Sc and Zr addition on the mechanical properties of Friction Stir Processed 2024 Aluminium alloy

The effect of Friction Stir Processing (FSP) on the mechanical properties of a Sc, Zr modified 2024 aluminium alloy was investigated in the present paper. The room temperature tensile properties of the material were obtained in longitudinal direction respect to the processing one and compared with those of the unstirred material and unmodified alloy. Tensile tests were also performed at higher temperatures and different strain rates in the nugget zone. The superplastic properties of the recrystallized material were evaluated and the differences with the parent material as a function of the strong grain refinement due to the Friction Stir Process were put in evidence. The high temperature behavior of the material was studied, in longitudinal direction, by means of tensile tests in the temperature and strain rate ranges of 450–525°C and 10⁻¹–10⁻³ s⁻¹ respectively.     

Processing, microstructure and mechanical properties of nickel particles embedded aluminium matrix composite

Nickel particles were embedded into an Al matrix by friction stir processing (FSP) to produce metal particle reinforced composite. FSP resulted in uniform dispersion of nickel particles with excellent interfacial bonding with the Al matrix and also lead to significant grain refinement of the matrix. The novelty of the process is that the composite was processed in one step without any pretreatment being given to the constituents and no harmful intermetallic formed. The novel feature of the composite is that it shows a three fold increase in the yield strength while appreciable amount of ductility is retained. The hardness also improved significantly. The fracture surface showed a ductile failure mode and also revealed the superior bonding between the particles and the matrix. Electron backscattered diffraction (EBSD) and transmission electron microscopy analysis revealed a dynamically recrystallized equiaxed microstructure. A gradual increase in misorientation from sub-grain to high-angle boundaries is observed from EBSD analysis pointing towards a continuous type dynamic recrystallization mechanism.     

X-ray microdiffraction and EBSD study of FSP induced structural/phase transitions in a Ni-based superalloy

Severe plastic deformation during Friction Stir Processing (FSP) of an IN738 Ni-based superalloy was studied by means of X-ray polychromatic microdiffraction, EBSD, scanning electron and optical microscopies. Modeling of the physical properties and phase composition was also performed. Several distinct zones are formed during FSP including a stir zone (SZ), a thermal-mechanical affected zone (TMAZ) and a heat affected zone (HAZ). Each zone has distinct microstructure after FSP. The initial dendrite structure is preserved in the HAZ, while strengthening γ′-phase particles partially dissolve and coagulate. Plastic deformation of the base material dendrites takes place in the TMAZ and a large number of geometrically necessary dislocations are formed. The extent of deformation increases toward the SZ and the dendrite structure is completely destroyed in the SZ and replaced by a fine submicrocrystallinne microstructure.     

Effect of dual size particle distribution on processing and properties of AZ91D/SiCp magnesium matrix composites prepared by rotation cylinder method

Abstract

Spiral fluidity and hardness and wear experiments were carried out to investigate the effect of dual size (5 and 50 μ m) SiC particle distributions on the fluidity, hardness, and wear resistance of Mg - 9.1Al - 0.7Zn (wt-%) alloy containing 10 vol.-% SiC particles, with the aim of tailoring properties to specific applications. Although a decrease in the fluidity of the composites is observed, as expected, in the presence of SiC particles, the fluidity of the composites with dual size particle distributions was in some instances better than that of composites containing the same volume fraction of single size particles. The hardness and wear resistance of the composites with dual size distributions were weakly dependent on the mixing ratio. In terms of complete molten processing and tailored mechanical properties, the optimum mixing ratio of 5 and 50 μm particles appears to be 1:2.     

一种SiC/SixOyCz非连续增强陶瓷基复合材料的制备及性能

以聚硅氧烷类有机硅树脂YR3370(GE toshiba silicones)裂解生成的无定形Si_<em>xO_<em>yC_<em>z陶瓷为基质, 以0.8μm SiC颗粒为非连续增强介质, 制备了一种SiC/Si_<em>xO_<em>yC_<em>z非连续增强陶瓷基复合材料。含SiC颗粒50%的素坯在99.99%N₂气流中于1100~1300℃下保温1h, 所制备的陶瓷基复合材料密度可达2.27g/cm3, 维氏硬度可达741kg/mm2。通过结构模拟和强度计算分析了SiC/Si_<em>xO_<em>yC_<em>z陶瓷基复合材料的力学性能, 其结构特点是连续的无定形Si_<em>xO_<em>yC_<em>z陶瓷基质包围着分散的作为非连续增强介质的SiC颗粒, 基质与增强介质之间具有合理的热匹配, 并且可以改善单一陶瓷材料的脆性。     

Role of tool pin profiles on wear characteristics of friction stir processed magnesium alloy ZK60/silicon carbide surface composites

Poor friction and wear resistance are the major drawbacks that restrict structural applications of ZK60 magnesium alloys. The surface properties of magnesium alloy can be enhanced by reinforcing particles in the surface using friction stir processing (FSP). Tool pin profile is the significant process parameters which influences the material flow, particle breakups and its distribution in the processed zone. In this study, an attempt was made in order to understand the major effects of tool pin profiles namely, cylindrical thread (CT), plain cylindrical (PC), plain tapered cylindrical (PTC) and square (SA) pin profiles on the microstructure characteristics and particle distribution of friction stir processed/silicon carbide particle surface composites. The surface composites fabricated by plain tapered cylindrical pin profile yield superior properties which is attributed to the higher shear force and balanced state of material flow and heat generation in the processed zone. The formation of smaller grains and hardness enhancement due to dispersion strengthening are the main causes to get better wear resistance of friction stir processed/silicon carbide particle magnesium alloy.