Some aspects on plastic deformation of copper and copper–titanium carbide powder metallurgy composite preforms during cold upsetting

The densification, workability and strain hardening behaviour of sintered copper and Cu–7.5%TiC powder metallurgy (P/M) composite preforms during cold upsetting were investigated by the constitutive model using the experimental data. Cold upsetting of copper and Cu–7.5% TiC composite preforms having different aspect ratios were carried out and the formability behaviour of the preforms under triaxial stress state was determined. The mechanisms most likely involved in the constitutive model, namely, densification and strain hardening were studied. The effects of aspect ratio and addition of titanium carbide to copper on the formability behaviour and various constants involved in the constitutive model, namely, instantaneous density coefficient, instantaneous strain hardening index, instantaneous strain rate sensitivity and instantaneous strength coefficient were discussed in detail.     

Corrosion resistance of electrodeposited Ni–Al composite coatings on the aluminum substrate

Ni matrix–Al particle composite coating was adopted via sediment co-deposition (SCD) method on the zincate coated aluminum substrate. Surface morphology was investigated by scanning electron microscopy (SEM). The electrochemical behavior of the coatings was studied by polarization potentiodynamic test in 3.5 wt.% sodium chloride using a three electrode open cell. The effect of the electroplating parameters on the Al co-deposition was studied. Maximum of 22 wt.% Al particles were deposited in the coating. It was found that the zincate coating plays an important role in improving the nickel layer adherent. Furthermore, incorporation of aluminum particles in Ni matrix refined the Ni crystal coatings. However, polarization curves shifted to negative potentials and corrosion rate is decreased.     

Electrolytic concentration effect on the abrasive assisted-electrochemical machining of an aluminum–boron carbide composite

All engineering materials can be machined by one or combination of processes in such a way that the material’s potential is fully exploited. Electrochemical machining is found to be a most promising process that produces various components from the hard-to-machine materials for the various applications. Electrolyte concentration is playing a positive role by improving the electrolyte conductivity, but negatively forming the passivation layer on the cut surfaces. In order to improve the surface finish and removal of generated residual materials from the cut surfaces, abrasive particles were fed along with electrolyte into the machining zone. This present paper investigates the sodium chloride (NaCl) electrolyte with varied concentration (10–30%) in association with SiC abrasive particles on the material removal rate, surface roughness, and radial overcut while machining of aluminum 6061–boron carbide (5–15?wt%) composites. This study conclusively derived that electrolyte concentration up to 20% exhibited a positive role in the material removal rate for the machining of composites because the rate of dissolution was of higher magnitude. Externally supplied abrasive particles along with electrolyte reduced the surface roughness and radial over cut to an extent. Conversely, at higher electrolyte concentration, the externally supplied abrasive particles have a little effect on the removal of the formed passivation layer as confirmed by SEM analysis.     

Thermal conductivity of polystyrene–aluminum nitride composite

The thermal conductivity of polymer composites having a matrix of polystyrene (PS) containing aluminum nitride (AlN) reinforcement has been investigated under a special dispersion state of filler in the composites: aluminum nitride filler particles surrounding polystyrene matrix particles. Data for the thermal conductivity of the composites are discussed as a function of composition parameters (aluminum nitride concentration, polystyrene particle size) and temperature. It is found that the thermal conductivity of composites is higher for a polystyrene particle size of 2 mm than that for a particle size of 0.15 mm. The thermal conductivity of the composite is five times that of pure polystyrene at about 20% volume fraction of AlN for the composite containing 2 mm polystyrene particle size. The relationship between thermal conductivity of composites and AlN filler concentrations has been compared with the predictions of two theoretical models from the literature.     

Effect of titanium on copper–titanium/carbon nanofibre composite materials

Copper/carbon nanofibre composites containing titanium varying from 0.3 wt.% to 5 wt.% were made, and their thermal conductivities measured using the laser flash technique. The measured thermal conductivities were much lower than predicted. The difference between measured and predicted values has often been attributed to limited heat flow across the interface. A study has been made of the composite microstructure using X-ray diffraction, transmission electron microscopy and Raman spectroscopy. It is shown in these materials, that the low composite thermal conductivity arises primarily because the highly graphitic carbon nanofibre structure transforms into amorphous carbon during the fabrication process.     

Effect of calcinations of starting powder on mechanical properties of hydroxyapatite–alumina bioceramic composite

The effect of calcinations of starting powder on the mechanical properties of hydroxyapatite (HA)-based bioceramic composite was investigated. The calcinations of HA powder in air at 900 °C increased the crystallinity as well as the size of the powder. Ball milling after the calcinations was effective in eliminating large agglomerates in the powder. When the powder was mixed with reinforcing Al₂O₃ powder, the mixture became fine and homogeneous. The flexural strength of HA–Al₂O₃ composite was increased by the calcinations processes at all the Al₂O₃ concentration. However, the fracture toughness was not much influenced by the calcinations. These results lead to the conclusion that the calcinations process effectively reduced the critical flaw size in the body by removing the agglomerates in the HA powder.     

A preliminary study on the manufacturing aluminum–potassium feldspar metal matrix composite materials

This study reports the results of a preliminary study of manufacturing aluminum–potassium feldspar metal matrix composites including its castability and mechanical properties. The material was composed considering 0.25 %, 0.5 %, and 0.75 % additive ratios to examine the impact of the amount of potassium feldspar on the material and mechanical properties of the manufactured aluminum metal matrix composite material. Aluminum alloy (A356) was utilized as the matrix of the composition. The composite material was manufactured by the stir casting technique. The modulus of elasticity, yield strength, tensile strength, elongation, density, and quality index of the material parameters was taken into account to determine the materials′ practicality. The preliminary results indicated that potassium feldspar is a promising mineral to be utilized as an additive for aluminum metal matrix composites since it has a positive impact on mechanical properties. By optimizing the casting parameters, the positive aspects of the potassium feldspar may make the material more practical to be utilized in vast engineering applications.     

Studies on the mechanism of the structural evolution in Cu–Al–Ni elemental powder mixture during high energy ball milling

The present work is focused on the understanding of the phase and microstructural evolution during mechanical alloying of 82Cu–14Al–4Ni powder mixture. Morphology and phase evolution in the milled powder at different stages of milling were studied and a physical modeling of the mechanical alloying has been proposed. It has been demonstrated that milling process mainly consisted of four stages, i.e., flattening and cold welding of powder particles to form a porous aggregate followed by its fragmentation, plastic deformation of small aggregates to form layered particles, severe plastic deformation of layered particles to form elongated flaky particles, and fragmentation of elongated particles into smaller size flaky powder particles. It was also found that the initial period of milling resulted in rapid grain refining, whereas alloying was accomplished during the later period of milling. TEM study of the 48 h milled powder revealed that the microstructure was equiaxed nanocrystalline in nature. It was found that the grains were either randomly distributed or arranged as banded type. A possible explanation for such a behavior has been presented.     

Hot tearing mechanisms of B206 aluminum–copper alloy

In this study, the mechanisms of hot tearing in B206 aluminum alloy were investigated. Castings were produced at three mold temperatures (250 °C, 325 °C and 400 °C) and with two levels of titanium (0.02 wt% and 0.05 wt%) to investigate the effects of cooling rate and grain refinement. A constrained-rod casting mold attached to a load cell was used to monitor the contraction force during solidification and subsequently determine the onset temperature of hot tearing in B206. The corresponding onset solid fraction of hot tearing was estimated from the solid phase evolution of α-Al in B206 using in situ neutron diffraction solidification analysis. Hot tears were found to occur at solid fractions ranging from 0.81 to 0.87. Higher mold temperatures significantly reduced hot tearing severity in B206 but did not alter the onset solid fraction. In contrast, additions of titanium to B206 were effective at eliminating hot tears by transforming the grain structure from coarse dendrites to finer and more globular grains. Finally, in situ neutron diffraction solidification analysis also successfully determined the solid phase evolution of intermetallic Al₂Cu during solidification, which in turn, provided a better understanding of the role of Al₂Cu in the development of hot tears in B206.     

Experimental study on capillary and mechanical properties of a porous nickel–copper composite

A novel porous nickel–copper composite was designed and fabricated by sintering a mixture of a high-porosity open-cell copper foam plate and fine nickel powder. The microstructure of the porous nickel–copper composite was characterised by the scanning electron microscope. The effects of sintering temperature and dwelling time on the sintering shrinkage, sintered porosity, capillary performance and mechanical properties of the porous composite and monoporous sintered nickel powder were investigated experimentally. The nickel–copper composite presented significant lower sintering shrinkage, higher porosity, lower tensile strength and better capillary performance than the sintered nickel powder under all sintering conditions. The sintering temperature has more influence than the dwelling time on both the capillary performance and tensile strength of the sintered composite.     

Effect of friction stir processing on corrosion resistance of aluminum–copper alloy gas tungsten arc welds

Gas tungsten arc welds in aluminum–copper alloy AA2219-T6 were friction stir processed (to a depth of about 2 mm from the weld top surface) for improving their corrosion resistance. Unprocessed and friction stir processed welds were comparatively evaluated for their microstructural characteristics and corrosion resistance. Friction stir processing was found to result in substantial microstructural refinement with fine, uniformly distributed CuAl₂ intermetallic particles. Friction stir processing was also found to result in a more uniform copper distribution in the weld metal, leading to significant increase in weld corrosion resistance. This work demonstrates that friction stir processing is an effective strategy for overcoming corrosion problems in aluminum–copper alloy fusion welds.     

The effect of strontium on the mechanical properties of aluminum–silicon alloy

Technical Physics Letters - We have studied the influence of strontium additives on the microstructure and mechanical properties of an aluminum alloy with 15 wt % silicon prepared by directional...     

Influence of atomized powder size on microstructures and mechanical properties of rapidly solidified Al–Cr–Y–Zr aluminum alloys

Rapidly solidified powders of Al–5.0Cr–4.0Y–1.5Zr (wt%) were prepared by using a multi-stage atomization-rapid solidification powder-making device. The atomized powders were sieved into four shares with various nominal diameter level and were fabricated into hot-extruded bars after cold-isostatically pressing and vaccum degassing process. Influence of atomized powder size on microstructures and mechanical properties of the hot-extruded bars was investigated by optical microscopy, X-ray diffraction, transmission electronic microscopy with EPSX and scanning electron microscopy. The results show that the fine atomized powders of rapidly solidified Al–5.0Cr–4.0Y–1.5Zr aluminum alloy attains supersaturated solid solution state under the exist condition of multi-stage rapid solidification. With the powder size increasing, there are Al₂₀Cr₂Y (cubic, a = 1.437 nm) and Ll₂ Al₃Zr (FCC, a = 0.407 nm) phase forming in the powders, and even lumpish particles of Al₂₀Cr₂Y appearing in the coarse atomized powders, as can be found in the as-cast master alloy. Typical microstructures of the extruded bars of rapidly solidified Al–5.0Cr–4.0Y–1.5Zr aluminum alloy can be characterized by fine grain FCC α-Al matrix with ultra-fine spherical particles of Al₂₀Cr₂Y and Al₃Zr. But a small quantity of Al₂₀Cr₂Y coarse lumpish particles with micro-twin structures can be found, originating from lumpish particles of the coarse powders. The extruded bars of rapidly solidified Al–5.0Cr–4.0Y–1.5Zr aluminum alloy by using the fine powders eliminated out too coarse powders have good tensile properties of σ_0.2 = 403 MPa, σ_b = 442 MPa and δ = 9.4% at room temperature, and σ_0.2 = 153 MPa, σ_b = 164 MPa and δ = 8.1% at high temperature of 350 °C.     

Thermomechanical behaviour of a copper–chromium in situ composite

Abstract

The mechanical response of an in situ copper–chromium composite was investigated over a range of temperatures by means of tensile and isothermal creep tests. Scanning electron microscopy was used to characterise the extent, type, and distribution of damage. It was found that the failure mechanisms fell into distinct regimes. At cryogenic temperatures damage tended to occur in the form of reinforcement fracture. Around room temperature, very little damage was observed in the composite. At temperatures of about 400°C, extensive damage was again observed in the form of reinforcement failure and cavitation. Further increase in the test temperature resulted in a transition from a local to a global load sharing, with damage distribution becoming more homogeneous. These experimental observations were rationalised by considering the relative extent of deformation within the two phases as a function of temperature.     

Accelerated wear testing for evaluating the life characteristics of copper–graphite tribological composite

Sliding wear is a key determinant of the performance of electrical sliding contacts used in electrical machines. The behavior of the contact in sliding couple is controlled by the mutual metal transfer, friction and wear. Product life and reliability of sliding contacts are dictated by wear phenomenon. The present paper focuses on evaluation of tribological performance of copper–graphite composites using reliability theory. These composites are made up of a high electrical and thermal conductivity matrix with a solid lubricant reinforcement, making it most suitable for sliding contacts. Traditional life tests under normal operating condition would be a time consuming process due to a very long expected life of the composite. Hence, accelerated wear testing was carried out for evaluating the life characteristics. Analysis was then performed on the times-to-failure data and reliability models were developed. Life-stress relationship based on the inverse power law-Weibull model was used to make reliability predictions at normal usage level.     

Microstructure of SiCw reinforced Al–12Ti composites prepared by powder metallurgical technique

Abstract

Silicon carbide whisker reinforced Al–12Ti composites were fabricated by a powder metallurgical technique, and the microstructures were characterised by the means of X-ray diffraction, SEM, TEM, and energy dispersion X-ray analysis. It has been shown that secondary phase particles, Al₃ Ti, form in situ during hot pressing after premechanically ball milling, and a small amount of α-Ti is left because the in situ reaction between α-Ti and Al is not complete. High density dislocations including dislocation lines and dislocation loops exist in the coarse Al₃ Ti grains, while, hardly any dislocations can be found using TEM in the very fine (～150 nm) Al₃ Ti grains. In addition, nanometer equiaxed γ-Al₂O₃ and stick shaped Al₄ C₃ dispersoids form in the Al matrix as a result of the addition of a processing control agent. There is no fixed orientation relationships between γ-Al₂O₃ , Al₄ C₃ , and the Al matrix. Dislocations in the Al matrix are too sparse to be found even in the zones around SiC whiskers. Silicon carbide whiskers uniformly scatter in the Al matrix, and no reaction products are formed. A few microzones with nanosized (～20 nm) Al grains exist in the Al matrix, and an amorphous phase is usually found in the zones adjacent to SiC whiskers. The formation mechanism of the amorphous phase is discussed.     

Constitutive modeling and the effects of strain-rate and temperature on the formability of Ti–6Al–4V alloy sheet

The constitutive model considering the strain-rate and temperature effects was presented by fitting the true stress–strain curves of Ti–6Al–4V alloy over a wide range of strain-rates (0.0005–0.05 s⁻¹) and temperatures (923–1023 K). The Forming Limit Curve (FLC) of Ti–6Al–4V alloy at 973 K was measured by conducting the hemispherical dome test with specimens of different widths. The forming limit prediction model of Ti–6Al–4V alloy, which takes strain-rate and temperature sensitivity into account, was predicted based on Marciniak and Kuczynski (M–K) theory along with Von Mises yield criterion. The comparison shows that the limit strain decreases with temperature lowering but strain-rate increasing. The comparison between theoretical analysis and experiment of FLC verifies the accuracy and reliability of the proposed methodology, which considers the strain-rate and temperature effects, to predict limit strains in the positive minor strain region of Forming Limit Diagram (FLD).     

Effect of nano-metal particles on the fracture toughness of metal–ceramic composite

A theoretical model is proposed to study the influence of nano-metal particles (NMPs) on the fracture toughness of metal–ceramic composites (MCC). In the framework of the model, the crack tip intersects the grain boundary of the NMPs. Stress concentration at crack tip initiates edge dislocations which makes a shielding effect on the crack and leads to fracture toughness of the MCC. The dependence of critical crack intensity factors on grain size of the NMPs was calculated. The calculation suggested that the existence of the NMPs lead to an increase of critical crack intensity factors by 14%.     

Investigation on TIG welding of SiCp-reinforced aluminum–matrix composite using mixed shielding gas and Al–Si filler

Using He–Ar mixed gas as shielding gas, the tungsten inert gas (TIG) welding of SiCp/6061 Al composites was investigated without and with Al–Si filler. Welded joint with filler were submitted to tensile tests. The microstructure and fracture morphology of the joint were examined. The results show that adding 50 vol.% helium in shielding gas improves the arc stability, and seams with high-quality appearance are obtained when the Al–Si filler is added. In addition, the interface reaction between SiC and matrix is greatly suppressed when using Al–Si filler. The microstructure of the welded joint displays non-uniformity with many SiC particles distributing in the weld center. The average tensile strength of weld joints with Al–Si filler is 70% above that of the matrix composites under annealed condition.