Effect of Rotation Rate on Microstructures and Mechanical Properties of FSW Mg-Zn-Y-Zr Alloy Joints

Friction stir welding (FSW) of Mg-Zn-Y-Zr plates with 6 mm in thickness was successfully carried out under a wide range of rotation rates of 600-1200 r/min with a constant traverse speed of 100 mm/min. After FSW, the coarse grains in the parent material (PM) were changed into fine equiaxed recrystallized grains at the nugget zone (NZ). Furthermore, the coarse Mg-Zn-Y particles (W-phase) were broken up and dispersed homogenously into the Mg matrix. With increasing rotation rates, the size of the W-phase particles at the NZ significantly decreased, but the recrystallized grain size tended to increase. The hardness values of the NZs for all the FSW joints were higher than those of the PM, and the lowest hardness values were detected in the heat affected zone (HAZ). The fracture occurred in the thermo-mechanical affected zone (TMAZ) on the advancing side for all the FSW joints in the tensile test, due to the incompatibility of the plastic deformation between the NZ and TMAZ caused by remarkably different orientation of grains and W-phase particles. The strength of FSW joint reaches 90% of that of its PM.     

等径角挤压道次对SiC_p/Al复合材料显微组织的影响

为改善超高强度SiCp/Al复合材料的塑性,以Bc路径对喷射沉积SiCp/7090Al（SiC颗粒体积分数15%,名义尺寸10μm）复合材料进行等径角挤压变形,研究了复合材料显微组织和力学性能的演变规律.结果表明：经过4个道次变形后,获得等轴晶粒,尺寸大约为400 nm;SiC颗粒在剪切应力作用下被破碎,尺寸约2μm;...     

A356Al/TiB2颗粒增强铝基复合材料的搅拌摩擦焊

采用纯机械化的固相连接技术--搅拌摩擦焊成功地焊接了应用原位反应合成法制造的铸态A356Al/6.5%TiB2(体积分数)颗粒增强铝基复合材料,与铝合金相比,铝基复合材料搅拌摩擦焊的焊缝质量对焊接参数更为敏感.该连接方法在较低温度下实现铝基复合材料的焊接,避免了基体铝合金与增强相之间的化学反应,同时在搅拌头机械搅拌、挤压和摩擦热的共同作用下,焊缝区基体材料的晶粒和增强相被破碎并形成再结晶晶核,细化了组织结构,增强相分布也更加弥散.焊缝区的硬度值波动范围很小,抗拉强度比母材增加约20%.研究表明,搅拌摩擦焊用于连接颗粒增强铝基复合材料具有明显的优势.     

Evolution of Thermoplastic Shear Localization and Related Microstructures in Al／SiCp Composites Under Dynamic Compression

The localized shear deformation in the 2024 and 2124 Al matrix composites reinforced with SiC particles was investigated with a split Hopkinson pressure bar (SHPB) at a strain rate of about 2.0×103 s-1. The results showed that the occurrence of localized shear deformation is sensitive to the size of SiC particles. It was found that the critical strain, at which the shear localization occurs, strongly depends on the size and volume fraction of SiC particles. The smaller the particle size, the lower the critical strain required for the shear localization. TEM examinations revealed that Al/SiCp interfaces are the main sources of dislocations. The dislocation density near the interface was found to be high and it decreases with the distance from the particles. The Al matrix in shear bands was highly deformed and severely elongated at low angle boundaries. The AI/SiCp interfaces, particularly the sharp corners of SiC particles, provide the sites for microcrack initiation. Eventual fracture is caused by the g     

搅拌铸造SiCp/2024复合材料热挤压-轧制变形组织及性能

利用搅拌铸造-热挤压-轧制工艺制备SiCp/2024复合材料薄板。通过金相观察(OM)、扫描电镜(SEM)及力学测试等手段研究了该复合材料在铸态、热挤压态及轧制态下的显微组织及力学性能,分析了材料在塑性变形过程中显微组织及力学性能的演变。结果表明,该复合材料铸坯主要由80～100μm的等轴晶组成,粗大的晶界第二相呈非连续状分布,SiC颗粒较均匀地分布于合金基体中;热挤压变形后,晶粒沿挤压方向被拉长,SiC颗粒及破碎的第二相呈流线分布特征;轧制变形后,基体合金组织进一步细化,晶粒尺寸为30～40μm,SiC颗粒破碎明显,颗粒分布趋于均匀,轧制变形对挤压过程中形成的SiC颗粒层带状不均匀组织有显著的改善作用。数学概率统计指出,塑性变形有利于提高颗粒分布的均匀性。力学测试表明,塑性变形后,复合材料的抗拉强度、屈服强度和延伸率显著提高。SiCp/2024铝基复合材料主要的断裂方式为:合金基体的延性断裂、SiC颗粒断裂及SiC/Al界面脱粘。     

扭转圈数对高压扭转SiC_P/Al复合材料界面扩散行为和组织性能的影响

采用OM和EDS研究不同扭转圈数下高压扭转法制备SiC_P/Al复合材料的显微组织和界面扩散行为,并结合组织特点和界面特征分析扭转圈数对复合材料拉伸性能和断裂机理的影响。结果表明:扭转圈数的增加可以有效提高SiC颗粒分布的均匀性,闭合孔隙,界面处Al元素扩散能力增强,扩散距离增大,Al扩散系数实际计算值较理论值增大了10~(17)倍,形成以元素扩散和界面反应为主的强界面结合,试样抗拉强度和伸长率不断提高,少量的SiC颗粒均匀分布在断口韧窝中,断裂主要以基体的韧性断裂为主;当扭转圈数较大时,SiC颗粒在剧烈剪切作用下破碎加剧,颗粒"再生团聚"导致孔隙率增大,潜在裂纹源增多,形成大量结合强度较低的断裂新生界面,试样抗拉强度和伸长率显著降低,在团聚位置易形成尺寸较大的深坑韧窝,复合材料断裂呈现韧性断裂与脆性断裂的混合模式。     

高压扭转对SiC_P/Al复合材料微观组织和力学性能的影响

为研究大塑性变形对金属基复合材料微观组织和力学性能的影响,利用高压扭转工艺(HPT)在200℃下将纯Al粉末和经氧化处理的SiC粉末混合固结成10wt%SiC_P/Al复合材料。采用TEM观察HPT变形后不同圈数试样的SiC-Al界面及Al基体微观组织,采用EDS能谱仪分析界面处原子扩散现象,采用万能拉伸试验机测试研究不同扭转圈数试样的力学性能。结果表明:不同圈数试样Al基体内出现大量位错、非平衡晶界等晶格缺陷;组织内存在两种SiC-Al界面,含SiO_2层的原始界面和因颗粒破碎而新生成的界面。两种界面结合良好,界面处元素相互扩散;随着扭转圈数的增加,10wt%SiC_P/Al复合材料抗拉强度增加,延伸率得到较大提高。分析发现高压扭转后不同圈数组织内产生的大量晶格缺陷和细小晶粒,促进界面处元素的相互扩散,使界面结合良好,同时大量晶格缺陷和细小晶粒的产生以及结合良好的SiC-Al界面是SiC_P/Al复合材料力学性能大幅提升的主要原因。     

氧化膜对6082铝合金搅拌摩擦焊接头疲劳性能的影响

对6 mm厚的6082-T6铝合金进行两种表面处理然后实施搅拌摩擦焊接,研究了对接面氧化膜对接头组织和疲劳性能的影响。结果表明,进行速度为1000 mm/min的高速焊接时,对接面未打磨和打磨的接头焊接质量都良好,接头强度系数达到81%;两种接头的疲劳性能基本相同,疲劳强度均为100 MPa;少数样品在焊核区外断裂,大部分样品在热影响区断裂。与接头相比,两种接头焊核区的疲劳性能有所提高,均为110 MPa,在疲劳测试中裂纹并未沿“S”线萌生和扩展。     

Effect of FSW parameters on microstructure and mechanical properties of AM20 welds

This paper aims to demonstrate the successful friction stir welding (FSW) conditions of AM20 magnesium alloy. The maximum yield strength and ultimate tensile strength of weld were found to be 75% and 65% of the base metal strength, respectively. The maximum bending angle of the welded joint was 45°. Observations revealed that less plunging depth, high shoulder diameter, and low tool rotational speed and welding speed give better tensile properties. Maximum temperature was observed at 1?mm away from the tool shoulder toward the advancing side. Micro-hardness variation is found to be decreasing along the depth of the weld, and nugget zone (NZ) gives the higher hardness values when compared with base material (BM) and other welded zones. Needle-like grains of the BM became equiaxed grains due to grain recrystalized by the FSW process. The grains in the NZ were finer than thermo-mechanically affected zone and almost same size of grains observed at bottom, middle, and top of the NZ.     

Microstructure and mechanical properties of double-side friction stir welded 6082Al ultra-thick plates

In the present work, 80 mm thick 6082Al alloy plates were successfully double-side welded by friction stir welding(FSW). The relationship between the microstructures and mechanical properties was built for the double-side FSW butt joint with more attention paid to the local characteristic zones. It was shown that a phenomenon of microstructural inhomogeneity existed in the nugget zone(NZ) through the thickness direction. The grain size presented an obvious gradient distribution from the top to the bottom for each single-pass weld, and the microhardness values decreased from both surfaces to the middle of the NZ.The lowest hardness zone(LHZ) exhibited a "hyperbolical"-shaped distribution extending to the middle of the NZ. Similar tensile properties were obtained in the three sliced specimens of the FSW joint, and the joint coefficient reached about 70% which achieved the same level as the conventional FSW Al alloy joints. Finite element modeling proved that the "hyperbolical"-shaped heat affected zone(HAZ) was beneficial to resisting the strain concentration in the middle layer specimen which helped to increase the tensile strength. Based on the analysis of the hardness contour map, tensile property and microstructural evolution of the joints, an Isothermal Softening Layer(ISL) model was proposed and established, which may have a helpful guidance for the optimization on the FSW of ultra-thick Al alloy plates.     

焊后时效对7046铝合金搅拌摩擦焊接头力学性能的影响

对厚度为3.5mm的7046铝合金挤压板材进行搅拌摩擦焊接并对焊接接头进行人工时效,研究了焊后时效对接头力学性能的影响.结果 表明,焊接接头时效前的硬度分布大致呈"W"形,抗拉强度为406.5 MPa,焊接系数为0.8,拉伸时在后退侧热影响区与热机影响区的过渡位置出现断裂,此处的硬度值最低,断裂面上有大量的韧窝;进行1...     

Effect of Y Addition on Microstructure and Mechanical Properties of Friction Stir Welded ZK60 Alloy

6 mm thick ZK60 and ZK60-Y alloy plates were successfully friction stir welded (FSW) at a tool rotation rate of 1200 r/min and a traverse speed of 100 mm/min.FSW resulted in the dissolution of MgZn2 particles in the ZK60 and the breakup and dispersion of W-phase (Mg3Zn3Y2) particles in the ZK60-Y alloy, thereby leading to a decrease in the hardness of the nugget zone (NZ) for the ZK60 alloy and an increase in the hardness of the NZ for the ZK60-Y alloy, respectively.While two FSW joints exhibited similar joint efficiency (87%-89% of ultimate tensile strengths of the parent materials), the yield strength of the FSW ZK60-Y joint was substantially higher than that of the FSW ZK60 joint.The fracture occurred in the NZ and the heat affected zone for the ZK60 and ZK60-Y joints, respectively, which were consistent with the lowest hardness distribution of the welded joints.     

Microstructure and mechanical properties of cast (Al–Si)/SiCp composites produced by liquid and semisolid double stirring process

Abstract

A stirring process containing two steps, i.e. liquid and then semisolid stirring, was used to produce SiC particle reinforced aluminium matrix composites. The major advantages of this process are that full wetting of SiC particles by molten aluminium can be readily achieved at relatively low stirring rates, and undesirable Al₄ C₃ is not formed at the Al/SiC interface due to lower processing temperatures. Cast Al–Si matrix composites reinforced with 15 and 20 vol.-%SiC particles were produced in the present work. The mechanical properties of the composites were evaluated under the conditions of investment mould casting and heat treatment. For the composites obtained without employing semisolid stirring, the aggregation of SiC particles observed in the microstructure of composites resulted in quite poor mechanical properties. Observations and analyses indicated that some Al/SiC interfaces were very clean, and a reaction product of spinel MgAl₂O₄ was also found at some Al/SiC interfaces. Silicon dioxide (SiO₂ ) was found to exist on the surface of as purchased and 250°C dried SiC powders. This SiO₂ is involved in the spinel reaction at the interface between the SiC particles and the matrix in the present Al/SiC composites.     

Effects of copper addition on the sintering behavior and mechanical properties of powder processed Al/SiC<Subscript><Emphasis Type="Bold">p</Emphasis></Subscript> composites

The effect of copper addition on powder processed Al-10 vol% SiC composites was studied in regards to their sintering responses. Copper was mixed with aluminum powder either as elemental powders or as the coated layer on SiC particles. After sintering at 600°C for 1 h, Al-SiC composites with no copper addition showed little densification. It also demonstrated very low bend strengths of 49 and 60 MPa, indicating poor bonding between the powders in the sintered composite. The addition of 8% copper to the Al/SiC system effectively improved the sintering response, producing over 95% theoretical density, a bend strength of 231 MPa with the copper coated SiC, and a 90% density with over 200 MPa bend strength with the admixed copper.The as-sintered microstructures of the Al–SiC composites clearly revealed particle boundaries and sharp pores, indicating that only a limited neck growth occurred during sintering. In the case of Al–Cu–SiC composites, however, a liquid phase was formed and spread through particle boundaries filling the interfaces or voids between SiC particles and the matrix powders. The coated copper on SiC particles produced a somewhat better filling of the interface or voids, resulting in a little more densification and better sintered strength. Since the solubility of copper in aluminum is less than 2% at the sintering temperature, the alloying of copper in the aluminum matrix was limited. Most of the copper added was dissolved in the liquid phase during the sintering and precipitated as CuAl₂ phase upon cooling.     

Fabrication and evaluation of nanostructure Al-SiCp composite by accumulative roll-bonding

A nanostructured Al/SiCp composite was fabricated by accumulative roll bonding (ARB) process. The amount of SiC particles introduced into aluminum sheet by one cycle ARB was 0.22 mg/cm2. Increment of the number of ARB cycles increased the amount of SiC particles and enhanced the homogeneity of the distribution of SiC particles. Microstructural change in aluminum matrix with proceeding of the ARB was very similar to that of the ARB-processed unreinforced aluminum; showing a dislocation cell and/or sub-grain structure in samples of lower ARB cycles and ultrafine grained structure in samples of higher ARB cycles. The variation of tensile strength with the ARB was also very similar to that of unreinforced aluminum. However, the effect of strengthening by the ARB was higher in the Al/SiCp composite than in unreinforced aluminum due to an existence of the SiC particles and the formation of finer grains.     

Pressure infiltration casting process and thermophysical properties of high volume fraction SiCp/Al metal matrix composites

Abstract

SiC_p/Al composites containing high volume fraction SiC particles were fabricated using a pressure infiltration casting process, and their thermophysical properties, such as thermal conductivity and coefficient of thermal expansion (CTE), were characterised. High volume fraction SiC particulate preforms containing 50–70 vol.-%SiC particles were fabricated by ball milling and a pressing process, controlling the size of SiC particles and contents of an inorganic binder. 50–70 vol.-%SiC_p/Al composites were fabricated by high pressure infiltration casting an Al melt into the SiC particulate preforms. Complete infiltration of the Al melt into SiC preform was successfully achieved through the optimisation of process parameters, such as temperature of Al melt, preheat temperature of preform, and infiltration pressure and infiltration time after pouring. Microstructures of 50–70 vol.-%SiC_p/Al composites showed that pores resided preferentially at interfaces between the SiC particles and Al matrix with increasing volume fraction of SiC particles. The measured coefficients of thermal expansion of SiC_p/Al composites were in good agreement with the estimated values based on Turner's model. The measured thermal conductivity of SiC_p/Al composites agreed well with estimated values based on the 'rule of mixture' up to 70 vol.-% of SiC particles, while they were lower than the estimated values above 70 vol.-% of SiC particles, mainly due to the residual pores at SiC/Al interfaces. The high volume fraction SiC_p/Al composite is a good candidate material to substitute for conventional thermal management materials in advanced electronic packages due to their tailorable thermophysical properties.     

Effects of particle size on fatigue crack initiation and small crack growth in SiC particulate-reinforced aluminium alloy composites

Fatigue crack initiation and small crack growth were studied under axial loading using powder metallurgy 2024 aluminum-matrix composites reinforced with SiC particles of three different sizes of 5, 20 and 60 μm. The 5 and 20 μm SiC_p/Al composites exhibited nearly the same fatigue strength as the unreinforced alloy, while the 60 μm SiC_p/Al composite showed a significantly lower fatigue strength due to its inferior crack initiation resistance that could be attributed to interface debonding between particles and the matrix. Small crack growth behaviour was different depending on stress level. At a low applied stress, the addition of SiC particles enhanced the growth resistance, particularly in the composites reinforced with coarser particles, while at a high applied stress, the 60 μm SiC_p/Al composite showed a considerably low growth resistance, which could be attributed to interaction and coalescence of multiple cracks. In the 5 μm SiC_p/Al composite, small cracks grew avoiding particles and thus few particles appearing on the fracture surfaces were seen, particularly in small crack size region. In the 20 and 60 μm SiC_p/Al composites, they grew along interfaces between particles and the matrix and the number of particles appearing on the fracture surfaces increased with increasing crack size or maximum stress intensity factor.     

Strengthening mechanism of load sharing of particulate reinforcements in a metal matrix composite

A 15 v% SiC particle reinforced Al-2618 matrix composite was selected to study strengthening mechanisms under different heat treatments to produce specimens in hard or soft matrices. The investigation showed that the conventional micro-mechanism models play a minor role in strengthening the composite by further addition of the SiC particles. A load sharing mechanism of the particulate reinforcements is suggested to explain the experimental yield strength increase. An analytical model based on Eshelby equivalent inclusion approach and Mori–Tanaka mean field extension was established by introducing numerical matrix and composite secant moduli to simulate the stress–strain curve of the composite. The same modeling work was also carried out by FEM analysis based on the unit cell model using a commercial ANSYS code. The modeling results by both models on evolution of the load carried by the SiC particles during straining provide strong evidences to back up the strengthening mechanism of the load sharing. However, the modeling work exposes that the load transfer mechanism plays a dominant role only for the composite with hard matrix and the reason for load transfer is mainly the mismatch strain between particulate reinforcement and matrix rather than commonly believed friction at their interfaces. Nevertheless, an experiment was used to estimate average stress level in the SiC particles by observation of the numbers of broken particles in the composite with different strains, which also offers a good support to the modeling work.     

等通道角变形对搅拌铸造SiC_P/AZ91复合材料显微组织与室温性能的影响

采用搅拌铸造法成功制备了SiC_P/Mg(AZ91)复合材料并对铸态复合材料进行了等通道角挤压变形(Equal channel angular pressing,ECAP)。结果表明,搅拌铸造态SiC_P/AZ91复合材料的基体组织致密,颗粒与基体结合良好,没有出现宏观团聚;SiC_P大部分聚集在晶界附近区域并呈"项链状"分布。ECAP变形可以有效地消除铸态SiC_P/AZ91复合材料中的SiC_P"项链状"分布,并且随着ECAP道次的增加,SiC_P分布更加均匀;在ECAP过程中,SiC_P发生了一定断裂但并不明显。SiC_P/AZ91复合材料基体晶粒随着变形道次的提高而逐渐细化。基体晶粒细化以及SiC_P分布均匀化是SiC_P/AZ91复合材料屈服强度和抗拉强度随着道次提升而逐渐增加的主要原因。     

碳化硅纤维增强铝基复合材料的界面组织研究EI

本文利用透射电子显微术（ＴＥＭ）和微区能谱分析（ＥＤＸ）对化学气相沉积碳化硅纤维增强ＬＤ２铝合金的界面结构进行了研究，并对显微组织与性能的关系进行了讨论。结果发现，用热压扩散工艺生产的ＳｉＣ／Ａｌ复合材料，其基体与ＳｉＣ纤维结合良好。界面处有棒状相Ａｌ＿４Ｃ＿３生成（该相是菱形结构，对纤维强度有较大破坏作用），且存在镁元素富集。