Fatigue properties and fatigue fracture mechanisms of SiC whiskers or SiC particulate-reinforced aluminium composites

Fatigue properties and fracture mechanisms were examined for three commercially fabricated aluminium matrix composites containing SiC whiskers (SiC_w) and SiC particles (SiC_p) using a rotating bending test. The fatigue strengths were over 60% higher for SiC_w/A2024 composites than that for the unreinforced rolled material, while for the SiC_p/A357 composites, fatigue strengths were also higher than that for the unreinforced reference material. For the SiC_p/A356 composites at a volume fraction of 20%, the fatigue strength was slightly higher than that of the unreinforced material. Fractography revealed that the Mode I fatigue crack was initiated by the Stage I mechanism for the SiC_w/A2024 and SiC_p/A357 composites, while for the SiC_p/A356 composite, the fatigue crack initiated at the voids situated beneath the specimen surfaces. On the other hand, the fatigue crack propagated to the whisker/matrix interface following the formation of dimple patterns or the formation of striation patterns for SiC_w/A2024 composites, while for the SiC_p/A356 and SiC_p/A357 composites the fatigue crack propagated in the matrix near the crack origin and striation patterns were found. Near final failure, dimple patterns, initiated at silicon carbide particles, were frequently observed. Mode I fatigue crack initiation and propagation models were proposed for discontinuous fibre-reinforced aluminium composites. It is suggested that the silicon carbide whiskers or particles would have a very significant effect on the fatigue crack initiation and crack propagation near the fatigue limit.     

Synthesis of an Al2O3/Al co-continuous composite by reactive melt infiltration

The route for the fabrication of an Al₂O₃/Al co-continuous composite by reactive melt infiltration was investigated using scanning electron microscopy, energy dispersive X-ray microanalysis and X-ray diffraction analysis. It was found that in the process of molten aluminium infiltration into the SiO₂ preform, the chemical reaction of 3SiO₂ + 4Al → 2Al₂O₃ + 3Si occurred at the infiltration front, and generated a transition zone containing a new type of continuous porosity about 100 μm in width. The reaction continued with further infiltration of molten aluminium alloy into this porosity which reacted with the residual SiO₂ until all the SiO₂ was transformed into Al₂O₃. A comparison was made between this route and that by direct infiltration of molten aluminium alloy into the open porosity of an Al₂O₃ preform. As a result of the increased wetting ability of the molten aluminium alloy by the chemical reaction, reactive melt infiltration took place at a higher rate for the SiO₂ preform than that for the direct infiltration of the Al₂O₃ preform. A fracture surface examination demonstrated a toughening effect provided by the continuous aluminium alloy in the composite.     

Processing of Al2O3/SiC ceramic cake preforms and their liquid Al metal infiltration

In order to prepare ceramic preforms, chemical processes were used rather than using mixing of ceramic powders to obtain porous Al₂O₃/SiC ceramic foams. A slurry was prepared by mixing aluminium sulphate and ammonium sulphate in the water, and silicon carbide powder was added into the slurry so that a uniform mixture of Al₂O₃/SiC cake could be produced. The resulting product was (NH₄)₂SO₄·Al₂(SO₄)₃·24H₂O plus silicon carbide particles (SiC_p) after dissolving chemicals in the water. This product was heated up in a ceramic crucible in the furnace. With the effect of heat it foamed and Al₂O₃/SiC cake was obtained. Resulting Al₂O₃ grains were arranged in a 3D honeycomb structure and the SiC particles were surrounded by the alumina grains. Consequently, homogeneous powder mixing and porosity distribution were obtained within the cake. The morphology of the powder connections was networking with flake like particles. These alumina particles resulted in large amounts of porosity which was desired for ceramic preforms to allow liquid metal flow during infiltration. The resulting high porous ceramic cake (preform) was placed in a sealed die and liquid aluminium was infiltrated by Ar pressure. The infiltration was achieved successfully and microstructures of the composites were examined.     

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.     

Preparation and properties of nano-SiCp/A356 composites synthesised with a new process

Nano-SiC_p reinforced A356 aluminium alloy composites were prepared by solid–liquid mixed casting. Nano-SiC particles 40?nm in diameter were pre-oxidised at 850°C. Millimetre-sized composite granules were then fabricated by milling a mixture of nano-SiC_p and Al powders, and then remelting to form an alloy melt, which was treated by mechanical stirring and ultrasonic vibration to prepare the composites. Results showed that nano-SiC particles were dispersed pretty well within the matrix and no serious agglomeration was observed. As the weight fraction of SiC_p increased, the tensile strength, yield strength and elongation of the composites increased as well, by 22%, 62% and 24%, respectively, when compared to A356 alloy with 2wt-% nano-SiC_p.     

Processing of Al–SiCp Metal Matrix Composites by Pressureless Infiltration of SiCp Preforms

An optimum method for producing Al-SiC_p metal matrix composites was developed by determining the optimum conditions for wetting SiC by aluminum and the optimum parameters for pressureless infiltration of SiC_p preforms. The quantitative effect of magnesium and silicon additions to aluminum, free silicon on the SiC substrate, nitrogen gas in the atmosphere, and process temperature on the wetting characteristics of SiC by aluminum alloys was investigated using the sessile drop technique. The contribution of each of these parameters and their interactions, in terms of a relative power, to the contact angle, surface tension, and driving force for wetting were determined. In addition, an optimized process for enhanced wetting was suggested and validated. The optimum conditions for wetting SiC by aluminum that were arrived at were used to infiltrate SiC_p preforms and the mechanical properties of the resulting metal matrix composites were measured. The effect of SiC particle size, infiltration time, preform height, vol.% SiC in the preform, and Si coating on the SiC particles on the pressureless infiltration of SiC_p compacts with aluminum was investigated and quantified. The contribution of each of these parameters and their interactions to the retained porosity in the composite, the modulus of elasticity, and the modulus of rupture were determined. Under optimum infiltration conditions, metal matrix composites with less than 3% porosity, over 200 GPa modulus of elasticity, and about 300 MPa modulus of rupture were routinely produced.     

Phase distribution and associated mechanical property distribution in silicon carbide particle-reinforced aluminium fabricated by liquid metal infiltration

The reaction between silicon carbide and aluminium to form silicon and Al₄C₃ in SiC particle-reinforced aluminium fabricated by liquid aluminium infiltration was most severe near the original interface between liquid aluminium and the SiC preform. This resulted in the highest concentration of Al₄C₃ and the lowest concentrations of silicon and SiC in the part of the composite near this interface. In particular, the silicon concentration was highest in the bottom centre of the composite when infiltration occurred from the top, because silicon diffused toward the surrounding aluminium melt before solidification. These non-uniform phase distributions, as measured by X-ray diffraction and differential scanning calorimetry, did not cause any non-uniform shear strength distribution. However, excessive reaction between SiC and aluminium, as observed for an infiltration (=mould=liquid metal) temperature of 780° C, caused the tensile strength to decrease. In the case where a steel mould was used during infiltration at 780° C, iron-containing precipitates, such as ternary Al-Fe-Si, were observed in the part of the composite within 5 mm from the above-mentioned interface; their formation was related to the silicon out-diffusion in the form of liquid Al-Si; they caused the shear strength to be lower in this part of the composite; larger such precipitates (up to 100 m) were observed in the excess aluminium adjacent to the cast composite. For pure aluminium as the infiltrating metal, the optimum infiltration temperature for the highest tensile strength was 700° C. An infiltration temperature of 670° C resulted in incomplete infiltration, which was more severe when a steel mould rather than a graphite mould was used because of the higher thermal conductivity of the former.     

Casting particulate and fibrous metal-matrix composites by vacuum infiltration of a liquid metal under an inert gas pressure

A new method of making metal-matrix composites is reported. This method combines the essentials of three liquid-phase fabrication methods: (i) vacuum infiltration, (ii) infiltration under an inert gas pressure, and (iii) squeeze casting. In this method, the particulate or fibrous preform is placed in a mould and the matrix alloy is placed above the preform. The matrix alloy is heated to the liquidus temperature together with the mould and the preform under vacuum. Then an inert gas like argon is compressed on to the top surface of the matrix-alloy melt, forcing the melt to infiltrate the preform. The pressure is 1000 to 2500 psi. As the melt is just at liquidus temperature, it is much lower than that used in squeeze casting. Moreover, the pressure is an order of magnitude lower than that used in squeeze casting. The low temperature lessens the interfacial reaction between the matrix and the filler, while the low pressure essentially eliminates preform compression. This method has been successfully used to fabricate aluminium-matrix composites reinforced by short ceramic fibres, continuous ceramic fibres, SiC particles, Al₂O₃ particles, graphite flakes and SiC whiskers.     

Microstructure, mechanical properties and reaction mechanism of KD-1 SiCf/SiC composites fabricated by chemical vapor infiltration and vapor silicon infiltration

Three-dimensional (3D) KD-1 silicon carbide fiber reinforced silicon carbide matrix (KD-1 SiC_f/SiC) composites were fabricated by a combining chemical vapor infiltration (CVI) and vapor silicon infiltration (VSI) process. The microstructure and mechanical properties of the resulting KD-1 SiC_f/SiC composites were studied. The results show that the resulting SiC_f/SiC composites have high bulk density and low open porosity (<6%). The mechanical properties of the resulting SiC_f/SiC composites firstly increase and then decrease with decreasing the open porosity of the SiC_f/C composites. The KD-1 SiC fibers were not severely deformed and adhered to the matrix with a weak interface during the VSI process. As a result, the composites exhibit non-catastrophic failure behavior. Additionally, the diffusion mechanism for the VSI process was also investigated in our work.     

Fabrication of an electronic package box of SiCP/Al composites with high volume SiCP

In this paper, a SiC_P preform was prepared by Powder Injection Molding (PIM), and the melting aluminum was injected into the SiC_P preform by the pressure infiltration method to manufacture an electronic package box of SiC_P (65%)/Al composites. SiC_P (65%)/Al composite prepared by pressure infiltration has full density and a homogeneous microstructure. The relative density of the composite is higher than 99%, the thermal expansion coefficient and thermal conductivity of the composite are 8.0×10⁻⁶/K and nearly 130 W/(m · K) at room temperature, respectively, which meet the requirements of electronic packaging. Translated from Journal of Acta Materiae Compositae Sinica, 2006, 23(6): 109–113 (in Chinese)     

Superior high-temperature resistance of aluminium nitride particle-reinforced aluminium compared to silicon carbide or alumina particle-reinforced aluminium

Aluminium-matrix composites containing AlN, SiC or Al₂O₃ particles were fabricated by vacuum infiltration of liquid aluminium into a porous particulate preform under an argon pressure of up to 41 MPa. Al/AlN had similar tensile strengths and higher ductility compared to Al/SiC of similar reinforcement volume fractions at room temperature, but exhibited higher tensile strength arid higher ductility at 300–400 °C and at room temperature after heating at 600 °C for 10–20 days. The ductility of Al/AIN increased with increasing temperature from 22–400 °C, while that of Al/SiC did not change with temperature. At 400 °C, Al/AlN exhibited mainly ductile fracture, whereas Al/SiC exhibited brittle fracture due to particle decohesion. Moreover, Al/AlN exhibited greater resistance to compressive deformation at 525 °C than Al/SiC. The superior high-temperature resistance of Al/AlN is attributed to the lack of a reaction between aluminium and AlN, in contrast to the reaction between aluminium and SiC in Al/SiC. By using Al-20Si-5Mg rather than aluminium as the matrix, the reaction between aluminium and SiC was arrested, resulting in no change in the tensile properties after heating at 500 °C for 20 days. However, the use of Al-20Si-5Mg instead of aluminium as the matrix caused the strength and ductility to decrease by 30% and 70%, respectively, due to the brittleness of Al-20Si-5Mg. Therefore, the use of AIN instead of SiC as the reinforcement is a better way to avoid the filler-matrix reaction. Al/Al₂O₃ had lower room-temperature tensile strength and ductility compared to both Al/AlN and Al/SiC of similar reinforcement volume fractions, both before and after heating at 600 °C for 10–20 days. Al/Al₂O₃ exhibited brittle fracture even at room temperature, due to incomplete infiltration resulting from Al₂O₃ particle clustering.     

高体积分数SiCp/A356复合材料的显微组织和电导率

铝基复合材料在电子封装领域存在着潜在的应用前景。为获得高体积分数的铝基复合材料,利用压力浸渗法制备了高体积分数SiC颗粒增强A356复合材料(SiC_p/A356),通过金相显微镜、XRD、SEM和EDS等分析手段对其物相、显微结构和电导率进行了表征。结果表明:用该方法制备的SiC_p/A356复合材料组织致密,颗粒分布均匀,界面结合性能较好;SiC增强颗粒与A356基体界面反应控制良好,仅有少量Al4C3脆性相生成。SiC粉体经颗粒表面氧化处理在其表面生成一层SiO_2薄膜,虽抑制了界面反应的发生,但也使复合材料的收缩减小,电阻率增大,导电性能变差。     

Influence of atmosphere and carbon contamination on activated pressureless infiltration of alumina–steel composites

Al₂O₃/steel metal–matrix composites (MMCs) were fabricated by activated pressureless infiltration at atmospheric pressure in different gas atmospheres; N₂, Ar and Ar–5%H₂. The infiltration quality was evaluated with examination of the microstructure, infiltrated area and remaining porosity. The atmosphere with the best infiltration quality was chosen for improvement of infiltration by varying infiltration parameters such as temperature, holding time and heating and cooling rates. Further improvement was achieved by addition of Si or SiO₂ powder to the preform in order to reduce the effect of the residual carbon. The results show that the activated melt infiltration can be successfully done at atmospheric pressure in inert gas.     

Densification and microstructural evolution during laser sintering of A356/SiC composite powders

This article reports experimental results on laser sintering of A356 aluminum alloy and A356/SiC composite powders. Effects of scan rate, sintering atmosphere, hatch spacing, and SiC volume fraction (up to 20%), and particle size (7 and 17 μm) on the densification were studied. The phase formation and microstructural development were analyzed by X-ray diffraction (XRD) and scanning electron microscopy (SEM) coupled with energy-dispersive X-ray spectroscopy (EDS). Laser sintering under argon atmosphere exhibited higher densification compared to nitrogen. A faster sintering kinetics was observed as the scan rate decreased. Except at a low SiC content (5 vol%), the composite powders exhibited lower densification kinetics. The densification was improved when finer SiC particles were utilized. Microstructural studies revealed directional solidification of aluminum melt to form columnar grains with inter-columnar silicon precipitates. In the presence of SiC particles, aluminum melt reacted with the ceramic particles to form Al₄SiC₄ plates.     

Interfacial Thermal Resistance and the Solidification Behavior of the Al/SiCp Composites

The objective of this investigation is to study the effects of applied pressure on the solidification time and interfacial thermal resistance of A356/10% SiC_p during squeeze casting. Samples were prepared for various but constant squeeze pressures up to 130 MPa while maintaining the melt and mold temperatures at 800°C and 400°C, respectively. It was observed that the solidification time was 60 s when no squeeze pressure was applied but it decreased to 42 s when the squeeze pressure was maintained at 130 MPa. The results also showed that the cooling rate increased with squeeze pressure. The solidification time calculated from one-dimensional heat flow theory was found to be close to that obtained from the experimental cooling curves. The interfacial thermal resistance between the mold and the casting was calculated and it decreases when the squeeze pressure increases.     

The effects of magnesium additions on the structure and properties of Al-7 Si-10 SiCp composites

The additions of magnesium to an aluminium alloy matrix, which contains insufficient magnesium, was found to be essential during the synthesis of composites by the stir-casting technique. Magnesium promotes interfacial wetting between the dispersoid surface and the matrix. Dispersion of SiC_p in Al-7 Si-0.3 Mg (356) alloy matrix without agglomeration and rejection was not possible. Hence, the addition of up to 3 wt% Mg was made to the alloy matrix during the dispersion of 10 wt% SiC_p (34 m), and the microstructure and mechanical properties of the composites were investigated with a view to optimize the magnesium content. With a magnesium content less than 1 wt% in the matrix, the SiC_p particles were essentially in agglomerated form. The highest UTS of 280–300 MPa was obtained with 1 wt% Mg content and SiC_p was uniformly distributed in the matrix. A higher magnesium content (>1.0 wt%) did not further improve the uniformity in the dispersion of SiC_p but the ultimate tensile strength properties deteriorated. This decrease in strength was attributed to the observed coarseness of the Mg₂Si phase, the precipitation of Mg₅Al₈ phase and the presence of a higher amount of porosity in the composites in the heat-treated condition. The aspect ratio (length/width) of precipitates changed from 1–3 for 1% Mg to 3–9 for 3.2% Mg in the matrix. Corresponding values for per cent porosity were 2% and 6%, respectively.     

Fabrication of SiCf/SiC composites by chemical vapor infiltration and vapor silicon infiltration

Three-dimensional (3D) silicon carbide fiber reinforced silicon carbide matrix (SiC_f/SiC) composites, employing KD-1 SiC fibers (from National University of Defense Technology, China) as reinforcements, were fabricated by a combining chemical vapor infiltration (CVI) and vapor silicon infiltration (VSI) process. The microstructure and properties of the as prepared SiC_f/SiC composites were studied. The results show that the density and open porosity of the as prepared SiC_f/SiC composites are 2.1 g/cm³ and 7.7%, respectively. The SiC fibers are not severely damaged during the VSI process. And the SiC fibers adhere to the matrix with a weak interface, therefore the SiC_f/SiC composites exhibit non-catastrophic failure behavior with the flexural strength of 270 MPa, fracture toughness of 11.4 MPa·m^1/2 and shear strength of 25.7 MPa at ambient conditions. Moreover, the flexural strength decreases sharply at the temperature higher than 1200 °C. In addition, the thermal conductivity is 10.6 W/mk at room temperature.     

Properties of SiCf/SiC composites fabricated by slurry infiltration and hot pressing

Abstract

Two-dimensional SiC fibre reinforced SiC ceramic matrix composites (SiC_f/SiC) were fabricated by vacuum infiltration and hot pressing using a 200 nm thick pyrolytic carbon coated Tyranno SA3 fabric and 50 nm sized β-SiC powder. Hot pressing was carried out at 1750°C for 3 h in an Ar atmosphere under a pressure of 20 MPa. Al₂O₃–Y₂O₃–MgO sintering additive (10 wt-%) and polyvinyl butyral resin (45 wt-%) with respect to the matrix SiC were found to be the optimum contents for the high density composite. Vacuum infiltration with a force gradient produced much higher amount of slurry infiltration than simple dipping. Much improved density of 3·02 g cm^?3, compared to the previous reports, was achieved for the SiC–SiC_f containing approximately 67 vol.-% of fibre. This composite showed a step increase with a stress–displacement behaviour during the three-point bending test due to the fibre reinforcement. The displacement for failure and flexural strength were 0·58 mm and 342 MPa respectively, which were much larger than those for monolithic SiC.     

Studies on machinability of Al/Si<Subscript>p</Subscript> + SiC<Subscript>p</Subscript> composite materials

This paper presents the experimental results on the machinability of silicon and silicon carbide particles (SiC_p) reinforced aluminium matrix composites (Al/Si_p + SiC_p) during milling process using a carbide tool. The total volume fraction of the reinforcements is 65 vol%. The milling forces, flank wear of the tool and the machined surface quality of composites with different volume fraction of SiC_p were measured during experiments. The machined surfaces of composites were examined through SEM. The results showed that the flexural strength and Vickers hardness are improved when certain volume fraction of silicon particles are replaced by silicon carbide particles with the same volume fraction and particle size and the effect of SiC_p on machinability is optimal when 9 vol% silicon particles in Al/Si_p was replaced by silicon carbide particles with the same volume fraction and the same particle size. Cracks and pits were found on the machined surfaces of composites due to the intrinsic brittleness of silicon particles.