Squeeze-casting conditions of Al/Al2O3 metal matrix composites with variations of the preform drying process

The characteristics of the preform play a role in determining the final properties of MMCs. Effects of organic binder and microwave drying on preform microstructure have been examined by SEM. In the preform with organic binder, flocking processes are observed during drying. The preform has a uniform distribution of binder and dries quickly with microwave drying owing to its internal and volumetric heating patterns. The fundamental manufacturing process and controlling parameters of squeeze casting, including preform temperature, mould temperature, applied pressure and molten metal temperature, have been studied in Al/Al₂O₃ composites. MMCs have poor mechanical properties with too high temperatures of preform and molten metal due to thermal shocking of the preform, oxidation of the matrix and thermal damage to the fibers. Mould temperature barely affects the tensile strength of MMCs. High applied pressure reduces voids and solidifies the matrix faster. Conditions for squeeze casting to achieve optimal processing, are suggested. The tensile strength of MMCs can be improved by up to about 20% compared with the unreinforced matrix alloy.     

Void formation in metal matrix composites by solidification and shrinkage of an AlSi7 matrix between densely packed particles

Particle reinforced metals are developed as heat sink materials for advanced thermal management applications. Metal matrix composites combine the high thermal conductivity of a metal with a low coefficient of thermal expansion of ceramic reinforcements. SiC and carbon diamond particle reinforced aluminum offer suitable thermal properties for heat sink applications. These composites are produced by liquid metal infiltration of a densely packed particle preform. Wettability, interface bonding strength and thermal mismatch are critical for void formation which leads to thermal fatigue damage under operation. The evolution of voids in AlSiC and AlCD has been studied by in-situ high resolution synchrotron tomography during matrix solidification. Large irregularly shaped matrix voids form during eutectic solidification. These voids help alleviate thermal expansion mismatch stresses by visco-plastic matrix deformation during cooling to RT after solidification, if sufficient interface bonding strength is assumed.     

Fabrication process of carbon nanotube/light metal matrix composites by squeeze casting

Multi-walled carbon nanotubes (MWCNTs) should be attractive for the reinforcement of metal-matrix composites, because of their high strength, high modulus and high thermal conductivity. However, the fiber diameter of MWCNTs is hundreds of times smaller than that of carbon fiber. This causes difficulty in infiltration into the MWCNT preform. Moreover, the threshold pressure which was applied to the preform will cause preform deformation. Therefore, knowledge of preform compressive properties which are the buckling strength and elastic modulus are necessary to fabricate the composites. In this study, at first, wettability of the basal plane of graphite by molten aluminum or magnesium was measured using the sessile drop method. Moreover, trial fabrication of MWCNT-reinforced aluminum or magnesium alloy composites was carried out by squeeze casting. As a result, these composites were fully infiltrated. An order-of-magnitude agreement was found between the estimated threshold pressure and the applied infiltration pressure to the MWCNT preform.     

Numerical Simulation of Unidirectional Infiltration of Silicon Carbide Preforms

Mathematical model of unidirectional infiltration was set up and metal infiltration velocity and temperature fields of the metal, preform, and composites were calculated using the finite difference method. The metal infiltration velocity has a close relationship with infiltration time. It is very large after the infiltration begins in a few seconds, then the velocity keeps almost constant. The temperature field of the composite proves that metal matrix composites (M MCs) after unidirectional pressure infiltration can solidify from the entrance of the preform to the infiltration front, which is useful for obtaining the MMCS with low porosity and high properties.     

Characterization of metal-matrix composites fabricated by vacuum infiltration of a liquid metal under an inert gas pressure

Silicon carbide whisker-reinforced aluminium was fabricated by vacuum infiltration of liquid aluminium into a porous whisker preform under an argon gas pressure, using an infiltration temperature of 665 °C. The volume fraction of whiskers ranged from 11% to 37%. No whisker pull-out was observed on the fracture surface for an infiltration temperature of 665 °C, but some whisker pull-out was observed for an infiltration temperature of 720 °C. Both the tensile strength and ductility decreased with increasing infiltration temperature above 665 °C. Tensile test results from room temperature to 300 °C are reported. They showed that the quality of these composites was comparable to that of composites made by powder metallurgy or squeeze casting. The coefficient of thermal expansion at 100–150 °C was decreased by 45% by the addition of 37 vol % whiskers.     

Numerical simulation of metal matrix composites and polymer matrix composites processing by infiltration: a review

The injection of a liquid metal through a fibrous preform is one of the techniques used to manufacture metal matrix composites (MMCs). The flow of metal through fibrous preform is a problem of fluid mechanics in porous medium. Numerical simulations of this process were developed in particular for non-isothermal infiltrations which take into account the phenomena of phase change. In addition, numerical models were developed to predict the appearance of defects in the end product and to study the evolution of the deformation of the fibrous preform during metal infiltration. After pointing out the analogous numerical studies devoted to the Resin Transfer Moulding (RTM) process, we give a progress report on the models developed to date for MMCs.     

SiCp/Al Composites Fabricated by Modified Squeeze Casting Technique

A cost effective method was introduced to fabricate pure aluminum matrix composites reinforced with 20% volume fraction of 3.5 μm SiC particles by squeeze casting followed by hot extrusion. In order to lower volume fraction of the composites, a mixed preform containing pure aluminum powder and the SiC particles was used. The suitable processing parameters for the infiltration of pure aluminum melt into the mixed preform are： melt temperature 800℃, preform temperature 500℃, infiltration pressure 5 MPa, and solidification pressure 50 MPa. Microstructure and properties of the composites in both as-cast and hot extruded states were investigated. The results indicate that hot extrusion can obviously improve the mechanical properties of the composite.     

Fabrication of gradient distribution alumina short fibre reinforced aluminium alloy

Gradient distribution alumina short fibre reinforced 6061 aluminium alloy have been fabricated by taking advantage of preform compressive deformation during squeeze casting. Pressure was applied mechanically by a punch. Velocity of the punch, pre-heat temperature of the preforms and pouring temperature were controlled during the infiltration of molten 6061 alloy into alumina short fibre preforms. The distribution of hardness along the infiltration direction in the composites was measured and the distribution of volume fraction along the infiltration direction was calculated by the hardness. Velocity of the inflow, pre-heat temperature of the preform, pouring temperature of the molten metal, binder content of the preform and volume fraction of fibres, all have a very great effect on the gradient distribution of alumina short fibres in the aluminium alloy composites.     

挤压铸造硼酸铝晶须增强Al基复合材料浸渗过程理论分析

本文作者采用挤压铸造法,制取了硼酸铝晶须增强Al基复合材料,并根据Laplace方程及多孔体的渗流物理基本原理,从多孔渗流动力学角度分析了挤压浸渗过程中金属液在多孔体中的流动,认为紊流才是其主要的表现形式。并较详细地分析了晶须长度对预制件孔结构及浸渗的影响。     

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.     

用K2ZrF6溶液处理碳化硅涂层碳纤维制造碳/铝复合丝

在碳纤维表面用CVD法涂覆碳化硅涂层,接着用K₂ZrF₆溶液处理,干燥后通过700℃的熔融铝制得碳/铝复合丝。复合丝的强度约为复合准则强度的70%。当碳纤维的体积分数为54%时,复合丝的强度达到1200MPa。用扫描电镜观察复合丝的断口发现界面结合状态良好。用X射线衍射分析了碳化硅-K₂ZrF₆一铝在高温下的反应情况,表明K₂ZrF₆的良好的改善润湿的作用是由于它与铝和碳化硅之间发生了强烈的化学反应。     

注射条件对LCM工艺非饱和流动特性影响

双尺度多孔纤维预制体填充过程中延迟浸润的非饱和流动现象,对基于树脂流过区域为完全饱和区域的充模理论及模拟方法提出了挑战。通过控制体/有限单元（CV/FE）法结合沉浸函数实现了液体模塑成型工艺（LCM）中非饱和填充浸润的数值模拟,并对比了恒压下的实验结果,验证了其可靠性。分析讨论了注射口压力、流量和液体黏度对双尺度多孔纤维织物非饱和填充浸润特性的影响。结果表明:在允许误差内,该数值模拟结果可靠,可用于分析讨论各因素对双尺度多孔织物非饱和流动特性的影响;填充浸润过程中,纤维织物内部非饱和区域长度并非保持不变,而是随着填充浸润的进行经历了4个变化过程;不同注射条件下,压力、流量及黏度对非饱和流动特性影响不同。研究结果对合理控制注射条件及流体特性实现双尺度多孔纤维预制件的完全浸润具有指导意义。      

Analysis and minimization of void formation during resin transfer molding process

In the resin transfer molding process, residual air in the pores of fiber preform results in dry spots and microvoids in the finished product. The dry spots are usually formed due to irregular permeability of fiber mat and improper injection locations. The microvoids result from non-uniform microarchitecture of the fiber preform, and they are transported through the gap between fiber tows during infiltration of the resin. In this study, a real-time simulation/control method was proposed to actively control the formation and the transport of air voids during the mold filling. The flow equations were solved in real time to predict the change of the flow front shape. The flow front was detected by optical sensors and the control actions were taken based on the sensor signals. Through this automated simulation/control scheme, a real-time control of resin flow could effectively avoid the dry spots and minimize the formation of microvoids by modulating the injection pressure.     

PROCESSING OF METAL AND CERAMIC MATRIX COMPOSITES WITH THREE-DIMENSIONAL BRAIDED REINFORCEMENT

This paper summarizes some of the pioneering work done in developing the processing techniques to consolidate metal and ceramic matrix composites with 3-D braided fiber architecture. The 3-D braided fiber architecture features a fully integrated structure with multidirectional reinforcement and allows for the braiding of complex shapes. For metal matrix composite, a 3-D braided AI₂O₃ fibers preform reinforced Al-Li matrix composite has been successfully fabricated by liquid vacuum infiltration methods. For ceramic matrix composites, chemical vapor infiltration technique has been used to densify a 3-D braided Nicalon fibers preform with SiC matrix composite. A significant improvement in composite performance can be achieved through the architecture of 3-D integrated reinforcement geometry. The future needs and directions for developing viable methods for fabricating strong, tough high temperature composites with 3-D reinforcements is also discussed.     

Low-volume-fraction particulate preforms for making metal-matrix composites by liquid metal infiltration

A preform technology for making particulate metal-matrix composites with a low particulate volume fraction (as low as 18%) by liquid metal infiltration is provided. This technology used a non-combustible reinforcement (SiC) as the primary particulate and combustible particles (carbon) as the secondary particulate in the preform. The secondary particulate was removed from the preform by oxidation prior to liquid metal infiltration.     

纤维初始构形对金属基复合材料微观组织的影响

研究了束簇纤维预制型中纤维束内原丝自然分布、框架涂层结构和颗粒混杂三种初始形对液相浸渗效果及微观组织的作用，实验发现：纤维自然排布时浸渗缺陷的存在是必然的，浸渗压力的提高只能减小而不能完全消除该缺陷；采用框架结构涂层首先填充预制型中细小尖角空隙后，可在较低的压力下实现完全浸渗；颗粒与纤维的混杂使纤维相互分离，消除了细小空隙而使纤维束内完整充填；与框架结构相比，混杂后浸渗形成的复合材料中纤维相互分离     

Acoustic emission for in situ monitoring in metal-matrix composite processing

The attractive elevated-temperature properties of metal-matrix composities (MMCs) have not been exploited in commercial applications partly because of the high processing cost and lack of reliability in fabrication. In this exploratory study, the feasibility of using acoustic emission (AE) as an in-process, non-destructive quality control technique is examined. A variation of the squeeze casting technique is selected for investigation. Acoustic emission is employed with the intent of non-intrusively establishing whether complete infiltration has occurred during composite fabrication. The problems due to the background noise during AE monitoring are overcome by using transducers with different frequency responses. The acoustic signatures of machine noise, preform crushing and metal solidification are obtained by employing suitable transducers in a series of tests that systematically evaluate the individual processes that comprise infiltration casting. The results form a strong basis for the development of an in situ AE sensor for the infiltration process.     

Stability of nickel coatings on carbon fiber preforms: A SEM investigation

Metal Matrix Composites (MMC's) reinforced with continuous fibers were generally fabricated by a foil-sandwich technique or by liquid metal infiltration. Liquid metal infiltration may be used to cast final shapes in molds containing fiber preforms. It is also used to make composite wire from which may be fabricated panels and shapes by hot-press diffusion bonding or pultrusion. The major drawback of this method is that the molten matrix must wet the fiber for successful infiltration to occur, requiring special fiber surface treatments or matrix additives, and that, molten metals generally dissolve or degrade the fibers, necessitating a barrier coating on the fibers. All these problems can be solved using carbon fibers coated with metallic layers, e.g. nickel. This work analyses an easy method to produce modified carbon fibers by electroplating and the process of its recristallization. The topography of the growth front of the deposit has been studied. At temperatures higher than about 300° C an annealing under vacuum is required, because of the high reactivity of metal coating, nevertheless the heat treatment of metal deposit produces always an embrittled material.     

Retention of mechanical performance of polymer matrix composites above the glass transition temperature by vascular cooling

An actively cooled vascular polymer matrix composite containing 3.0% channel volume fraction retains greater than 90% flexural stiffness when exposed continuously to 325 °C environmental temperature. Non-cooled controls suffered complete structural failure through thermal degradation under the same conditions. Glass–epoxy composites (T_g = 152 °C) manufactured by vacuum assisted resin transfer molding contain microchannel networks of two different architectures optimized for thermal and mechanical performance. Microchannels are fabricated by vaporization of poly(lactide) fibers treated with tin(II) oxalate catalyst that are incorporated into the fiber preform prior to resin infiltration. Flexural modulus, material temperature, and heat removal rates are measured during four-point bending testing as a function of environmental temperature and coolant flow rate. Simulations validate experimental measurements and provide insight into the thermal behavior. Vascular specimens with only 1.5% channel volume fraction centered at the neutral bending axis also retained over 80% flexural stiffness at 325 °C environmental temperature.