Thixoforming of a novel layered metal matrix composite

Abstract

Thixoforming is a semisolid processing route capable of producing near net shape components with low levels of porosity in a single, rapid operation. It has potential for the processing of aluminium alloy based metal matrix composites (MMCs). In contrast with casting of fully liquid metal, the flow of material into the die in thixoforming is primarily laminar. Thus, a novel layered MMC structure, generated by spray forming, consisting of alternate lamellae of reinforced and unreinforced alloy, might be preserved in thixoforming. The laminated structure is intended to give an increase in toughness, compared to a homogeneously reinforced material. The material was produced by spray forming alternate layers of aluminium matrix alloy 2014 (Al–4Cu–0·8Si–0·8Mn–0·5Mg) and matrix alloy reinforced with ∼17 vol.%SiC particles. Following thixoforming, the layered structure was well preserved with good retention of layer integrity and arrangement. Impact measurements for estimating toughness (Charpy and Izod) showed limited improvement with the layered materials, relative to homogeneously reinforced ones. However, in slow crack growth (Tattersall–Tappin tests), toughness was nearly doubled when estimated in terms of an average energy of fracture from the area below the load–crosshead displacement curve. This was attributed to the reduction in the energy of the propagating crack at low strain rates, which led to a greater potential for the structure, and in particular for the unreinforced layer, to stop or slow the crack. Additionally, these layered MMC materials have provided a striking record of the die filling behaviour for metallic materials during thixoforming. The flow pattern is akin to that in conventional hot forging. This may assist in the establishment of design rules for thixoforming dies.