Alloy Composite Materials Research Articles

Quasi-static and dynamic mechanical properties of interpenetrating zirconia-toughened alumina-aluminum alloy composite material

Interpenetrating zirconia-toughened alumina-aluminum alloy composite material (3D-ZTA/Al) was prepared, using a combined material extrusion and pressureless infiltration method. The analysis focused on the microstructure of 3D-ZTA/Al and variations in interface microhardness, along with its compression behaviors (from 226.7 to 668.3 MPa) from the perspective of experimentation and simulation, which revealed energy absorption mechanisms. Meanwhile, 3D-ZTA/Al with three types of interpenetrating structures all exhibit “J”-shaped crack propagation curves. The fracture energy of 3D-ZTA/Al prepared in this work ranges from 3.99 to 28.80 kJ·m−2 as the crack expands, and the energy absorption reaches 43.8 MJ·m−3 at impact speeds of ∼ 12 m/s. Among the three interpenetrating structures, the helicoidal structure exhibiting the highest JR-integral resistance to cracks and the lowest transmission impulse.

Microstructure and Corrosion Resistance of 7075 Aluminium Alloy Composite Material Obtained from Chips in the High-Energy Ball Milling Process.

The high-energy ball milling process was applied to fabricate a composite material from 7075 aluminium alloy milling chips, silicon carbide, and titanium dioxide powders. Raw materials were ground, and the obtained powders were cold pressed and sintered. It was demonstrated that this method can be used in the recycling of aluminium alloy scrap characterised by a high surface-to-volume ratio, and also that chemical removal of the oxide layer from chips is not necessary. The finest particles, with 50 vol.% of their population below 36 μm, were obtained after grinding for 60 min at a 1000 rpm rotational speed. Such an intensive grinding was necessary to fabricate the compact composite material with a homogeneous microstructure and a low porosity of 0.7%. The corrosion resistance of the composites was studied in 3.5 wt.% NaCl solution using cyclic voltammetry and electrochemical impedance spectroscopy, and corrosion rates in the range of ca. 342 and 3 μA∙cm-2 were obtained. The corrosion mechanism includes aluminium alloy dissolution at the matrix/reinforcement interphase and around intermetallic particles localised within the matrix grains.

Research on the Structural Design of a Pressurized Cabin for Civil High-Speed Rotorcraft and the Multi-Dimensional Comprehensive Evaluation Method

For civil high-speed rotorcraft designed to operate at specific cruising altitudes, this study proposes nine structural design schemes for pressurized cabins. These schemes integrate commonly used materials and processing technologies in the aviation industry with advanced PRSEUS (Pultruded Rod Stitched Efficient Unitized Structure) technology. An analysis of the structural composition reveals that frames constitute 8–19% of the total structural weight, while stringers and beams make up 15–50%, and skins account for 11–25%, with thicknesses ranging from 1.0 mm to 2.0 mm. The separating interface of the pressurized cabin contributes 4–29% of the total structural weight. The weight distribution of each component in the pressurized cabin structure varies significantly depending on the chosen materials and processing technologies. Utilizing the Analytic Hierarchy Process (AHP), along with Gray Relational Analysis (GRA) and Dempster–Shafer (D-S) evidence theory, this study compares the simulation results of the nine schemes across multiple dimensions. The findings indicate that the configuration combining 7075 aluminum alloy and T300 composite material has the greatest advantages in terms of the high structural reliability of the configuration, light weight, mature processing technology, and low production cost. This comprehensive evaluation method quantitatively analyzes the factors influencing the structural configuration design of the pressurized cabin for civil high-speed rotorcraft, offering a valuable reference for the design of similar structures in related fields.

Microstructure and mechanical properties of ZrB2 ceramic particle reinforced AlCoCrFeNi high entropy alloy composite materials prepared by spark plasma sintering

In this study, xZrB2-AlCoCrFeNi (x = 0,5,10,15) (wt%) based high entropy alloy (HEA) composites were prepared by Spark Plasma Sintering (SPS). The influence of ceramic particle ZrB2 content on the densification behavior, microstructural evolution, and mechanical properties of the composites was investigated through scanning electron microscopy, X-ray diffraction, and mechanical performance testing. The results indicate that the HEA composites undergo a phase transformation, from (FCC + BCC + B2) structure to (FCC + BCC + B2+Laves) structure with the addition of ZrB2. The incorporation of ZrB2 facilitates the emergence of the Cr precipitate phase, and the grain size of this phase enlarges as the ZrB2 content rises. Additionally, when the ZrB2 content is 10 %, the maximum compressive strength reached 2071 MPa. Furthermore, at the ZrB2 content of 15 %, the composite material achieves a maximum densification of 99.13 % and a maximum hardness of 1222.2 HV.

Feasibility study of an integrated pre‐curing and forming process for 6061 Al alloy and carbon fiber hybrid composites

AbstractThis article proposes a 6061‐T6 Al alloy and carbon fiber hybrid composite material pre‐curing and forming integrated new process, which can significantly reduce the hybrid composite material processing time, improve the production efficiency, and provide the possibility of hybrid composite materials in automotive parts applications. The process started by placing hand‐stacked carbon fiber reinforced plastic (CFRP) composites on the surface of 6061 Al alloy sheets, followed by bonding and pre‐curing of the CFRP to the Al alloy sheets through two different sets of dies in a hydraulic press, and ultimately full curing in an aging furnace. Mechanical properties of the CFRP/Al hybrid composite material were measured by flexural tests. The results show that the flexural strength of CFRP/Al hybrid composites with different layups ([90]12, [0/45/90/−45]3, and [0]12) was increased by 159%, 93.4%, and 67.9%, respectively, compared with the single 6061 Al alloy. According to the macro‐morphological observation, [90]12 lay‐up parts have the least thinning. According to the microstructure observation, no obvious cracks or voids were found in the [90]12 lay‐up parts. Elongated cracks and void defects could be found in the [0]12 lay‐up parts. For the [0/45/90/−45]3 lay‐up parts, voids are mainly exist in ±45°layups. The results of the spring‐back analysis show that the standard deviation of the formed parts obtained from the three lay‐up methods is within 1 mm, indicating that the forming effect is good.Highlights New process improves productivity and reduces production costs The flexural strength of CFRP/Al hybrid parts is greatly improved [90]°12 lay‐up parts have the least thinning and no cracks were found The forming precision of the three lay‐up parts is good

Fabrication and investigation of microstructural, mechanical and wear properties of in situ ZrB2/fly ash/AA7075 hybrid composite

This research explores the microstructural, mechanical and wear characteristics of hybrid aluminum metal matrix composites (HAMMCs). Initially ZrB2 is fabricated by melt reaction and then fly ash incorporated into the aluminum composite melt as secondary reinforcements to fabricate HAMMCs through the ultrasonic agitated stir casting method. Micrographic and phase analysis of the HAMMCs and base alloy is conducted x-ray Diffraction (XRD), and Energy-Dispersive x-ray Spectroscopy (EDS). A wear test was conducted to study the wear properties of alloy and hybrid composite material. The generated wear scar was analyzed using a profilometer to find the wear rate. The tensile strength and hardness of the hybrid aluminum metal matrix composites (HAMMCs) improved remarkably as compared to base alloy. The wear resistance of the fabricated composite also increases on increasing the in situ ZrB2 up to 3 weight fractions.

Friction and wear performance of aluminum-based self-lubricating materials derived from the 3D printed graphite skeletons with different morphologies and orientations

Using selective laser sintering 3D printing, this study shapes graphite in sphere, flake, and fiber morphologies into skeletons with various orientations. These skeletons are then used to create graphite/aluminum alloy composite self-lubricating materials. The results show that graphite morphology and orientation greatly affect the friction and wear properties of these composites. Graphite fiber exhibits the worst friction and wear performance. Perpendicular flake graphite forms a uniform, continuous lubricating film with high thermal conductivity for heat dissipation, preventing severe wear. Spherical graphite modifies the friction surface, achieving the lowest friction coefficient (0.2 ± 0.02) and wear rate (6.64 ×10−4 mm3/Nm) due to protective film, filling, and ball bearing effects.

Synthesis and characterization of WC-FeCr base alloy composite produced by spark plasma sintering

This study investigates the microstructural and mechanical properties of WC-FeCr base alloy composite materials prepared using spark plasma sintering (SPS) technique. The composites with different FeCr alloy content (2% and 6%) were sintered at temperatures of 1100 °C, 1200 °C, and 1300 °C. The characterization of the sintered samples involved analyzing the surface morphology, phase composition, and grain structure of the sintered samples using scanning electron microscopy (SEM), X-ray diffraction (XRD), electron backscatter diffraction (EBSD), and transmission electron microscopy (TEM). The results indicate that the FeCr alloy content has a significant influence on the microstructural characteristics, hardness, and density of the WC-FeCr composites. Increasing FeCr alloy content results in improved surface quality and enhanced hardness. Additionally, the sintering temperature plays a crucial role in determining the microstructural features and mechanical properties of the composites.

Investigation for the optimum selection of hybrid AA2024 – ceramic particulate alloy composite materials prepared through stir casting using the hybrid AHP-TOPSIS MCDM technique

ABSTRACT In most of the manufacturing industries, the selection of optimal material among the finite available alternatives becomes more difficult with the more required performance criteria to satisfy certain objectives. In such scenarios, Multi-Criteria-Decision-Making (MCDM) techniques, such as hybrid AHP (Analytical hierarchy process) – TOPSIS (Technique for Order Preferences by Similarity to Ideal Solution) and others assist in quantitative decision-making by accounting for qualitative human judgments. The present work illustrates the application of a hybrid AHP-TOPSIS technique to the ranking of alloy composites. The properties defining data such as physical, mechanical, thermal, thermo-mechanical, etc. are weighted using the AHP technique; thereafter, relative weights are used to rank the alloy composite compositions by the TOPSIS method. The compositions comprise the AA2024 alloy as the matrix phase and the reinforcing phase consists of silicon carbide, silicon nitride and graphite particulates. The ranking analysis orders are consistent with subjective analysis.

Development of pressure infiltration preparation of metal matrix composites

<p>This paper summarizes the process of metal matrix composites from pressure infiltration preparation to pressure ultrasonic assisted infiltration to pressure solvent assisted infiltration. The advantages of preparing metal matrix composites by pressure infiltration alone are low cost and convenient for mass production. However, the equipment and process requirements are too high, and the quality of composite materials can not be guaranteed. Because of the high pressure of ultrasound, ultrasonic infiltration has become an auxiliary physical method for the preparation of metal matrix composites by pressure infiltration. But this method tends to damage the fibers. Therefore, the fibers need to be coated. The coating on the fiber surface is divided into metal coating and non-metal coating. Some people mixed SiC particles or whiskers in continuous carbon fibers to prepare aluminum alloy composite materials, forming a hybrid assisted infiltration method. Later, people began to pay attention to the flux-assisted role of pressure infiltration. Therefore, solvent-assisted infiltration of fiber-reinforced metal matrix composites has become an important research field.</p>

Analysis and Characterization of Three Charge Thicknesses in TA1/Al1060/Al7075 Explosive Welding Composite Process

The titanium/aluminum composite materials overcome the limitations of single metal materials and achieve lightweight, high-strength, and corrosion-resistant properties. However, there have been no reports on explosion-welded composites of titanium alloys and seven-series aluminum alloys. Therefore, TA1/Al1060/Al7075 explosion-welded plates with three different explosive thicknesses were successfully prepared using Al1060 as the transition layer. The SPH-FEM coupled algorithm was employed to analyze the detonation process in detail and predict the interface under different explosive thicknesses. The results showed that during the explosion welding process, the high temperature, pressure, and high-speed impact resulted in significant plastic deformation and jetting phenomena at the bonding interface, which were in good agreement with the experimental observations. With the increase in explosive thickness, the TA1/Al1060 bonding interface exhibited a flat shape, while the Al1060/Al7075 interface transitioned from a flat to a wavy morphology. Moreover, the crack, vortex, and TiAl3 were observed at the interface. Mechanical testing results revealed that the composite plate with a 35 mm explosive thickness exhibited the best tensile, shear, and bending performance, indicating the optimal process parameter. This study provides significant support and reference for the application of explosion welding technology in titanium alloys and seven-series aluminum alloy composite materials.

Tribological and Corrosion Behavior of Eggshell and Agro-waste RHA Reinforced Al Alloy Composite Material with and without Ball-Milling

Tribological and Corrosion Behavior of Eggshell and Agro-waste RHA Reinforced Al Alloy Composite Material with and without Ball-Milling

Влияние армирования высокодисперсной фазой карбида титана и последующей термической обработки на структуру и свойства сплава АМг6

The analysis of mechanical properties and corrosion resistance of industrial alloy AMg6 and composite material AMg6-10%TiC obtained by self-propagating high-temperature synthesis is carried out. It is shown that the existence of a carbide phase and subsequent heating up to 230 ℃ allows increasing the hardness by 17 % and maintaining a high corrosion re-sistance of the composite.

Research on Electromagnetic Shielding Effectiveness of Multi-layered LZ91/Al Alloy Composite Materials by Asynchronous Accumulative Roll Bonding

In this paper, the multi-layered LZ91/Al alloy composite materials were prepared by asynchronous accumulative roll bonding (AARB), and the effect of the multilayer structure on the electromagnetic shielding effectiveness of the alloy was investigated. The result show that the number of LZ91 and Al layers increase exponentially with the increase of AARB passes, and the LZ91 layer and Al layer, α-Mg phase and β-Li phase in the alloy are arranged alternately. Besides, as the aggregate thickness of the Al layer increases in the AARB process, the electrical conductivity of the alloy also increases. Thish can effectively improve the electromagnetic shielding effectiveness of the alloy.

Tribological performances of CuSn10Bi3 alloy containing MoSi2 and ferrophosphorus under starved lubrication

The effects of molybdenum disilicide (MoSi2) and ferrophosphorus (FemPn) particles on the tribological properties of copper-tin bismuth (CuSn10Bi3) bimetallic bearing materials were studied in this paper. The samples of CuSn10Bi3 containing MoSi2 and/or FemPn were prepared by powder sintering technology and the metallographic structure of four kinds of self-lubricating copper alloy composite materials after sintering was observed. The tribological properties of the copper alloy composites under starved lubrication conditions were investigated and its worn surfaces and wear debris were discussed and analysed. The results show that the addition of MoSi2 and/or FemPn particles can effectively refine the grain size, optimise the grain boundary morphology, and improve the mechanical properties of the alloys. Under extreme working conditions, the hard particles reinforced copper-based alloy samples have better wear resistance and anti-seizure resistance.

Perspectives and Impact of the Hull Cell for the Electrodeposition of Alloys and Metal Matrix Composites

Alloy and metal matrix composite electrodeposited materials are of interest due to their unique and often superior properties compared to their elemental counterparts. However, the deposit composition is not always known a priori due to coupled kinetic behavior of different reduction reactions and the influence of second phase particles. Models can enable predicting deposit composition from different electrolytes, and to validate such models data is needed. While a Hull cell and a rotating Hull cell are convenient tools to survey resulting deposit compositions with current density, it can also be used to provide information to better understand the deposition mechanisms and kinetic-transport behavior. In this talk, the history of the use of a Hull cell and rotating Hull cell will be discussed in the context of the underlying theory in current distribution, and the cautionary tale of when a Hull cell design is not always useful. Today, integrating scanning compositional tools with linear sweep voltammetry, the rotating Hull cell can be used to swiftly determine the partial current densities of metal ion reduction in the study of alloy systems that exhibit anomalous and induced codeposition. It can also aid in the study of composite electrodeposition to incorporate second phase particles into a growing metal matrix alloys. Extracting kinetic and mass transport data from this approach can help to develop better models for the electrodeposition process itself that governs the resulting deposit composition. Furthermore, new directions in the use of a Hull cell cell to assess electrodeposits for gas evolving reactions, such as the hydrogen evolution reaction (HER) and the oxygen evolution reaction (OER) in water splitting will be discussed.

Mechanical behaviour of Al7075 alloy Al2O3/E-Glass hybrid composites for automobile applications

Due to their light weight, high strength, and improved tribological qualities, aluminium alloy composite material are in high demand for sophisticated technological applications. The aluminium alloy (Al7075) hybrid composite was created using a sand mold technique in an electric resistance furnace, and it was reinforced with aluminium oxide (Al2O3) particles and E-glass shot fibres. The goal of this study was to look at the mechanical behaviour of Al7075-Al2O3-E-glass hybrid composites with various Al2O3 (3–12%) and E-glass weight percentages (2–8 %). In this study, Al7075 alloy hybrid composites were developed using a sand molding process to investigate their density and mechanical properties. The presence of reinforced particulate matter in the Al alloy was revealed by EDS and XRD analyses. Mechanical properties such as tensile strength, yield strength, and hardness increased to 9 percent by weight Al2O3 and 6 percent E-glass and then decreased slightly, according to the results. The density of the hybrid composites increased as the volume portion of the reinforcement increased.

Mechanical properties of a new kind of porous aluminum alloy composite from ceramic hollow spheres with high strength

A new kind of porous 6061 aluminum alloy composite material was successfully fabricated using self-made high-strength silicon-containing ceramic hollow spheres as reinforcement. For comparison, another composite with commercial alumina hollow spheres was produced. All of these porous composite materials were produced by sintering at 650 ℃ for 2 h. Their microstructures display that the aluminum alloy reacts with the self-made ceramic hollow spheres, forming a thin transition layer containing MgO and Al2O3. Moreover, it was analyzed that the influence of the different classes of ceramic hollow spheres on the properties of porous composites, including the compressive strength, specific strength and energy absorption performance. The results indicate that the self-made silicon-containing ceramic hollow sphere can help to hinder the plastic deformation of the aluminum alloy metal matrix, which makes the sample display a short yield platform where the stress remains relatively stable. As a comparison, there is no yield platform where the stress remains relatively stable in the sample with commercial alumina hollow spheres under compression. Due to the formed transition layer, the sample with the self-made ceramic hollow sphere has a significantly higher compressive strength, specific strength and energy absorption performance. Compared with the porous magnesium alloy composite, the compressive behavior of porous composite is subject to that of the metal matrix to a great extent, and the content of Mg in the matrix determines the resultants and the level of the interface reaction. In addition, the compressive strength, specific strength, and energy absorption capacity of the porous aluminum alloy composite are all significantly higher than those of the porous magnesium alloy composite.

Analysis of copper foam/low melting point alloy composite phase change material

• Copper foam has a more significant improvement in n-tricosane. • Copper foam/47 alloy is still better in temperature management performance. • Copper foam limits the temperature rise of 47 alloy during the phase transformation. • The low ratio of copper foam greatly improves 47 alloy. • The higher the porosity, the better the temperature management performance. In the current paper, we present the influence of adding high thermal conductivity materials on the thermal management performance of low-melting-point alloys in different aspects. We analyze the phase change process of 47 alloy and n-tricosane before and after compounding with copper foam based on numerical simulation. Moreover, we calculate the temperature management curve of low-melting-point alloy composite materials with different foam porosity. Our results indicate that the addition of copper foam significantly improves the thermal management performance of n-tricosane. Due to the difference in latent heat, the thermal management time of copper foam/47 alloy is 1.21 times higher than the former. The addition of copper foam mainly improves its thermal response and inhibits the temperature rise in the phase transition stage. Just 5% of copper foam has a significant effect. For copper foam/47 alloy, the higher the porosity, the stronger the temperature management ability. This feature is more prominent when the upper limit is the temperature below the melting point.

Research on Preparation and Properties of Carbon Fiber Reinforced Zinc-Based Aluminum Rich Alloy Composite.

Aiming at the problems of poor bonding between the carbon fiber and the metal matrix and the friction and wear performance of the composite material during the preparation of carbon fiber reinforced zinc-based aluminum rich alloy composites, the carbon fiber surface metallization process was studied. Taking ZA27 as the research object, a new type of zinc-based aluminum rich alloy composite material was prepared by using surface metallized chopped carbon fibers with different contents as reinforcement materials. The microscopic morphology, element distribution and phase composition of the surface metallized carbon fiber and composite materials were characterized, and the hardness and friction and wear properties of the composite materials were tested. The results show that: the surface metallization of carbon fiber effectively reduces the diffusion of carbon elements into the matrix material during the sintering process, and improves the interface bonding between the carbon fiber and the matrix material; Compared with ZA27 alloy, the hardness of 6vt% carbon fiber is increased by 29.6%, and the average friction coefficient and wear rate are reduced by about 18.4% and 96%, respectively, indicating that the carbon fiber reinforced zinc-based aluminum rich alloy composite material optimizes the friction and wear performance of traditional materials.