Carbide Particles Research Articles

Tribological analysis of titanium alloy (Ti-6Al-4V) hybrid metal matrix composite through the use of Taguchi’s method and machine learning classifiers

The preparation and tribological behavior of the titanium metal matrix (Ti-6Al-4V) composite reinforced with tungsten carbide (WCp) and graphite (Grp) particles were investigated in this study. The stir casting procedure was used to fabricate the titanium metal matrix composites (TMMCs), which had 8 weight percent of WCp and Grp. The tribological studies were designed using Taguchi’s L27 orthogonal array technique and were carried out as wear tests using a pin-on-disc device. According to Taguchi’s analysis and ANOVA, the most significant factors that affect wear rate are load and distance, followed by velocity. The wear process was ascertained by scanning electron microscopy investigation of the worn surfaces of the composite specimens. Pearson’s heatmap and Feature importance (F-test) were plotted for data analysis to study the significance of input parameters on wear. Machine learning classification algorithms such as k-nearest neighbors, support vector machine, and XGBoost algorithms accurately classified the wear rate data, giving an accuracy value of 71.25%, 65%, and 56.25%, respectively.

Effect of the incorporating of refractory NbC precipitates in intermetallic iron-aluminide coatings on corrosion and high-temperature oxidation behavior

This study aims to investigate the effects of growing niobium carbide (NbC) particles into intermetallic iron-aluminide (FeAl) coatings on ductile cast iron (SGI) by thermo-reactive diffusion technique (TRD). The study compares the corrosion and oxidation behavior of the FeAl-NbC coatings with SGI, FeAl, and NbC coatings. Corrosion tests were conducted through polarization tests in a 3.5 wt% NaCl solution, while oxidation tests were performed at 900 °C for 4, 16, and 64 h. Before and after corrosion and oxidation tests, the coatings were examined using scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), and X-ray diffraction (XRD). The findings show that FeAl coatings with NbC particles had lower graphite nodules, porosity, and surface roughness values compared to FeAl coatings. FeAl-NbC composite coatings provided better corrosion and oxidation resistance compared to untreated SGI, FeAl, and NbC coatings. The results of the comparative analysis of FeAl-NbC, FeAl, NbC, and untreated SGI specimens indicate that corrosion resistance in a 3.5 wt% NaCl solution and oxidation resistance at 900 °C followed the order FeAl-NbC > FeAl > NbC > SGI.

Microstructure and Mechanical Properties of Carbon Fiber Phenolic MatrixComposites containing Carbon Nanotubes and Silicon Carbide

A novel class of hybrid composites was prepared containing carbon fibers along with carbon nanotubes and silicon carbide particles in phenolic resin for improved mechanical performance. The loading of carbon fibers was ~60 wt% while carbon nanotubes and silicon carbide particles were reinforced in the fractions of 0.1 wt% and 5 wt%, respectively. Individually reinforced composites containing 0.1 wt% carbon nanotubes and 5 wt% silicon carbide particles were also manufactured for comparison with hybrid composites. Microstructural and mechanical property characterization was performed using electron microscopy and mechanical testing, respectively. Uniform dispersion of nanometer-scale carbon nanotubes and micrometer-scale silicon carbide particles was observed under microscopy. The pooled effect of carbon nanotubes and silicon carbide particles significantly increased the tensile, compressive, and flexural performance of composites while carbon nanotubes offered greater weight fraction value improvement than silicon carbide particles.

Evaluating the Effect of Different Percentage Addition of SiC on Mechanical and Wear Properties of Al6061 Composite

AbstractAluminum 6061 alloy using silicon carbide (SiC) particles as a reinforcement is a promising metal matrix composite (MMC) that has gained significant attention in the automotive and aerospace industries. Till now the effect of the addition of SiC particles in Al6061 composite is not studied in depth and also very few studies are reported the on‐wear properties of Al6061‐SiC composite. So, to further enhance the properties of Al6061 alloy and to study in depth this work is carried out. In this study, MMCs are prepared using the stir casting route with varying weight fractions (5–10 wt%) of SiC particles. The properties of composites including tensile strength, compression strength, and wear are evaluated experimentally. The results demonstrated that the incorporation of SiC particles into the Al alloy matrix leads to a notable improvement in mechanical and wear parameters. The tensile and compression strength of the Al composites increases with an increase in the weight percentage addition of SiC particles (from 5% to 7.5%). At 7.5 wt% addition of SiC, it is found that the particles are uniformly distributed throughout the Al6061 alloy matrix. And also shows higher mechanical and wear properties as compared to 5% and 10% addition.

Optimization of cutting force and surface roughness in end milling of AA-TiCp composite

Nowadays Aluminium alloy (AA) based composites are used in many fields such as automotive, aerospace, electronics, and marine industries. But for the utilization of these composites for different applications with different shapes, machining especially end milling is the essential process. Hence, this work describes the optimization of surface roughness and cutting forces during end milling of A356 aluminium alloy reinforced with titanium carbide particle (TiCp) metal matrix composites (MMCs). A356 alloy with 0, 3 and 6 vol% of TiCp (average size of 50 µm) composites were prepared using a stir casting process. The effects of milling process factors, namely cutting speed, feed, depth of cut, and volume % of TiCp, on average surface roughness (Ra) and cutting forces have been studied using a Box-Behnken design of the experiment technique. The end milling experiments were performed in a CNC vertical machining center without any cutting fluid using uncoated cemented carbide inserts. Using Design Ease software, the predictive model analysis and change in performance measurements for process variables were provided. The results showed that the depth of cut, followed by cutting speed, is the most important criterion and finally optimal levels of process variables were also identified to improve the machinability of the composites.

On the Possibility of Using Secondary Alloys in the Production of Aluminum-Based Metal Matrix Composite

Aluminum-based composites provide tribological performance and thermophysical properties that, combined with being lightweight, are suitable for their application in automotive brake discs. Aluminum alloys allow the use of secondary materials to produce composites, with the drawback of several elements, impurities, and oxides that can harm the mechanical and thermophysical properties. This preliminary study explored the mechanical and thermophysical performance of a composite material produced with a secondary matrix alloy. Overall, the results are promising, with a minimal decrease in mechanical and thermophysical properties despite clustered silicon carbide particles in the composite with the secondary matrix. The challenges in effectively dispersing carbides in the melt seem linked to aluminum oxides, and future microstructural investigations will aim to clarify this aspect.

The effect of carbon content on the printability and mechanical properties of Ni-based superalloy in laser additive manufacturing

The role of trace elements in additively manufactured superalloys remains a subject of ongoing discussion. It is crucial to investigate the effective mechanism and control range of trace elements in superalloys for additive manufacturing (AM). In this study, C was focused on and investigated to analysis the effect of C content on the printability and mechanical properties of a dedicated additive manufacturing superalloy. The results indicated that the cracking susceptibility of the alloy firstly increased and then decreased when the C content increased within a certain range (0–0.092 wt%). The alteration of C content affected the precipitation temperature and size of γ′ precipitates, and changed the freezing range of the alloy. As a result, a nonlinear relationship was observed between cracking susceptibility and C content. Furthermore, under thermal cycling, the gradually grown carbides filled microporosity and reduced the porosity of the alloy. The dispersion of carbide particles could effectively prevent dislocation movement and enhanced the strength of the alloy. These findings clarify the influence of C content within a certain range on the printability and mechanical properties of the alloy and provide guidance for the regulation of C content in subsequent alloy design.

Wear Behavior of Epoxy Resin Reinforced with Ceramic Nano- and Microparticles.

Cavitation erosion poses a significant challenge in fluid systems like hydraulic turbines and ship propellers due to pulsed pressure from collapsing vapor bubbles. To combat this, various materials and surface engineering methods are employed. In this study, nano and micro scale particles of silicon carbide (SiC) or boron carbide (B4C) were incorporated as reinforcement at 6% and 12% ratios, owing to their exceptional resistance to abrasive wear and high hardness. Microparticles were incorporated to assess the damage incurred during the tests in comparison to nanoparticles. Wear tests were conducted on both bulk samples and coated aluminum sheets with a 1mm of composite. Additionally, cavitation tests were performed on coated aluminum tips until stability of mass loss was achieved. The results indicated a distinct wear behavior between the coatings and the bulk samples. Overall, wear tended to be higher for the coated samples with nanocomposites than bulk, except for the nano-composite material containing 12% SiC and pure resin. With the coatings, higher percentages of nanometric particles correlated with increased wear. The coefficient of friction remained within the range of 0.4 to 0.5 for the coatings. Regarding the accumulated erosion in the cavitation tests for 100 min, it was observed that for all nanocomposite materials, it was lower than in pure resin. Particularly, the composite with 6% B4C was slightly lower than the rest. In addition, the erosion rate was also lower for the composites.

Key reaction steps in the combustion synthesis of Ti3SiC2/SiCp ceramic composites using titanium reactant in foil form: Microstructural evidence

The paper is devoted to the microstructural evidence of key reaction steps in the combustion synthesis of SiC particulate reinforced Ti3SiC2 ceramic matrix composites from multilayer stack of titanium foils and polymer films filled with SiC and TiC particles. It was found that the primary interaction step results in the formation of intermediate product layer, which exhibits a duplex microstructure consisting of a continuous Ti5Si3 matrix embedded with islands of TiC0.52 particles. Next, in the combustion step, a significant rise in the sample temperature leads to complete melting of the titanium foils. The molten titanium infiltrates then the area occupied by SiC and TiC particles. Finally, the peritectic reaction between Ti-rich melt and carbide particles results in the formation of a Ti3SiC2 MAX phase matrix. An excess quantity of SiC particles remains uniformly entrapped within the matrix, eventually giving a microstructure of particulate-reinforced ceramic matrix composite.

Experimental Investigation of WE43(T6) magnesium metal matrix composites to enhance mechanical properties and EDM process parameters

In recent years, magnesium metal matrix composites (MMCs) are increasingly used in the automotive, aerospace, and biomedical industries due to their superior physical and thermal properties compared to their parent materials. Magnesium metal matrix composites are noteworthy for numerous reasons, including their light weight, high specific modulus, wear resistance, corrosion resistance, high toughness, fracture resistance, thermal stability, and ability to perform at higher temperatures. Our research primarily focuses on enhancing the mechanical properties of the magnesium metal matrix composite (WE43-T6) reinforced by silicon carbide (SiC) and aluminum oxide (Al2O3) particles with a size of 10 μm to 30 μm. The composite was examined using SEM and EDAX to investigate its microstructure and elemental composition. The distribution of the reinforcement particles is well represented in the microstructural analysis. In addition, the present research also focuses on studying MRR, TWR, and surface roughness in EDM machining process using copper, brass, and tungsten carbide electrodes to improve MRR and limit TWR and surface roughness. The results of the study showed that pulse on-time, pulse current, and spindle speed have a significant influence on MRR and TWR. A parametric analysis using a linear regression model was performed to verify the effects of experimental machining performance The experimental results were found to have less than 5% error. The addition of silicon carbide and aluminum oxide particles to magnesium metal matrix composites, makes materials harder and stronger while reducing their weight by 0.98–1.05%.

Microstructure and wear resistance of tungsten carbide particle reinforced titanium alloy coating by WAAM

A tungsten carbide particle reinforced Ti-6Al-3Nb-2Zr-1Mo alloy coating was prepared by wire arc additive manufacturing (WAAM) with wire-powder feeding simultaneously. The study shows that the titanium alloy matrix exists in the form of a metastable phase β-Ti, and the addition of tungsten carbide particles significantly refines its grains. Tungsten carbide particles retain a spherical shape, with only the surface undergoing dissolution and releasing W and C atoms. The results of the dry sliding friction test reveal the superior wear resistance of the composite coating, primarily attributed to the shadow effect of the tungsten carbide particles, the enhanced hardness, and the formation of a self-lubricating oxide layer.

Numerical crashworthiness analysis of 2014 Aluminium-Silicon Carbide Particle (SiCp) foam filled Carbon Fiber-Reinforced Plastic (CFRP) tube under impact loading

Aluminium foam and Carbon Fiber Reinforced Plastic (CFRP) are widely used composite materials in automobile industries due to the benefits of lightweight and energy absorption capacity. Therefore, in this study, the numerical crashworthiness analysis of 2014 Aluminium-SiCp (2014AA-SiCp) foam filled in CFRP tube has been performed under impact loading. Quasi-static compression tests have been conducted on 2014AA-SiCp foam to extract the mechanical parameters required for numerical simulations. To understand the crushing behavior under the axial impact loading, 2014AA-SiCp foam-filled CFRP tube has been numerically modelled using ABAQUS® software. The parametric study was carried out to explore the effects of filler material, foam densities, and impact velocities on crushing behavior. It was found that load increases with the rise in foam density and impact velocity. Moreover, the deformation increases with the increase in impact velocity. Results showed that the load carrying capacity of foam filled CFRP tubes was significantly improved compared to that of empty CFRP tubes. The foam filled CFRP specimens exhibited peak load of 122 kN and an energy absorption capacity of 3012 J, showcasing an approximate improvement of 43% and 11% respectively, over the values obtained for empty CFRP tubes.

Mechanical‐wear behavior and microstructure analysis of Al2214 alloy with B4C and graphite particles hybrid composites

AbstractIn the present work, hybrid composites made of Al2214 alloy with B4C and graphite were produced by using a liquid metallurgical process. Al2214 alloy was utilized to create hybrid composites that had 1.5–6 wt% of B4C particles and a constant 3 wt% of graphite particles. Microstructural analysis using scanning electron microscope (SEM), energy dispersion spectroscopy (EDS), and X‐ray diffraction (XRD) was done on the produced composites. The density, hardness, ultimate, yield strength, and elongation as a percentage were carried out using ASTM E8 for tensile and E10 standard for hardness test. The wear behavior of Al2214‐B4C and graphite composites was examined as per ASTM G99 standard using a wear testing device under a variety of loads and rotation speeds. Graphite and boron carbide particles were equally dispersed throughout the Al2214 alloy, according to SEM photographs. Graphite and B4C particles were detected in the Al2214 alloy by EDS and XRD analyses. The density of Al alloy composites was decreased by adding dual particles to the matrix. The Al2214 alloy's hardness, ultimate strength, yield strength, and wear resistance were all enhanced by the inclusion of dual particles, which increased these properties by 15.4%, 40.4%, and 46.7%, respectively. The presence of hybrid particles in the Al2214 alloy was revealed by EDS and XRD patterns. The density of Al alloy composites was decreased by adding dual particles to the matrix. Tensile force micrographs provided further evidence of the unique fracture behaviors shown by the Al2214 alloy and its composites. In order to examine the wear mechanisms and different morphologies of worn surfaces, scanning electron micrographs were taken.

Silicon carbide nanoparticles featured AZ63/BN alloy nanocomposite made by using liquid stir vacuum die cast: characteristics study

ABSTRACT With the unique class, the reinforcements play a precious role during the composite fabrication, expanding the specific properties. The novel research intensively enhances the micro-structural and mechanical behaviour of magnesium alloy (AZ63/3 wt% boron nitride) nanocomposite featured 2, 4, and 6 wt% of nano-size silicon carbide (SiC) particles via liquid state vacuum stir cast route. The exposure of SiC and BN on composite density, voids contribution, changes in AZ91D microstructure, impact toughness, hardness, and stress-strain individuality of AZ63 alloy nanocomposite is evaluated with ASTM policy. The composite composed with 3 wt% BN and 6 wt% SiC proved their identity. It showed the lower contribution of voids-free homogenous dispersion particle results in a maximum impact strength of 14.7J/mm2, hardness of 74HV, and superb tensile strength of 247MPa. This optimum behaviour will be recommended for automotive roof frame applications.

A physically based constitutive model considering dynamic recrystallization of ERNiCrMo-3 alloy

ERNiCrMo-3 alloy is widely used in the welding of nickel-based alloys. This study investigated the hot deformation and discontinuous dynamic recrystallization (DRX) behavior of ERNiCrMo-3 alloy through hot compression tests at deformation temperatures ranging from 990 °C to 1170 °C and strain rates ranging from 0.01 to 10 s−1. Experimental results showed that under conditions of elevated temperatures and lower strain rates, discontinuous dynamic recrystallization was prone to occur upon reaching critical strain, and the distribution of carbide and nitride particles within the alloy matrix affects recrystallization nucleation and grain boundary migration. A two-stage constitutive model was established based on classical dislocation density theory and DRX kinetics. Comparison between predicted and experimental data demonstrated a strong agreement, highlighting the accuracy and utility of the proposed constitutive model.

Comparative analysis of microstructure and selected properties of WC-Co-Cr coatings sprayed by high-velocity oxy fuel on S235 and AZ31 substrates

Abstract The purpose of this work was to carry out comparative studies of WC-Co-Cr coatings deposited using the high velocity oxy fuel (HVOF) method onto two types of substrate material: structural steel S235 and magnesium alloy AZ31. The influence of the substrate material type on the microstructure, phase composition, crystallite size, porosity, Vickers microhardness, instrumental hardness (HIT), Young’s modulus (EIT), and fracture toughness was investigated. For both substrates, the deposited coatings deposited were characterized with fine-grained and compact microstructure. The X-ray diffraction (XRD) revealed presence of following phases: WC, W2C, Co0.9W0.1, and Co3W9C4. The WC phase was the most desirable and stable one with crystallites were below 100 nm. On the other hand, the size of the W2C crystallites was below 30 nm. The coatings obtained showed porosity values equal to 2.3 ± 0.4 vol% and 2.8 ± 0.7 vol% for AZ31 and S235, respectively. The average Vickers microhardness for both types of sample was appproximately 1200 HV0.3. The average HIT values for carbide particles and metallic matrix were around 29 GPa and 6.5 GPa, respectively. In the case of EIT, it was around 620 GPa and 190 GPa for WC and Co-Cr, respectively. The differences between coatings were negligible. The EIT value for both coatings was equal to 344 ± 11 GPa. The fracture toughness was around 4.5 MPa · m1/2 in both cases. The investigations revealed that it is possible to replace steel substrate material with a much lighter equivalent, in this case AZ31 alloy, without deterioration of the coating properties.

The evaluation of machining performances and surface roughness of TZM-molybdenum superalloy processed by silicon carbide powder mixed EDM process using RSM and ANOVA

In the present era, the concept of Industry 4.0 plays a significant part in improving the efficiency, quality, and utilization of resources by automation and enabling intelligent operations in manufacturing processes. As a result, there is a requirement to develop an environment that improves efficiency as well as quality in order to accomplish net zero in manufacturing. The objective of powder mixed electric discharge machining (PMEDM) is to enhance the quality of the surface and machining efficiency of traditional electrical discharge machining. The PMEDM method was applied to TZM-molybdenum superalloy in the present investigation by incorporating silicon carbide particles into the dielectric medium. Powder concentration, peak current, pulse on time, pulse off time, and gap voltage were the considered input variables for the investigation. The impacts of the input variables on the surface of the specimen’s roughness and the rate of material removal (MRR) were examined. The experiment model was built using response surface methodology. To find out if the input factors were significant with regard to each response, an analysis of variance (ANOVA) was performed. Powder concentration, pulse current, gap voltage, and pulse on time are found to be the important input variables for both surface roughness and MRR based on ANOVA analysis.

Laser additive remanufacturing Ni-based multilayers reinforced with dual-scale tungsten carbides via a novel integrated strategy

This study entailed the development of a novel integrated strategy that incorporates hot-wire-feed laser deposition and remelting for repairing stainless steel having WC-Ni composite multilayers reinforced with homogeneously distributed dual-scale tungsten carbide particles. The microstructural characteristics, phase compositions, and microstructural evolution of the composites obtained under three representative combinations of operating parameters were thoroughly investigated. On the basis of the partial dissolution of WC/W2C particles and the temperature variation of the molten pool between laser deposition and remelting, microsized WC particles were successfully synthesized in situ around the large retained WC/W2C in the repaired zone when the optimal energy input during the repair process was employed. Combined atomic-scale high-angle annular dark-field scanning transmission electron microscopy, high-resolution transmission electron microscopy, and ab initio analysis based on density functional theory calculations were employed to reveal the crystallographic orientation relationship between in situ WC and the matrix. The growth mechanism and morphology evolution were clarified. Compared to the substrate, the surface wear resistance of the obtained multilayers was significantly improved owing to the duplex-strengthening effect of the evenly distributed reinforcements in terms of the retained WC/W2C and in situ WC particles. This study affords new insights into the tailoring of reinforcements in composites with excellent wear performance for repairing metallic components.

Strength Enhancement of Laser Powder Bed Fusion 316L by Addition of Nano TiC Particles.

316L stainless steel is widely used in various industrial fields, but its strength is relatively low. The improvement of its strength has become a research hotspot. In this study, nano titanium carbide (TiC) particles are ball milled with 316L with the addition of 2 wt% and 4 wt%. The composite powder was then used for the fabrication of samples by laser powder bed fusion. The results show that the TiC is uniformly distributed in the microstructure. With the addition of TiC, the average size of the grains is significantly reduced. The strength, hardness, and wear resistance of TiC/316L samples have been greatly improved. The tensile strength of formed 2 wt% TiC/316L is 948 MPa, together with a extension rate of 36.0%, which has been increased by 42.6% and 79.7%, respectively. This study provides an effective way to improve the strength at room temperature and the high temperature of 316L built by laser powder bed fusion.

Comparison of Crack Initiation Sites and Main Factors Causing Hydrogen Embrittlement of Tempered Martensitic Steels with Different Carbide Precipitation States

The dependence of crack initiation sites and main factors causing hydrogen embrittlement fracture on carbide precipitation states has been investigated for tempered martensitic steels with the same tensile strength of 1450 MPa. Notched specimens charged with hydrogen were stressed until just before fracture and subsequently unloaded. The crack initiation site exhibited intergranular (IG) fracture at 21 μm ahead of the notch tip as observed by scanning electron microscopy (SEM) for 0.28% Si specimens with plate-like carbide precipitates on prior austenite (γ) grain boundaries. This crack initiation site corresponded to the vicinity of the maximum principal stress position as analyzed by a finite element method (FEM). The initiation site corresponded to the triple junction of prior γ grain boundaries as analyzed by electron backscattered diffraction (EBSD). In contrast, the crack initiation site exhibited quasi-cleavage (QC) fracture at the notch tip for 1.88% Si specimens with fine and thin carbide particles in the grains. This crack initiation site corresponded to the maximum equivalent plastic strain site obtained by FEM. Additionally, the crack initiated on the inside of prior γ grain boundaries and propagated along the {011} slip plane with higher kernel average misorientation (KAM) values as analyzed by EBSD. These findings indicate that differences in carbide precipitation states changed the crack initiation sites and fracture morphologies involved in hydrogen embrittlement depending on mechanical factors such as stress and strain and microstructural factors.