Distribution Of SiC Particles Research Articles

Effect of hot rolling on microstructures and mechanical properties of SiCp/A356 aluminum matrix composites

This study focuses on the fabrication of SiCp/A356 aluminum matrix composites (AMCs) through stir casting and hot rolling, with the objective of investigating the effects of reduction on microstructural evolution and mechanical properties of SiCp/A356 AMCs. The composites were subjected to hot rolling at 500 °C for varying reduction levels of 30%, 50%, 70%, and 90%. As the reduction increased to 70%, the size of α-Al grains and SiC particle clusters increased. However, further reduction to 90% resulted in the flattening and elongation of α-Al grains, the dispersion of SiC particles into the grains, and a more uniform distribution of SiC particles. The relationship between reduction and SiC particle distribution was established. The ultimate tensile strength (UTS) and yield strength (YS) of SiCp/A356 AMCs showed a gradual increase with increasing reduction. The rolled composite with a 90% reduction exhibited the optimal combination of UTS, YS, and elongation (EL) values. Besides, the strengthening mechanisms were discussed and the dislocation strengthening has a significant contribution to the improvement of YS.

Effect of SiC content on the microstructure and wear behavior of cold-sprayed Al-SiC coatings deposited on AZ31 alloy substrate

As a promising and recently developed deposition technique, cold spray deposition method is among the most recently implemented approaches to enhance the poor hardness and wear resistance of AZ31B magnesium alloy. This study investigated the effect of SiC content on the microstructural characteristics, microhardness, and wear behavior of cold-sprayed Al-(16, 28, and 38 wt%) SiC composite coatings. The incorporation of SiC particles into the Al-matrix coating led to the development of a mechanical interlocking mechanism and improved coating-substrate interfacial bonding. The microhardness of the Al-38 wt% SiC coating was approximately 80 % higher than that of the bare substrate due to reduced porosity and a uniform distribution of SiC particles. For coatings with higher SiC content, the dominant wear mechanism transitioned from adhesive to abrasive wear, as evidenced by the friction coefficient (COF) values and wear track micromorphology. The Al-16 wt% SiC coating exhibited the lowest COF and wear rate values, indicating superior wear resistance among the specimens.

Regulation on microstructure and mechanical properties of SiC particles reinforced AZ31 magnesium matrix composites fabricated by synchronous feeding of powder and wire in wire-arc directed energy deposition

Ceramic particles reinforced magnesium matrix composites (CMMCs) have attracted widespread attention and investigation due to their excellent comprehensive performances. However, limited research on additive manufacturing of CMMCs has been performed. In this work, the SiC/AZ31 composites were fabricated by wire-arc directed energy deposition (WA-DED) based on the synchronous feeding strategy of powder and wire. The defects, SiC particle distribution, microstructure and mechanical properties of the prepared WA-DED SiC/AZ31 composites were studied. The results indicated that SiC particles with the content range of 0.3–1.7 wt% have been successfully added into the single-channel monolayer AZ31 matrix by adjusting the turret speed (TS) and the argon gas flow rate (AGFR) flowing through the powder feeder. The mathematical model is established to predict the introduced SiC particle content by correlating the relationship between SiC particle content and process parameters (TS and AGFR) of the powder feeder. The transformation from columnar to equiaxed grains occurs after adding SiC particles, more precipitated phases are formed after introducing more SiC particles. Compared to the AZ31 matrix, the WA-DED SiC/AZ31 composites exhibit the highest yield strength of 92.8 MPa and tensile strength of 213.3 MPa on the premise of almost no loss of elongation, and the maximum improvement efficiency of tensile strength reaches 56%, which is mainly ascribed to refinement strengthening, while thermal mismatch strengthening, Orowan strengthening and load-bearing strengthening play a booster action.

Hybrid additive manufacturing of aluminum matrix composites with improved mechanical properties compared to extruded counterparts

Great difficulties existed in fabricating large components of SiC particles reinforced aluminum matrix composites with excellent mechanical properties using existing manufacturing procedures. This study demonstrated that the challenges can be addressed by developing a hybrid solid-state additive manufacturing method. The influence of the deposition procedures and the post-processing heat treatment on the microstructure and mechanical properties of the SiC particles reinforced 2009 aluminum ally matrix composites (SiCp/2009Al composites) was systematically investigated using advanced technologies such as spherical aberration corrected transmission electron microscope, atom probe tomography, etc. The results showed that the SiCp/2009Al composites produced by the hybrid solid-state additive manufacturing exhibited enhanced tensile properties and improved isotropy in mechanical properties compared to the extruded feedstock of SiCp/2009Al composites. This was attributed to the formation of dense metal with uniformly distributed SiC particles, high-density of Cu–Mg co-clusters, refined grains and SiC particles, low deformation texture, tightly bonded SiCp/2009Al interface, and sound interfacial bonding between deposited layers.

Effect of particle volume fraction on wear behavior in Al–SiC MMC coated on DIN AlZnMgCu1.5 alloy

Abstract In this study, DIN AlZnMgCu1.5 alloy surface (Al + SiC) was coated with metal matrix composite (MMC) by using hot press sintering method (HPSM). Al was used as matrix material and SiC powders were used as reinforcing material in the coating process on DIN AlZnMgCu1.5 alloy surface. Al/SiC MMC coating was produced at 600 °C under 120 MPa pressure and with varying SiC content (5, 10 and 15 vol.%). Optical microscopy (OM), scanning electron microscopy (SEM), energy dispersive X-ray spectroscopy (EDS), and X-ray diffraction (XRD) were used to examine the microstructure, elemental analysis and phase structure of both the coating zone and the transition zone between the substrate and the coating. The hardness was measured and a dry sliding linear reciprocating wear test was run to determine the mechanical properties of the coating layer. Consequently, the coefficient of friction (COF) and wear volume were determined. OM and SEM images showed a homogeneous distribution of SiC particles and a less porous structure. The hardness of the MMC coating increased with increasing SiC content. Also, the numerical analysis of the wear test simulation was done based on Archard’s law. The results of both wear tests showed that the volume loss values were consistent with each other and the amount of wear significantly reduced by increasing the rate of SiC reinforcement.

Pulsed Laser Ultrasonic Vibration-Assisted Cutting of SiCp/Al Composites through Finite Element Simulation and Experimental Research

Silicon carbide particle-reinforced aluminum matrix composites (SiCp/Al) find diverse applications in engineering. Nevertheless, SiCp/Al exhibit limited machinability due to their special structure. A pulsed laser ultrasonic vibration assisted cutting (PLUVAC) method was proposed to enhance the machining characteristics of SiCp/Al and decrease surface defects. The finite element model was constructed, considering both the thermal effect of the pulsed laser and the location distribution of SiC particles. The model has been developed to analyze the damage forms of SiC particles and the formation mechanisms for the surface morphology. The influence of pulsed laser power on average cutting forces has also been analyzed. Research results indicate that PLUVAC accelerates the transition from the brittleness to the plastic of SiC particles, which helps to reduce surface scratching caused by fragmented SiC particles. Furthermore, the enhancement of surface quality is attributed to the decrease in surface cracks and the beneficial coating effect of the Al matrix. The accuracy of the simulation is verified by experiments, and the feasibility of PLUVAC method to enhance the surface quality of SiCp/Al is confirmed.

Mechanical, tribological, and morphological properties of SiC and Gr reinforced Al-0.7Fe-0.6Si-0.375Cr-0.25Zn based stir-casted hybrid metal matrix composites for automotive applications: Fabrication and characterizations

The main goal of this research is to meet the demanding need for developing lightweight materials with improved properties that are appropriate for several engineering applications. The investigators proceeded to considerable efforts to assess the mechanical, micro-structural, and tribological characteristics of Al-0.7Fe-0.6Si-0.375Cr-0.25Zn/10 wt%SiCP/3 wt%GrP-MMC, Al-0.7Fe-0.6Si-0.375Cr-0.25Zn/15 wt%SiCP/5 wt%GrP-MMC, and Al-0.7Fe-0.6Si-0.375Cr-0.25Zn/20 wt%SiCP/8 wt%GrP-MMC based hybrid metal-matrix nano-composites (HMMC's). These hybrid aluminum matrix nano-composites were fabricated using the liquid processing stir casting method for automobile, aviation, defense, and chemical handling sectors owing to their superior strength, and higher thermal conductive properties. The machinability of Al-0.7Fe-0.6Si-0.375Cr-0.25Zn/(SiCp + Grp) - MMC has received limited attention to date. Owing to its exceptional characteristics, this hybrid composite could take the role of cast iron or aluminum composites in a wide-variety multitude of engineering applications. The Mechanical properties of fabricated Hybrid-MMCs have been examined along with tribological properties & other factors, affecting the tensile strength of cast composites in this study. Additionally, the characterization has been performed through X-ray Diffraction (XRD), Energy Dispersive Spectrum (EDS), Scanning Electron Microscope (SEM), and Optical Microscopy. The fabricated samples of hybrid metal matrix nano-composites of Al-0.7Fe-0.6Si-0.375Cr-0.25Zn matrix have been tested for microstructure analysis, micro hardness test, density, tensile strength, and grain size. Microstructure study clears the claim of uniform distribution of SiC & Graphite particles in Al matrix alloy. An average tensile strength has been recorded as 258 MPa and a percent-elongation of 4.6 during the tensile test. Tensile-fractography findings have portrayed the intrinsic fractured-rupture microstructure of tensile-tested samples that seemed to have particle deformation breakage and pull-outs. The density of Al/(SiCp + Grp)-MMCs have been found to be 2.76 g/cm3 whereas the average hardness has been recorded at 120HV. An increase in graphite content in Al/SiC-MMC's provides a significant improvement in friction coefficient as well as a reduction in wear rate. Findings have observed that the wear rate is increased with increasing the sliding speed, however, it is almost constant between 300 and 600 rpm, and beyond this wear rate increases drastically. Likewise, the coefficient of friction also shows a considerable increase with the increase in sliding speed. As the composition of graphite in the material increases, a considerable decrease in the wear has been noted down because of the presence of tribo-layer formed between mating surfaces. A high value of applied load and high rotating speed imposed high deformation of the surface and increase in frictional force, as a result, an increase in wear rate. Wear rate increases with the increment in load during the wear test, while friction coefficient decreases. Hence, the development of HMMCs with better mechanical, microstructural, and tribological properties that can be utilized as cast iron or aluminum composites in a diverse spectra multitude of engineering applications involving the study's scientific insights and technological developments. Manufacturers in the myriads of industries, including aerospace, ground-transportation, thermal management, industrial, recreational, and infrastructure, could profit inventors/producers from the findings of the current study.

Dispersion of reinforcing micro-particles in the laser welding of metal matrix composites: High-fidelity modeling with experimental characterization

Understanding the interaction mechanism between keyhole, solid phase (ceramic particles), and liquid phase (metal matrix) will offer key insights into laser welding/additive preparation of high-performance metal matrix composites. The laminar SiC particle–reinforced Al matrix composite, which is extensively used in aviation structural parts, is utilized as the experimental model. The effect of the keyhole mode on the migration behavior of SiC particles in the weld pool was revealed by simulating the multiphysical thermal fluid flow during the laser-welding process. The simulation results revealed that the flow of the molten pool and the keyhole mode have significant effects on the migration behavior of particles. The variation of keyhole mode leads to considerable changes in molten pool dynamics and corresponding SiC particle distributions in the molten pool. The observed selective distribution of SiC particles is due to the flow characteristics of the molten pool. In addition, results showed that the keyhole mode can maximize the uniform distribution of SiC particles in the melt pool, thereby addressing the nonuniformity problem of SiC particles. This work is a fundamental advancement in the modeling of laser-welded SiC particle–reinforced Al matrix composites and provides unprecedented details on the effects of keyhole patterns on weld pool dynamics. This work can further offer practical guidance for “temperature field–regulating reaction behavior” and “velocity field–regulating distribution behavior.”

SiCp/AlSi10Mg composites with simultaneously enhanced tensile strength and ductility fabricated by laser powder bed fusion additive manufacturing

Currently, SiCp/Al composites fabricated by laser powder bed fusion (LPBF) suffer from poor plasticity caused by their low density and a great deal of coarse needle-like brittle phases, which seriously limits their application in aerospace field. High scanning speed can shorten the reaction time between SiC and Al liquid due to the short existence time of molten pool, effectively suppressing the nucleation and growth of these needle-like brittle phases. Therefore, an LPBF with a high-speed scanning printing strategy was proposed to fabricate micro-SiCp/Al composites in this study. The effects of energy density (E) on the densification, microstructure and mechanical properties of the composites were studied systematically. The contradiction that the higher the density, the more and coarser needle-like phases produced was successfully resolved. The micro-SiCp/Al composites with simultaneously enhanced strength and ductility were achieved at a proper E of 47 J/mm3, whose tensile strength and elongation reached 356.7 ± 5.0 MPa and 11.6 ± 0.4%, respectively. Among them, the elongation is almost 4 times the maximum value reported in the literature, which is mainly attributed to the extremely high compactness without any visible defects, the moderate dissolution and uniform distribution of SiC particles, the refined grains, a few nano-sized Al4C3 and Al4SiC4, and the interfacial structure SiC–Al4SiC4–Al with high interfacial bonding strength. Because these factors greatly reduced the stress concentration inside the composites and made the stress evenly distributed during loading, thus improving the ductility. Especially these in-situ synthesized Al4C3 and Al4SiC4 can not only promote the transformation of α-Al columnar grains to cellular grains, but also hinder the bending and motion of dislocations, playing a role in grain refinement and dispersion strengthening. The fracture mode of the composites is ductile fracture. Our work provides theoretical guidance and technical support for fabricating SiCp/Al composites with simultaneously enhanced strength and ductility.

Fabrication of SiC/Al Functionally Graded Materials Via Filtration Extrusion

Functionally graded materials (FGMs) have broad application prospects owing to their outstanding material properties. Herein, a filtration extrusion device is designed, and low‐content SiC/Al composites are used to explore the feasibility of applying filtration extrusion techniques to the fabrication of FGMs. The results suggest that the extrusion force increases monotonically with an increase in the filtration extrusion ratio. Furthermore, the filtration extrusion process can be divided into two stages based on the change trend of extrusion pressure: at stage 1, extrusion force is small and increases slowly. At stage 2, the extrusion force increases significantly and rapidly. During the filtration extrusion process, the larger the initial content, the lower the extrusion temperature, the smaller the hole‐separation mold area ratio, the faster the increase in the extrusion force, and the greater the maximum extrusion force during the extrusion process. Based on filtration extrusion experiments for various extrusion distances, it is found that the transition from the nonflow to the flow influence zone is primarily responsible for the enrichment and gradient distribution of SiC particles. The SiC particles are distributed in a gradient, and the content of SiC particles near the separation mold is higher than that on the other side.

Silicon carbide particulate reinforced dual phase brass composites with improved wear resistance prepared via friction stir processing

ABSTRACT The purpose of this study is to develop brass based composites using friction stir processing (FSP) for improved wear resistance. SiC particles (volume percentage of 0–18) were efficiently reinforced into Cu−40Zn dual phase brass using FSP. A tool rotational speed of 1600 rpm and a traverse speed of 60 mm/min were used. The FSP process provided an excellent distribution of SiC particles without aggression and segregation. The solid state processing subdued the role of density gradient to have an adverse effect on particle distribution. EBSD maps demonstrated extreme refinement of grains because of dynamic recrystallisation. TEM micrographs hinted that the dynamic recrystallisation was interrupted i.e. discontinuous. Few dislocation fields as well as twinned grains were spotted. SiC particles were beneficial to improve the resistance to wear of the brass composite. Further, the role of SiC particles on the mode of sliding wear as well as the size of wear debris was reported.

Optimization of squeeze casting process parameters on mechanical properties of SiCp reinforced LM25 composites through Taguchi technique

Abstract The aim of the present work is to examine the influence of processing parameters on fabricated composites of LM25 alloy with SiC particle reinforcement through a squeeze casting technique. The following process parameters, like stirring speed from 550 to 750 rpm, SiCP (4 wt% to 8 wt %), and melting temperatures (from 600 to 700 °C) were employed. Then, the processed composites were subjected to microscopy analysis and mechanical tests to ascertain their metallurgical and mechanical properties. SEM micrographs of an LM 25 composite sample show better bonding of SiC particles with matrix, which is due to homogeneous dispersion of SiC particles in the stir casting process. The maximum tensile strength (211 MPa) and hardness (91 Hv) were achieved on the composite samples with processing parameters of 750 rpm stirring speed, 8% SiC proportions, and 650 °C melting temperature, respectively. From the design of the experiment by the Taguchi method, it is observed that the stirring speed plays a significant role in achieving a better distribution of SiC particles in the composite samples than other parameters like SiC weight ratios and the melting temperature of the alloy.

Development of hard and wear-resistant SiC-AISI304 stainless steel clad layer on low carbon steel by GMAW process

In the present investigation, a successful attempt has been done to utilize conventional gas metal arc welding (GMAW) setup to develop SiC reinforced AISI 304 stainless steel (ASS) clad layer on low carbon steel (LCS) substrate. The characteristics of the clad bead like bead profile and dilution depend on the GMAW processing parameters like GMAW voltage and consumable wire feed rate (CWFR). The clad deposition at a higher voltage range (30 V) developed a defect-free, uniformly distributed fine SiC-reinforced clad layer with better clad dilution with the substrate. Further, the SiC-reinforced clad layer showed a uniform distribution of fine SiC particles in the steel matrix and also the formation of different hard intermetallics like CrSi2, Mn3Ni2Si, Fe2C, Fe5C2, and Cr7C3 in the clad layer. The SiC-reinforced clad surface showed a significant improvement in Microhardness (up to 504 HV0.5) compared to the steel substrate (180 HV0.5). The clad layer also improved the adhesive wear resistance (upto 8.7 times) and abrasive wear resistance (upto 1.7 times) of low carbon steel substrate.

Influence of characteristic parameters of SiC reinforcements on mechanical properties of AlSi10Mg matrix composites by powder metallurgy

The bottleneck problems of SiC particles reinforced AlSi10Mg composites (SiC/AlSi10Mg) prepared by traditional casting method, such as composition segregation, interface reaction and coarse microstructure, can be effectively improved by powder metallurgy with lower processing temperature. In this study, the influence of SiC particle size and content on the properties of SiC/AlSi10Mg was systematically analyzed. SiC/AlSi10Mg composites were prepared by planetary ball milling, spark plasma sintering (SPS) and hot extrusion composite preparation process. The obtained composites presents dense microstructure without the formation of interfacial reaction phase. The distribution of micron SiC particles (μm-SiC) in the matrix is relatively uniform, and nano SiC particles (nm-SiC) slightly agglomerates with the increase of the content. The strength of SiC/AlSi10Mg increases with the increase of nm-SiC content, which is mainly attributed to dispersion strengthening, dislocation strengthening and grain refinement strengthening. The strength of SiC/AlSi10Mg hardly changes with the increase of μm-SiC content, but the elongation decreases gradually. The deformation between μm-SiC and AlSi10Mg matrix is not coordinated and μm-SiC cleave the AlSi10Mg matrix. The irregular boundaries of μm-SiC are easy to produce stress concentration during loading, leading to interface cracking or μm-SiC fracture. Therefore, μm-SiC are difficult to play a significant strengthening effect to composites. With the increase of SiC content, the fracture mechanism of composites gradually changes from ductile fracture to brittle fracture in SiC agglomeration region. This study lays a theoretical and experimental foundation for the controllable preparation and performance optimization of high strength and toughness AMCs reinforced by SiC particles.

Prediction of the tensile properties of ultrafine grained Al–SiC nanocomposites using machine learning

We discovered and analyzed the new prediction model by using machine learning (ML) for the tensile strength of aluminum nanocomposites reinforced with μ-SiC particles fabricated by accumulative roll bonding (ARB). The effect of the number of cycles and SiC content on the microstructure, phase analysis, tensile, and hardness properties have been investigated for the ARBed sheets and their composites. The experimental results showed the distribution of SiC particles improved by increasing ARB passes. The ARB approach greatly enhanced the ultimate tensile strength (UTS), yield strength (YS), and hardness. The UTS achieved was 254 MPa for 4% SiC after 9 ARB cycles. The hardness values of the ARBed AA1050, and AA1050-4 wt% SiC are 60, and 76.5, respectively, after 9 ARB cycles. The modified version of random vector functional link based on Growth Optimizer Algorithm is developed as a machine-learning model to predict the tensile properties of the produced composites. The efficiency of the developed ML model is evaluated with other methods according to the performance criteria.

Microstructure, texture, and mechanical properties analysis of novel AA7178/SiC nanocomposites

The current research aims to use stir casting to create a composite made from AA7178 aluminium alloy with nano SiC reinforcement at 1, 2, and 3 wt percent. Scanning electron microscope (SEM) with energy dispersive X-Ray (EDAX) was used to examine the microstructural changes of AA7178/nSiC composites. The addition of nano SiC reinforcement to the AA7178 matrix promotes grain refinement by providing additional nucleation sites for smaller grains to form. The microstructure of AA7178 composites underwent a considerable alteration due to the SiC addition, improving their mechanical properties. Electron backscatter diffraction (EBSD) study revealed the development of finer grains from coarser grains. All the samples seemed to have a completely random texture. The texture does not seem to be drastically altered by either the processing conditions or the incorporation of SiC. The uniform distribution of SiC particles and good interfacial bonding between the reinforcement matrix was confirmed by a transmission electron microscope (TEM). The maximum tensile strength was 206.12 MPa for AA7178 nanocomposite with 3 wt% of SiC reinforcement. The efficient transmission of load and dislocation strengthening were the strengthening mechanism for increasing in the tensile strength. The inclusion of 3 wt% of SiC particles increased the hardness of AA7178 nanocomposite to 51.70%.

Mechanical and thermal expansion behavior of hybrid aluminum matrix composites reinforced with SiC particles and short carbon fibers

In recent years, the research of hybrid composites reinforced by multiple reinforcements has received increasing attention because these composites have great potential to be tailored for various applications. In the present work, hybrid aluminum (Al) matrix composites reinforced with SiC particles and carbon fibers (SiCp-Cfs/Al composites) were fabricated by the colloidal dispersion and suction filtration method. It was found that SiCp-Cfs/Al composites had a dense structure and the carbon fibers and SiC particles were uniformly distributed in the Al matrix. The mechanical properties of SiCp-Cfs/Al composites with different reinforcement volume fractions were investigated. The results showed that the SiCp-Cfs/Al composites exhibited high tensile strength and elastic modulus (tensile strength 207 MPa and elastic modulus 92 GPa) when the volume fraction of SiC particles was 5% and the volume fraction of carbon fiber was 7%, which were significantly higher than that of SiCp/Al composites with 5% volume fraction of SiC particles (tensile strength 112 MPa and elastic modulus 80 GPa). The homogeneous distribution of carbon fibers and SiC particles in the Al matrix, which serves as co-reinforcing, is responsible for the high tensile strength and elastic modulus of SiCp-Cfs/Al composites. The coefficient of thermal expansion (CTE) of SiCp/Al composites and SiCp-Cfs/Al composites were measured at temperatures ranging from 25 °C and 400 °C. The results showed that the addition of carbon fibers caused the CTE of SiCp-Cfs/Al composites to be much lower than that of SiCp/Al composites.

Effect of tool tilt angle on microstructure, mechanical properties and fracture behavior of dissimilar friction stir lap welding joint of SiCp/ZL101 and ZL101

In order to achieve the lightweight goal of urban rail train braking system, friction stir lap welding (FSLW) was used to weld SiCp/ZL101 and ZL101 sheets to prepare a new type of brake disc material. The effects of different tool tilt angles (TTAs) on microstructure and mechanical properties of the welding joints were systematically studied. The TTA had a significant effect on the microstructure and defect formation of the dissimilar FSLW joints. There were tunnel defects under the advancing side at 1° and 2°. Internal defect-free weld structures were formed at 3° and 3.5°. A large number of dislocations caused by plastic deformation remained in the microstructure of the weld region at 1° and 2°, and the transformation of the microstructure of the weld region at 3° and 3.5° was dominated by dynamic recovery and dynamic recrystallization. The distribution of SiC particles in the nugget area was uniform, and the grains were obviously refined. With the increase of the TTA, the average grain size of the nugget area increased, the average size of the SiC particles decreased, and the average hardness of the nugget area increased. The four samples all formed a transition zone with good metallurgical bonding at the welding interface. The shear strength of the welding joints increased first and then decreased with the increase of the TTA. In the absence of welding defects, the shear strength reached the best level of 130.71 MPa at 3°. Both shear and tensile fractures were ductile fractures.

Simulation and experimental study on milling mechanism and tool wear of low volume SiCp/Al composites

Silicon carbide particles reinforced aluminum matrix composites are widely used in national defense and related high-end technology fields due to their excellent mechanical properties. To explore the milling mechanism and tool wear mechanism of low-volume SiCp/Al composites in high velocity milling, the milling experiments for 20% volume SiCp/Al2009 composites were performed using a polycrystalline diamond (PCD) tools. A three-dimensional milling model of SiCp/Al composite was established considering the random distribution of SiC particles, the influence of milling parameters on surface quality was comprehensively analyzed and its cutting mechanism was described, and the wear forms and mechanism of PCD tools were revealed during milling of SiCp/Al composites. The result showed that the cutting depth is the main factor affecting the machined surface quality, followed by the spindle speed, and the feed rate has the smallest effect on it. It was observed that when spindle speed ( n) was 17,000 r/min, the feed rate ( f) was 8 mm/min, the depth of cut ( ap) was 0.04 mm, the surface roughness value was the smallest, Ra was 0.056 μm. The surface morphology was mainly manifested as pits, cracks, burrs, and so on, subsurface defects included particle breakage, peeling, and matrix cracks, and the tool wear forms included chipping, flaking, and bond wear.

Effectuates of Direct Particle Injection Friction Stir Process tool for the Al/SiC surface coating fabrication

The Project is investigated the Direct Particle Injection Friction Stir Processing Tool (DPI-FSP) fabricating the Al/SiC Surface Coating (SC). The FSP using vertical milling machine which was performed the tool rotation speed 1000 rpm at traverse feed 20 mm/min.Peculiarity of the tool is the deletion of material preparation (Making grooves or Drill hole for filling the reinforcement particles) and continuously injected the reinforced particles during the process. The tool is fabricated the thin surface coating of Al/SiC. As a result, The micrograph is revealed that homogenous distribution of SiC particles and peneterated 340 µm thick on the surface matrix . The SC exhibited 55% of the increase in hardness as compared the base material. The X-ray diffraction results are showed that the no intermetallic was discovered besides the SiC particles. The SC wear test results is exhibited the superior frictional coefficient of 0.71 than the Empty Pass.