Particle Metal Matrix Composites Research Articles

Experimental Study to Analyze the Effect of Silicon Carbide on the Mechanical Properties on AA3103

Abstract: Metal matrix composites (MMCs), such as SiC particle reinforced Al, are one of the widely known composites because of their superior properties such as high strength, hardness, stiffness, wear, and corrosion resistance. These MMC’s are widely used in aircrafts, automobiles, electronic equipment’s, and sporting goods. Hence a solution is needed to solve the issues like selection of material based on their mechanical properties. In this study aluminum (Al-3103)/SiC Silicon carbide reinforced particles metal-matrix composites (MMCs) are fabricated by induction casting and manual stirring. The MMCs bars are prepared with varying the reinforced particles by weight fraction ranging from 5%, 10%, and 15%. Different tests are carried out on these MMC and base alloy to study the mechanical properties like tensile strength, hardness, and wear rate. It is observed that the addition of silicon carbide increased the tensile strength and hardness and also the wear resistance Keywords: AA 3103, Silicon carbide, Tensile strength, wear resistance

Effects of Electrical Parameters during Non conventional Machining of Al/Sic Metal Matrix Composites by Electrical Discharge Machine

Particulate Reinforced Al/SiC Metal Matrix Composites (PRALSICMMC) is gradually becoming very important materials in manufacturing industries e.g. aerospace, automotive, and automobile industries due to their superior properties such as lightweight, low density, high strength to weight ratio, high hardness, high temperature, and thermal shock resistance, superior wear and corrosive resistance, high specific modulus, high fatigue strength, etc. In this study aluminum (Al- 6063)/SiC Silicon carbide reinforced particles metal-matrix composites (MMCs) are fabricated by melt-stirring technique. The MMCs bars and circular plates are prepared with varying the reinforced particles of SiC by weight fraction ranging from 5%, 10%, 15%, and 20%. The average reinforced particles sizes of SiC are 220 mesh, 300 mesh, and 400 mesh respectively. The stirring process is carried out at 150 revs/min rotating speed by graphite impeller for 15 min. A series of machining tests are performed on EDM. Copper electrodes are used as tools (cathode), Prepared specimens of Al/SiC MMCs are used as workpiece (anode) and kerosene is used as the dielectric fluid. The Performance parameters measured during experimentation were Tool Wear Rate (g/min), Metal Removal Rate (g/min), Over Cut on diameter (mm), and Average Surface Roughness Ra (μm) for each experiment by varying Pulse Peak Current IP (2 Amp, 6 Amp, 10 Amp,14 Amp) and gap voltage Vg ( 25 Volts, 30 Volts, 35 Volts, and 40 Volts). The investigations of results are done graphically.

Material Modeling of Particle Reinforced In Metal Matrix Composite

The FEA model of particulate reinforced metal matrix composite which will be used for material optimization application. A particle distribution method will be introduced to get a random pattern of particles reinforcement model in the metal matrix FEA model. A FEA model of particle metal matrix composite that allows to vary particle distribution and the model is developed in ANSYS commercial FEA code .The particle distribution pattern is generated using sphere packing method for a given percentage of particulate mixture ratio. The effect of particle concentration and distribution and its mechanical behavior and metal matrix can be Analyzed and studied in this model. This model will be useful in optimizing the particle metal matrix against a given mechanical behavior or performance required for the variation of percentage in particle mixture ratio, particle grain size, particle material and matrix material.

Investigation on Tensile and Impact Behavior of Aluminum Base Silicon Carbide Metal Matrix Composites

Objectives: The scope of this work was to: 1. to fabricate Silicon Carbide (SiC) particle Metal Matrix Composites (MMC) by vortex method; 2. to investigate the effect of SiC particles on the tensile and impact behavior of SiC particle reinforced 6061 aluminum alloy composites. Recently, the material technology has seen many contemporary developments in the field of fabricating new materials which reinstates the current materials for different applications. Amidst these, the composite materials have an important aspect which is a combination of different materials possessing various physical and chemical properties. Methods: This Aluminum base metal Matrix Composite (AMC) has been manufactured by wrought aluminum alloy by varying the weight fractions of silicon carbide to compose five distinct forms of composites. Stir – casting has been chosen as the manufacturing technique, in this study. Findings: The manufactured composites were tested to determine their tensile and impact properties and the result proves that the sample with higher percentage of silicon carbide has better mechanical properties, comparably. Applications: This study essentially focuses on establishing AMC as they find applications on aerospace and automotive industries because of their admirable properties compared with the unreinforced alloysKeywords: Aluminum 6061, Mechanical Properties, Metal Matrix Composite, Silicon Carbide, Stir Casting

An Analysis of Mechanical Properties of the Developed Al/SiC-MMC’s

Metal Matrix Composites (MMC's) have evoked a keen interest in recent times for potential applications. Advance composite materials like Al/SiC metal matrix composite is gradually becoming very important materials in manufacturing industries e.g. aerospace, automotive and automobile industries due to their superior properties such as light weight, low density, high strength to weight ratio, high hardness, high temperature and thermal shock resistance, superior wear and corrosive resistance, high specific modulus, high fatigue strength etc. In this study aluminum (Al-6063)/SiC Silicon carbide reinforced particles metal-matrix composites (MMCs) are fabricated by melt-stirring technique. The MMCs bars and circular plates are prepared with varying the reinforced particles by weight fraction ranging from 5%, 10%, 15%, and 20%. The average reinforced particles size of SiC are 220 mesh, 300 mesh, 400 mesh respectively. The stirring process was carried out at 200 rev/min rotating speed by graphite impeller for 15 min. The microstructure and mechanical properties like Proportionality (MPa) limit, Tensile strength upper yield point (MPa), Tensile strength lower yield point (MPa), Ultimate tensile strength (MPa), Breaking strength(MPa), % Elongation, % Reduction in area, Hardness (HRB), Density (gm/cc), Impact Strength (N.m) are investigated on prepared specimens of MMCs. It was observed that the hardness of the composite is increased with increasing of reinforced particle weight fraction. The tensile strength and impact strength both are increased with rising of reinforced weight fraction. Different mechanical tests were conducted and presented by varying the particle size and weight fractions of SiC.

Effect of Localized Metal Matrix Composite Formation on Spot Friction Welding Joint Strength

In this study, metal particles were added during the spot friction welding (SFW) process, a solid state sheet metal joining process, to create a localized metal matrix composite (MMC) for the improvement of lap shear strength in AISI 6111-T4 aluminum alloy sheets. The Ancorsteel® 1000 particles were compressed between the upper and lower sheets and distributed concentrically around the tool axis perpendicular to the plate surface, which formed a localized MMC and were effective as the reinforcement particles in aluminum 6111-T4 alloy sheets. Results revealed that the MMC reinforcement improved the lap shear strength of SFW joints by about 25%. An aluminum-ferrous solid solution was formed around the steel particles along the aluminum matrix interface. The load-deflection curve shows that the steel particle MMC increased both the strength and ductility of SFW joint. This is attributed to two phenomena observed on the failed lap shear tensile specimens with SFW MMC. One is the longer and more torturous crack path, and the other is the secondary crack on steel particle MMC reinforced SFW joints.

Influence of Tool pin Profile on the Microstructure and Mechanical Behavior of Cu/SiC Metal Matrix Composites Produced by Friction Stir Processing

Friction stir processing (FSP) is a metal-working technique that causes microstructural modification and change in the upper surface of metal components. In this work the effects of tool pin profile on the microstructure and mechanical behavior of reinforced SiC particles metal matrix composites (MMCs) produced by friction stir processing were studied. Optical microscopy (OM) and Scanning electron microscopy (SEM) was employed to carry out the microstructural observations. Vickers Microhardness Machine used for microhardness evaluation. Results show that, tool pin profile play a major role in improvement of the surface quality, SiC particles dispersion in pure copper matrix, hardness behavior and wear resistance. Two different tool pin profile (straight cylindrical and square) were used to perform the process. It was found that, straight cylindrical tool pin profile led to finer grains, uniform dispersion of SiC particles, higher microhardness and wear resistance values.

Experimental Study on Fabrication of Al-Al2O3/Grp Metal Matrix Composites

In this study aluminum (Al-6070)/alumina (Al2O3), and Al-6070/ graphite (Gr) reinforced particles metal-matrix composites (MMCs) are fabricated by melt-stirring technique. The MMCs bars and plates are prepared with varying the reinforced particles volume fraction ranging from 5% to 15%. The average reinforced particles size of alumina (Al2O 3) and graphite (Grp) are 23 μm and 53 μm, respectively. The stirring process was carried out at 200 rev/min rotating speed by graphite impeller for 15 min. The microstructure and mechanical properties are investigated on prepared MMCs. It was observed that the hardness of the composite is increased with increasing of reinforced particle volume fraction. The tensile strength and impact strength both are decreased with rising of reinforced volume fraction. The prepared composite plates are welded by gas welding with Al-Si-base filler metal. Rockwell hardness test was conducted and presented the test result for un-welded and welded zone.

Effect of sub-micron Al 2O 3 concentration on dry wear properties of 6061 aluminum based composite

Dry wear tests of particle metal matrix composites (PMMC's) of the 6160 Al Alloy with sub-micron Al 2O 3 particles were performed using a pin-on-disc tribometer. The content of alumina in the composite was varied form 0 to 30%, (v/v), to study the effect of particles concentration on wear. The composites were prepared by powder metallurgy techniques. Tests were performed under different loads at room temperature (21 °C), at constant sliding speed of 1 m/s. Results clearly indicate that increasing the volume percentage of alumina particles in the composite improves the wear resistance. Addition of 10%, (v/v), of alumina particles improved the wear resistance of the 6160 aluminium alloy by an average of 45% compared to the alloy. Increasing the alumina content to 20% improves the wear resistance by 113%. Further addition of alumina to 30% improves wear resistance by 145%. Hardness test indicate that the hardness of the composite also increases linearly with the percentage of added alumina particles. SEM tests revealed complex combination of wear mechanisms on the surface of the warn test specimens.

Micromechanical investigation of the fatigue crack growth behaviour of Al–SiC MMCs

A defect tolerant approach to fatigue modelling for constant amplitude loading was developed by Bruzzi and McHugh (Int. J. Fatigue 24 (2002) 1071). It was applied to two metal matrix composites (MMCs): (1) a forged 2124 Al reinforced with 17% SiC particles and (2) a cast 359 Al reinforced with 20% SiC particles MMC, in Bruzzi and McHugh (Int. J. Fatigue 25 (2003) 577). However, no explicit representation of the two-phased microstructure was considered. The material was assumed to be homogeneous and behave as a continuum. In this work, the extreme effects of the reinforcing particles on the growth behaviour of a small fatigue crack, using the modelling methodology of Bruzzi and McHugh, is investigated for the Al 2124 MMC. This is performed using micromechanical models, in which separate representations of the matrix and the reinforcing particles are included, in order to assess local stress fields within the matrix. Two extreme cases of idealised crack growth are examined: (1) a predefined crack path approaching a reinforcing particle and (2) a predefined crack path lying between two reinforcing particles. The predicted stress gradients along each of the predefined paths are then included in the fatigue modelling methodology described by Bruzzi and McHugh. Finally, the predicted results of the extreme cases of the short crack growth behaviour for the two-phase Al 2124 MMC are presented, discussed and compared to the short crack growth rate behaviour of the homogenised MMC model of Bruzzi and McHugh.

Imaging damage evolution in a small particle metal matrix composite

It is difficult to study effectively microstructural damage in metal matrix composites (MMCs) due to artefacts arising from traditional metallographic sample preparation techniques. The sectioning and imaging capabilities of the focused ion beam (FIB) microscope provide an excellent method for studying damage accumulation in MMCs. The capabilities of the FIB system have been used to carry out a study of damage evolution in a powder-processed/hot-extruded Al2080/SiCp MMC. Microvoid damage is found to be preserved accurately during FIB sectioning, allowing measurements of the fraction of decohered particles and the void area fraction. These microscopic damage measurements are correlated with the macroscopic damage parameter, D, as determined by density measurements. Using transmission electron microscopy, the evolution of dislocation structures at the SiC-matrix interfaces has been examined. A previously unreported decohesion mechanism has been observed.

Precipitation and dissolution kinetics in Al–Cu–Mg–Fe–Ni alloy 2618 and Al–alumina particle metal matrix composite

The kinetics of precipitation and dissolution of precipitate phases in AA2618 and AA2618–alumina particle-reinforced metal matrix composite were studied using differential scanning calorimetry (DSC). Thermal effect peaks due to GPB (Guinier-Preston-Bagaryatskii) zone formation, GPB zone dissolution, formation of the θ′ and S′ phases, and the dissolution of the θ′ and S′ phases were identified. The kinetic parameters for GPB zone formation and dissolution reactions, calculated by using both the modified Avrami–Johnson–Mehl (AJM) equation and the Kissinger-type expressions, were comparable. GPB zone formation was found to be suppressed in the composite material while, on the other hand, GPB zone dissolution was enhanced.

Electrochemical Processing of Layered Composite Coatings of Nickel - Aluminum - Alumina / Alumina - Yttria Stabilized Zirconia

ABSTRACTMultilayered coatings of single and dual particle metal matrix composites, with or without ceramic overlayers, have been produced by a novel combination of electrochemical deposition (electroplating and electrophoretic deposition) and reaction bonding. The coatings contain the following layers in a variety of combinations deposited on Ni substrates: (i) electroplated composites of Ni with Al and/or alumina particles, (ii) precursor Al + A12O3 + yttria stabilized ZrO2 transformed into A12O3 + yttria stabilized ZrO2 by the reaction bonding method, and (iii) yttria stabilized ZrO2. In order to determine the appropriate processing parameters for the multilayered coatings, uniform one-layer coatings were deposited and characterized. We find that in the dual particle Ni-Al-Al2O3 coatings the volume percent of the particles does not show a dependence on deposition current density. However, volume percent alumina in these coatings has a strong dependence on the amount of this particle in the plating bath, while the volume percent Al shows only a weak dependence on its bath content. Comparison of the deposition behavior of these dual particle with single particle coatings, containing Al or alumina only, reveals that the presence of Al in the bath interferes with the codeposition of alumina. This interference, however, is not reciprocal. When coatings containing Al are annealed, Ni and Al react to form a solid solution of Al in Ni (γ) or a two phase mixture of this solid solution and the intermetallic, Ni3Al, (γ-γ') depending on the annealing temperature. Finally, we find that the formation of the reaction bonded alumina plus yttria stabilized zirconia layer requires the oxidation resistance afforded by aluminum in the underlying electroplated layer.

Dry sliding wear of Al alloy 2024-Al 20 3 particle metal matrix composites

In the present investigation, Al 2024-15vol.%Al 20 3 particulate (average size, 18 μm) composites were fabricated using the liquid metallurgy route. The wear and friction characteristics of AI alloy 2024 and Al 2024-15vol.%Al 20 3p composite in the as-extruded and peak-aged conditions were studied using a pin-on-disc machine (with a steel disc as the counterface material). The worn surfaces, subsurfaces and the debris were analysed in a scanning electron microscope. The performance of the composite in the as-extruded condition is slightly inferior to that of the unreinforced alloy. However, in the T6 condition, although the wear rates of two materials are initially comparable, the unreinforced alloy seizes while the composite does not within the tested range employed. In the as-extruded condition, the presence of A1 20 3 particles is not particularly beneficial as they fracture and result in extensive localized cracking and removal of material from the surface. In the peak-aged condition, however, while the unreinforced alloy exhibits severe plastic deformation and undergoes seizure, there is no significant change in the mechanism in the case of the composite. Except in the case of the peak-aged unreinforced alloy, worn surfaces of all other materials show the presence of an iron-rich layer.

Dry sliding wear of Al alloy 2024-Al2O3 particle metal matrix composites

Dry sliding wear of Al alloy 2024-Al2O3 particle metal matrix composites

The effect of the spatial distribution of reinforcement on the fabrication and heat treatment of (Al4wt.%Cu)SiC particle metal matrix composites

The hot workability of particulate-reinforced metal matrix composites (MMCs) is impaired by the presence of the reinforcement. The paper describes the effect of the spatial distribution of SiC particle (SiC p) reinforcement on the ability to subject (Al4wt.%Cu)SiC p MMCs to a hot-roll powder metallurgy route, with particular reference to the matrix-to-matrix-reinforcement-particle-size ratio. All MMCs exhibited edge cracks on rolling, whilst the unreinforced material did not. As the reinforcement became more uniformly distributed throughout the matrix, so cracking at the edges became less severe and a higher reduction in thickness could be achieved by rolling before edge cracks began to appear. The latter was achieved when the matrix-to-reinforcement-particle-size ratio tended towards unity. The time required to reach peak hardness under artificial aging at 463 K was not altered by the presence of the reinforcement. Differential scanning calorimetry experiments showed a change in precipitation sequence in the MMCs with precipitation of the θ′ phase occurring at lower temperatures, and the rate of precipitation of the θ″ phase slowed down. There was no direct correlation between the homogeneity of the distribution of the reinforcement within the matrix and the peak hardness. In MMCs with the same size of reinforcement a higher level of hardness was achieved when a smaller matrix mass median particle size was used.

Hydrogen effects in (AlTi)SiC particle metal matrix composites

The development of advanced air frames and propulsion systems has generated significant research and development activity in the area of light-weight high temperature intermetallic alloys. Exposure to hydrogen results in the severe embrittlement of many intermetallics. In the present study the microstructure of spray-atomized and codeposited metal matrix composites (MMCs) were characterized following hydrogen charging. The results show that, under severe conditions such as exposure to NaCl solutions at cathodic charging conditions, initial crack propagation in (AlTi)SiC p MMCs (which SiC p represents SiC particles) occurs without any applied stress. It is also important to note that hydrogen charging increases the amount of hydrogen in the material. There is always the possibility of preferential hydrogen accumulation at the large number of incoherent interfaces between the reinforcement particulates and the matrix. The phenomenology of hydrogen embrittlement and possible mechanisms of embrittlement are discussed.