Particle Reinforced Metal Matrix Composites Research Articles

Effect of heat treatment on the microstructure and properties of in-situ Mg2Si reinforced hypereutectic Al-18%Si matrix composites

The in situ preparation of particle reinforced metal matrix composites (PRMMCs) can prevent the particle surface from pollution, improve the wettability of particles and matrix metals, and reduce the production cost of composites. In this paper, in situ Mg2Si reinforced hypereutectic Al-18%Si matrix composites were prepared by adding an appropriate amount of magnesium. However, the Mg2Si enhanced phase often has developed dendrites, which are easy to cause stress concentration and cut apart the matrix, resulting in the decrease of the mechanical properties of the material. Therefore, in this study, necessary solution treatment and aging treatment were carried out, and the effect of heat treatment on the microstructure and properties of the prepared composites was discussed. The results showed that the in situ Mg2Si reinforced Al-18%Si matrix composites with an ideal microstructure could be prepared by adding 4% Mg. After solution treatment at 545 °C for 8 h and aging treatment at 170 ± 2 °C for 8 h, the coarse dendrites of Mg2Si were broke and granulated, which improved the strength, hardness and wear resistance of the composites. Compared with the common as cast hypereutectic Al-18%Si alloy, the hardness and the strength of the prepared composites were increased by 30% and 46%, respectively. Besides, the granulation process of the in situ Mg2Si phase was explained with the Gibbs-Thomson theorem in this paper.

Random model for radiation shielding calculation of particle reinforced metal matrix composites and its application

The work aimed to calculate the radiation biological shielding performance of particle reinforced metal matrix composite (PRMMCs) using more reasonable model instead of conventional Uniform Filling Model, also attempted to provide a basis for the radiation shielding optimal design of such materials. Firstly, RSA (Random Sequential Adsorption) Model and GRM (Grid Random Model) were established based on MATLAB and Monte Carlo Particle transport program MCNP, and then advantages and disadvantages of them were compared. Later, the influences of metal matrix type, particle (B4C) content, particle shape and particle shape parameters on the biological shielding performance of materials were calculated under different energy neutrons and different thickness shield using random models. Finally, the optimal aspect ratio of regular hexahedral B4C was calculated by Genetic Algorithm combined with MATLAB and MCNP. It indicated that GRM could be applied to radiation shielding calculation of PRMMCs.

Mechanistic force modeling in drilling of SiCp/Al matrix composites considering a comprehensive abrasive particle model

SiCp/Al composite is one of the key light metal matrix composites widely used in aerospace and electronics industries due to its excellent material properties. Understanding the mechanism of abrasive particle action and the cutting force generation is crucial for achieving desired hole quality and machining accuracy. However, there is no research on cutting force modeling in drilling of SiCp/Al composites. This paper proposes an energy-based mechanistic modeling method to predict the cutting force in drilling of SiCp/Al composites for the first time. A new comprehensive abrasive particle model considering different particle action mechanisms, such as cracking, debonding, and squeezing, is presented to depict the energy consumed by abrasive particle action. Experiments with a wide range of particle volume fractions and feed rates, and different particle sizes were carried out to validate the accuracy of the proposed model. Results show that the proposed model can accurately predict the cutting force with an average error of 6.55% in drilling of SiCp/Al composites. Furthermore, the energy consumed on abrasive particle action is estimated to be 8.2–13.6% of total cutting energy. The proposed model on SiCp/Al composites can be extended to other particle reinforced metal matrix composites.

Effects of Turning Parameters and Parametric Optimization of the Cutting Forces in Machining SiCp/Al 45 wt% Composite

Cutting force in the machining process of SiCp/Al particle reinforced metal matrix composite is affected by several factors. Obtaining an effective mathematical model for the cutting force is challenging. In that respect, the second-order model of cutting force has been established by response surface methodology (RSM) in this study, with different cutting parameters, such as cutting speed, feed rate, and depth of cut. The optimized mathematical model has been developed to analyze the effect of actual processing conditions on the generation of cutting force for the turning process of SiCp/Al composite. The results show that the predicted parameters by the RSM are in close agreement with experimental results with minimal error percentage. Quantitative evaluation by using analysis of variance (ANOVA), main effects plot, interactive effect, residual analysis, and optimization of cutting forces using the desirability function was performed. It has been found that the higher depth of cut, followed by feed rate, increases the cutting force. Higher cutting speed shows a positive response by reducing the cutting force. The predicted and experimental results for the model of SiCp/Al components have been compared to the cutting force of SiCp/Al 45 wt%—the error has been found low showing a good agreement.

A Review on the Finite Element Modeling of the Particle Reinforced Metal Matrix Composites in Cutting Process

Background:: Particle Reinforced Metal Matrix Composites (PRMMCs) are widely used because of the higher specific strength, better dimensional stability, lower thermal expansion coefficient, better wear and corrosion resistance. However, the existence of reinforcing particles makes it hard to machine. The main manifestations are as follows: severe tool wear, easy generation of debris tumors in processing, and many defects on the machined surface, etc. These seriously limit its wider application. The Finite Element Method (FEM) has been widely applied in the research of PRMMCs machining according to recent patents, which can improve the efficiency and reduce the cost of research. Therefore, it is necessary to carry out a deep research for the processing technology of PRMMCs. Methods:: In this paper, the latest research progress of finite element simulation of cutting PRMMCs was summarized. The key technologies of finite element simulation, including constitutive model, geometric model, friction model between chip and tool, fracture criterion and mesh generation, are comprehensively analyzed and summarized. The application in the specific processing methods was discussed, such as turning, milling, grinding, ultrasonic vibration grinding and drilling. The existing problems and development direction of the simulation of PRMMCs cutting are also given. Besides, a lot of patents on finite element simulation for PRMMCs machining were studied. Results:: Finite element model for the actual composition determines the accuracy of finite element simulation. Through the secondary development of finite element software, a more realistic finite element model of Particle reinforced metal matrix composites can be established. Conclusion:: Finite Element Method (FEM) provides a new approach for the study of mechanism of Particle reinforced metal matrix composites machining. Quantitative analysis and prediction of micro- details in cutting can be realized.

An approach of peridynamic modeling associated with molecular dynamics for fracture simulation of particle reinforced metal matrix composites

A peridynamic (PD) model that involves the interface constitutive relation constructed by molecular dynamics (MD) is proposed to simulate the mechanical properties of the particle reinforced metal matrix composites and reproduce the similar failure mode in the experiments. In our numerical simulation, the constitutive models of PD bond are proposed and employed to simulate the Al-Al and SiC-SiC systems. Then, a MD simulation is carried out to characterize the Al-SiC interface. The predicted results are validated by comparing with the existing researches. After that, a concluded constitutive model of interface bond is applied to PD simulations. The performance of the modified theoretical models is demonstrated by two quasi-static simulations with and without considering the strengthening effects that SiC inclusions have on Al-matrix. Besides, the proposed model is also applied to predict the failure behaviors of the overall composite system successfully. The obtained results indicate that the constructed approach is applicative in investigating both the quasi-static and dynamic problems.

Effect of Tio 2 particles on the mechanical, bonding properties and microstructural evolution of AA1060/Tio 2 composites fabricated by WARB

Reinforced aluminum alloy base composites have become increasingly popular for engineering applications, since they usually possess several desirable properties. Recently, Warm Accumulative Roll Bonding (WARB) process has been used as a new novel process to fabricate particle reinforced metal matrix composites. In the present study, Tio2 particles are used as reinforcement in aluminum metal matrix composites fabricated through warm accumulative roll bonding process. Firstly, the raw aluminum alloy 1060 strips with Tio2 as reinforcement particle were roll bonded to four accumulative rolling cycles by preheating for 5 min at 300°C before each cycle. The mechanical and bonding properties of composites have been studied versus different volume contents of Tio2 particles by tensile test, peeling test and vickers micro-hardness test. Moreover, the fracture surface and peeling surface of samples after the tensile test and peeling test have been studied versus different amount of Tio2 volume contents by scanning electron microscopy. The results indicated that the strength and the average vickers micro-hardness of composites improved by increasing the volume content of Tio2 particles and the amount of their elongation and bonding strength decreased significantly.

Fracture Analysis of Particulate Metal Matrix Composite Using X-ray Tomography and Extended Finite Element Method (XFEM)

Particle reinforced metal matrix composites (MMCs) offer high strength, low density, and high stiffness, while maintaining reasonable cost. The damage process in these MMCs starts with either the fracture of particles or by the de-cohesion of the particle-matrix interfaces. In this study, the extended finite elements method (XFEM) has been used in conjunction with X-ray synchrotron tomography to study fracture mechanisms in these materials under tensile loading. The initial 3D reconstructed microstructure from X-ray tomography has been used as a basis for the XFEM to simulate the damage in the 20 vol.% SiC particle reinforced 2080 aluminum alloy composite when tensile loading is applied. The effect of mesh sensitivity on the Weibull probability has been studied based on a single sphere and several particles with realistic geometries. Additionally, the effect of shape and volume of particles on the Weibull fracture probability was studied. The evolution of damage with the applied traction has been evaluated using simulation and compared with the experimental results obtained from in situ tensile testing.

A review on micromechanical methods for evaluation of mechanical behavior of particulate reinforced metal matrix composites

Particulate reinforced metal matrix composites (PRMMC) are the most promising alternative for applications where the combination of high strength, elastic modulus, specific stiffness, strength-to-weight ratio and ductility is essential. Experimental investigation does not provide insightful information about microstructural aspects affecting the mechanical behavior of PRMMC, while the micromechanical methods can describe effectively. This paper presents the review on various analytical and computational micromechanical methods to evaluate the mechanical properties of particulate reinforced metal matrix composites. The effects of particle size, shape and orientation and interface strength on the mechanical behavior are presented. Stress–strain relationships, damage evolution, elastic and plastic deformations are also described. Computational micromechanical methods were found to provide better estimate of properties than analytical micromechanical methods. The order of preference among computational micromechanical methods is serial sectioning method, statistical synthetic method, multi-cell method, 2D real microstructure method and unit-cell method. However, serial sectioning method is highly expensive and demands lot of experimental and computational resources while the statistical synthetic method is economical and doesn’t require many resources. Therefore, statistical synthetic method can be a better choice for computational micromechanics of particulate reinforced metal matrix composites to evaluate the mechanical behavior without experimentation.

Study on stress distribution in microregion close to the shell of core-shell particle reinforced metal matrix composites

The stress distribution in microregion close to the shell of core-shell particle reinforced metal matrix composites is studied by the finite element analysis in this work. It is found that the stress distribution of the composites is dependent on the elastic modulus of both shell and core phases as well as the difference between them. If the elastic modulus of the formed shell is larger than that of the core, the load borne by the shell will be increased, otherwise, the load borne by the matrix and the core will be increased. The formation of shell and its nature can also significantly change the position of the maximum stress on the reinforced particles but have little influence on that in the matrix. When the elastic modulus of the shell is smaller than that of the core, the maximum stress position in the core-shell particle will be at the core and close to the interface between core and shell, otherwise, it is shift to the shell and also close to the interface between core and shell. The degree of the stress concentration in Al matrix becomes more serious after the formation of the shell in the reinforced particles, while that in shell of core-shell particles mainly depends on the modulus difference of core and shell.

Microstructural evolution of hybrid aluminum matrix composites reinforced with SiC nanoparticles and graphene/graphite prepared by powder metallurgy

The dispersion of ceramic nanoparticles is of significance to the microstructure and properties of particulate reinforced metal matrix composites. In this study, two hybrid enhancers, SiC-graphite and SiC-graphene nanosheets (GNSs), were incorporated into aluminum matrix composites using powder metallurgy. The dispersion of the reinforcements and microstructural evolution of the composites were characterized by using Scanning Electron Microscopy, X-Ray Diffraction, Transmission Electron Microscopy, and Raman spectroscopy. The results show that thin GNSs accelerated the deformation of the aluminum particles, and defects were introduced into the carbonaceous phases during the ball milling process. Al4C3 needles generated during hot pressing, and were observed to bridge the aluminum grains. Compared with graphite, GNSs were more uniformly dispersed throughout the composite, which in turn restrained grain growth. As a result, a nanostructured composite (57.7 nm) was successfully produced upon the addition of SiC-GNSs.

Mechanical and tribological characterization of industrial wastes reinforced aluminum alloy composites fabricated via friction stir processing

Abstract The fabrication of particulate reinforced metal matrix composites via melt based processes poses issues like aggregation, wettability and formation of detrimental phases which may severely affect their performance. Recently developed solid-state process i.e., friction stir processing (FSP), is an efficient fabrication technique to counter the limitations of melt based processes. However, the incorporation of industrial waste in the metal matrix by using friction stir processing is rarely reported. Thus, the present investigation was carried out to reinforce the particulate type industrial waste in cast A356 alloy by friction stir processing. The performance of the fabricated composites as well as the as-cast A356 alloy was assessed through mechanical and tribological characterization. It was observed that FSP resulted in the eradication of porosity, fragmentation of α-Al dendrites, breakage and redistribution of Si particles, and grain refinement. A fair homogeneous distribution of reinforcement was observed in stir zone (SZ) with negligible aggregation of particulate reinforcement. The particle/matrix interface was free from any detrimental phase. The improvement in strength, ductility, and wear resistance was observed as compared to as-cast A356 alloy which was attributed to the microstructural changes that occurred during FSP, and the efficient reinforcement of particles via FSP.

Numerical analysis of mechanical properties and particle cracking probability of metal matrix composites

Particle-reinforced metal matrix composites (PRMMCs) are characterized by inhomogeneity and heterogeneity. The shape as well as volume fraction of the reinforcing particles and the mechanical properties of particles and matrix greatly affect the macro-mechanical properties of the metal matrix composites. Several analytical models were established to study the mesco-mechanical properties of the metal matrix composites based on the numerical simulation method combined with user-defined subroutine VUMAT in finite element codes ABAQUS in this article. Then the Weibull statistics model was adopted to study the effects of particle geometry shape and volume fraction on the probability of particle cracking under different applied strains. After that, an empirical formula for computing the probability of particle cracking was proposed which is a ternary function of the particle aspect ratio, the particle volume fraction and the applied strain based on the analysis of the computed data from different models. Finally, the validity and accuracy of the empirical formula in a certain range were verified through a model with an arbitrary set of particle parameters (particle aspect ratio AR and volume fraction Vf), which can provide a necessary guidance for the development and preparation of particle reinforced metal matrix composites.

An enhanced strength Ni matrix composite reinforced by a 3D network structure of TiN nano-particles

Strengthening is a critical issue for improving the mechanical properties of ceramic particles reinforced metal matrix composites (CPRMMCs). A Ni matrix composite reinforced by TiN nano-particles (TiNNP) with a three-dimensional (3D) network structure was synthesized via low-energy ball-milling (LEBM) and spark plasma sintering (SPS). The ultimate tensile strength (UTS) of the TiN/Ni composite is 690 MPa, an increase of 383% compared to that of the Ni matrix. The 3D network structure of TiN nano-particles formed at the grain boundaries refines the grains significantly and generates a high density of dislocations near the TiN/Ni interface, synergistically contributing to the enhanced strength. Ceramic particles of 3D network structure may be a potential solution to achieving superior properties of CPRMMCs.

Finite element investigation on the wave-particle interactions in ultrasonic inspection of SiCp/Al composites

While particulate-reinforced metal matrix composites are composed of two phase materials with dramatically different physical and mechanical properties, sound wave-particle interactions play an important role in their ultrasonic inspection tests. In the present work, we investigate the sound wave-particle interactions in silicon carbide (SiC) particle-reinforced aluminum (Al) matrix composites under the pulse-echo mode ultrasonic inspection by means of finite element simulations. Be consistent with experimentally observed real microstructures, the simulated SiC particles have polygon shapes and are randomly dispersed in the Al matrix. In particular, the sound wave-particle interactions are revealed, and their correlations with the A-scan signals are investigated. Furthermore, the effects of extrinsic pulse frequency and intrinsic SiC particle size on the ultrasonic inspection of the composites are addressed. Simulation results indicate that the interference of sound waves with heterogeneous SiC particles leads to more pronounced deflection, scattering and conversion of sound waves than the pure Al matrix, which in turn result in higher attenuation of sound waves in SiCp/Al composites. It is also found that the sound wave-particle interactions have a strong dependence on both pulse frequency and particle size.

Silicon Nitride as a Reinforcement for Aluminium Metal Matrix Composites to Enhance Microstructural, Mechanical and Tribological Behavior

In recent years, aluminium and its hybrid composites receiving more attention due to its excellent property combinations like improved mechanical properties, better wear and high corrosion resistance, ease to process and probably reduced production cost etc.. Composite is made of two phases one is matrix and another one is reinforcement. The performance of composite highly depends on some key factors that decide overall performance and they are properties of constituent phases, reinforcement size, reinforcement distribution in the matrix and their interfacial interaction. Particle reinforced metal matrix composites (particulate metal matrix composites- PMMCs) are becoming more popular due to their low cost, easy to process and compatible to conventional processing techniques. Also they give isotropic properties. The most commonly used reinforcements are carbides, oxides and nitrides. A lot of research has taken place including carbide and oxide as a reinforcement particles for aluminum matrix composites (AMCs) and hybrid aluminium matrix composites (HAMCs) while there is a bit research lag in use of nitride as a reinforcement for development of AMCs and HAMCs. Recent competitive market demands the material having better combination of properties, cost effectiveness and eco-friendly nature. Present article focused on to study the microstructural features, physical properties, mechanical and tribological behavior of aluminium matrix composites when reinforced with silicon nitride particles (Si3N4). Potential area of applications has also been suggested on the basis of literature data. In this review a comprehensive study has done for current scientific development carried out in Al based Si3N4 composites as well as its future scope has also been discussed.

Analytical model of cutting temperature for workpiece surface layer during orthogonal cutting particle reinforced metal matrix composites

Abstract There are huge disparities in the physical and mechanical properties between the two-phase materials of particle reinforced metal matrix composites (PRMMCs). Therefore, the heat generated by reinforced particles and metal matrix is different under the action of cutting and rubbing of the cutting tool. However, limited studies have been done using analytical method to predict the cutting temperature during cutting PRMMCs. The purpose of this paper is to establish an analytical model to predict cutting and friction temperatures for workpiece surface layer based on the moving heat source method during cutting varied PRMMCs. The material properties (i.e. particle volume fraction and average particle size) of PRMMCs, respective physical properties of reinforced particle and metal matrix, and accurate value of friction force were taken into consideration in the proposed model. The temperature field distribution for workpiece surface layer was acquired. This study proposed a new design method of experiment to accurately determine the friction force and temperature between tool flank-workpiece during cutting PRMMCs required in the analytical model. The parameters of the heat generation ratio for shear plane and tool flank-workpiece rubbing heat sources were proposed, which were appropriate for cutting temperature prediction for PRMMCs with different particle volume fraction and average particle size. The fraction of the heat generated by shear plane conducted into workpiece (heat partition ratio, B A 1 s h e a r ) was also identified. Conducting the orthogonal cutting experiment, the influence tendencies of the various parameters such as average particles size, particle volume fraction, cutting speed, uncut chip thickness and tool flank wear on cutting temperature during cutting PRMMCs were evaluated. With verification, the analytical results of the cutting and friction temperatures based on the proposed model captured an acceptable tendency with experimental results and yielded a prediction error being smaller than 16.0 %. The proposed model in this study was applicable to predict the cutting and friction temperatures of PRMMCs especially with high particle volume fraction and large average particle size.

Influence of homogenization and aging on tensile strength and fracture behavior of TIG welded Al6061-SiC composites

The present work deals with fractograph analysis and enhancement of mechanical properties like hardness and tensile strength on Al6061-SiC reinforced composites during homogenization and artificial aging at 100, 150 and 200 °C. Scanning Electron Microscope, followed by high end metallography testing techniques like, SEM, XRD, EDS etc. are used in the present study for characterization analysis. Metal matrix composites having 0, 8, 10 and 12 wt.% fractions of silicon carbide grits of average 25 μm size, are TIG welded using the filler material ER5356. Mechanical tests showed higher hardness and lower tensile strength for Al6061-12 wt.% SiC composite under non-homogenized and artificially aged condition owing to the presence of coarse micro-segregation of β-AlFeSi and α-Al(Fe, Mn) Si phase. Microstructure confirms dendritic segregation in non-homogenized specimen and after homogenizing, dendritic segregations are minimized leading to an improvement in hardness and tensile strength. Fracture surfaces of non-homogenized and artificially aged samples indicated the existence of shrinkage porosity and accordingly failure along the interdendritic regions. Homogenized and age hardened composites failed under combination of brittle and ductile mode as evident by the presence of equiaxial fine dimples. Amongst different kinds of the recently developed composites, particle reinforced metal matrix composites have a great demand and has led to the emergence of numerous structural composite materials as candidates for a wide variety of industrial applications like in marine, aerospace and automobile. Property enhancement is witnessed due to the combined effect of homogenizing and lower temperature aging. 60% escalation in ultimate tensile strength of composites aged at 200 °C and 90% increase in UTS of composites aged at 100 °C is observed when compared with as weld condition after homogenizing and aging.

Wear behavior and metallurgical characteristics of particle reinforced metal matrix composites produced by hardfacing: A review

Earth moving equipments and its components are generally susceptible to wear and erosion owing to the severe environmental conditions. Low carbon steel with nickel based Hardfacing layer is preferred to increase the wear and erosion resistance of these components. Also, corrosion performance is found to be increased. Particle Reinforced Metal Matrix Composite (PRMMC) is an emerging technology in hardfacing that will enhance the tribological performance of the components by adding hard metal or ceramic particles in the existing alloys. Tungsten Carbide (WC) is often selected as reinforcement in PRMMC to improve the wear and erosion behavior, however, there is only few researches conducted to study tribological behavior of WC hardface by varying the amount of WC reinforcement. So, this paper reviewed recent research on PRMMC (especially WC) hardfacing and correlated important findings from them with WC reinforced hardface.

Fabrication of A6061 PRMMC by using GTAW process and evaluating the material behaviour

In this project a composite is fabricated through the TIG (Tungsten inert gas) welding setup. In this new era, the composite materials play a vital role in all applications. Hybrid composites are composites that comprises two or more fibres or matrixes in their lamina. Alloys of aluminium are unanimously used in aircraft, aerospace and transportation industries due to their high strength to weight ratio. In this project, the particle reinforced metal matrix composites (PRMMC) were produced by using TWP (TIG Welding Process). The PRMMC manufactured through this process are Sic/B4C/A6061, Sic/graphite/A6061 and A6061/graphite/B4C/Sic. The SEM (scanning electron microscopy), XRD tests were conducted to illustrate the status and properties of samples. Uniform distribution of reinforcements in the hybrid composites is a direct sign of enriching the mechanical properties of three Al6061 plates. Pretending the mechanical behaviour of hybrid composites is always significant to find the safety of the composites.