Particle Reinforced Aluminum Matrix Composites Research Articles

Achieving Superior Strength‐ductility‐conductivity Combination in TiB2p/6201 Composites via Particle Rotation and Sub‐grain Refinement

The key factor in the material design of overhead power transmission lines is to obtain a desired balance among strength, ductility and electrical conductivity. In this study, TiB2 particulate reinforced aluminum matrix composites were prepared to find a way out of the intrinsic dilemma behind this balance by tailoring the sub‐grain refinement. The interaction in the form of inhomogeneous deformation induced by the flexibility discrepancy between the rigid particles and soft matrix was studied. On the one hand, the hexagonal plate‐like TiB2 particles rotate with the inhomogeneous deformation, forcing the biggest exposed plane ((0001) basal plane) parallel to the plastic flow direction, which is beneficial for the dislocation multiplication and hindrance of dislocation slipping. On the other hand, inhomogeneous deformation generates plentiful geometry necessary dislocations, and divides the microstructure into two types: in the particle‐rich region ultrafine grains are formed, and in the particle‐free region significant sub‐grains refinement is observed. The sub‐grains with 3 wt.% TiB2 is refined from ∽897 nm to ∽248 nm. Thanks to these microstructural benefits, the composites achieve the following strength‐ductility‐conductivity combination: ultimate tensile strength is 370 MPa, elongation after fracture is 11.2%, and electrical conductivity is 51.79% IACS. Besides, the elastic modulus reaches 75.43 GPa.This article is protected by copyright. All rights reserved.

Selection of groove dimension in the fabrication of particulate reinforced aluminium matrix composites using friction stir welding

Selecting groove dimensions has always been challenging for fabricating particulate reinforced aluminium matrix composites using friction stir welding. To address this, heat transfer physics coupled with the level set method was used to estimate material mixing between 6061-T6 Al-matrix and Al2O3 using the COMSOL Multiphysics tool. Groove dimensions of 2 mm width and depth resulted in the absence of volumetric/tunnel defects, nearly symmetric distribution, and minimal agglomeration of Al2O3 powder particles. This combination achieved an optimum trade-off between strength and ductility.

Research on the Ablation Resistance of TiC Particle-Reinforced Aluminium-Based Composite Coatings on Armature Surface

The work aims to enhance and modify the armature surface in electromagnetic rail launch systems and improve its anti-ablation performance to better resist the impact ablation effects of high-temperature and high-speed arcs during the electromagnetic rail launch process and improve launch reliability. TiC particles are widely selected as metal material reinforcements, with advantages such as high melting points and high hardness. In this paper, the arc impact model of pure aluminum alloy and the arc impact model of TiC particle-reinforced aluminum-matrix composite coating–pure aluminum alloy were constructed based on molecular dynamics simulation. The ablation resistance of the material was evaluated by analyzing the depth of arc impact, the mass loss of the model, the number of gasification atoms, and the surface temperature of the material. The protection mechanism of the modified layer on the substrate was revealed by analyzing the damage degree of the surface and subsurface of the material after arc impact. The results showed that the strengthening mechanism of TiC particle-reinforced aluminum-matrix composites included fine grain strengthening, dispersion strengthening, dislocation strengthening, and so on. Covering TiC particle-reinforced aluminum-matrix composite coating on the surface of aluminum alloy armature is helpful in improving its ablation resistance. The research results can provide a theoretical basis and technical support for the modification design and performance control of electromagnetic rail armature.

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.

Evolution of microstructure and mechanical properties of aluminum matrix composites reinforced with dual-phase heterostructures

The trade-off between strength and plasticity has long been challenging in particle-reinforced aluminum matrix composites (PRAMCs). This study proposes an innovative approach for preparing aluminum matrix composites (AMCs) using a dual-phase hybrid of FeCoNiCrMn high entropy alloy (HEA) and multiscale aluminum oxide (Al2O3) particles. The microstructure evolution and strengthening mechanisms were evaluated through scanning electron microscopy (SEM), electron backscatter diffraction (EBSD), and transmission electron microscopy (TEM). The results demonstrated that the dual-phase particle strengthening resulted from the alternating distribution and synergistic action of HEA and Al2O3 particles within the matrix, forming a continuous strain buffer with a strength gradient. Notably, introducing HEA and nano-Al2O3 led to a higher density of dislocations. Additionally, EBSD analysis revealed a uniform strain distribution within the AMCs, with a significant concentration of kernel average misorientation (KAM) near the grain boundaries (GBs). In terms of micromechanical properties, the micro-zones of heterogeneous phases exhibit exceptionally high elastic modulus and nanohardness. In terms of macroscopic mechanical properties, the material exhibited impressive ultimate compressive strength and compression ratio values of 447.9 MPa and 37.9 %, respectively. These results represented a remarkable enhancement of 72.1 % and 6.6 % compared to the single FeCoNiCrMn HEA strengthening. Moreover, when applying the HEA + nano-Al2O3 blending mode, the ultimate compressive strength further increased to 506.7 MPa, representing an astonishing boost of 94.7 %. This significant strength improvement can be attributed to effective interfacial bonding, grain refinement, and a high dislocation density resulting from both HEA and Al2O3 particles.

Enhancing strength-ductility synergy of thermally oxidized dual-phase HEA particles reinforced aluminum matrix composites via heterogeneous interface

This work firstly oxidizes single-phase high entropy alloy (HEA) to form FCC and BCC dual-phase structure, and also introduces multi-component nano-oxides on surface to prepare oxidized HEA (OHEA) reinforcements, followed by preparation of OHEA/Al composites by spark plasma sintering. The introduction of O element accelerates interdiffusion between OHEA and Al matrix. FCC phase inside OHEA evolves into soft phase, and BCC matrix phase evolves into hard phase, forming heterogeneous interface in OHEA/Al composites. During tensile process, cracks preferentially initiated in hard phase due to severe stress concentration, and the soft phase effectively retarded crack propagation. Compared with 2024Al matrix, yield strength, tensile strength, and elongation of OHEA/Al composites increased by 35.31%, 57.34%, and 63.33%, respectively, realizing excellent combination of strength and toughness. Grain refinement, thermal mismatch, Orowan, and load transfer strengthenings synergistically improve the performance. The proposed method provides a promising avenue to optimize the properties of composites by pre-oxidizing HEA particles to construct heterogeneous interfacial structure.

Enhancing strength–ductility synergy of AlNp/Al composite by regulating heterostructure of matrix grain and particle distribution

Three heterostructured AlNp/Al composites with different microstructure configurations were fabricated by liquid–solid reaction combined with subsequent thermal-mechanical treatment to obtain a superior strength and ductility combination. The effects of the microstructure configuration including the AlN particle distribution and matrix grain structure on the tensile strength and ductility were studied in detail. The results show that the simultaneous enhancement of tensile strength and ductility can be achieved. The Uniformed-AlNp/Al composite with relatively dispersed particles exhibits a superior ultimate tensile strength of ~387 MPa with an elongation to failure of ~9.1%. It shows an outstanding specific tensile strength and elongation combination compared with other reported particle reinforced aluminum matrix composites. Furthermore, the hetero-deformation induced (HDI) stress has been calculated and is shown to increase significantly in the Uniformed-AlNp/Al composite. It is revealed that the HDI stress plays a crucial role in the significant enhancement of strength and ductility for the AlNp/Al composite.

A comparison of the erosive wear performance of particle reinforced aluminum matrix composites

A comparison of the erosive wear performance of particle reinforced aluminum matrix composites

Research progress on aluminum matrix composites reinforced by medium and high volume fraction hybrid particles

Aluminum matrix composites reinforced with particles offer many advantages, including high specific strength, elevated specific stiffness, reduced thermal expansion coefficient, enhanced thermal conductivity, abrasion resistance, and dimensional stability. These composites find extensive application in aerospace, electronic packaging, and weaponry. The concept of hybrid particle reinforcement, involving multiple reinforcing particles, optimizes the performance attributes of each phase and the synergistic reinforcement effect, leading to potentially superior hybrid particle-reinforced aluminum matrix composites. This paper presents a comprehensive overview of the methods for preparing particle-reinforced aluminum matrix composites. It examines the toughening mechanisms in aluminum matrix composites reinforced with hybrid particles at medium and high volume fractions. These mechanisms include fine grain reinforcement, Orowan reinforcement, and heterogeneous deformation-induced reinforcement, including geometrically necessary dislocation reinforcement. This paper elucidates the role of micronano organizational structures-such as the morphology, size, distribution, and interfacial bonding state of hybrid particles and matrix-in determining the comprehensive performance of aluminum matrix composites. Additionally, it explores the effect of hybrid particle morphology, size, distribution, and micronano structure on the composite’s overall performance. Finally, future research directions and trends in the development of high-performance hybrid particle-reinforced aluminum matrix composites are discussed.

Aluminum carbide formation in Al-graphite composites: In situ study and effects of processing variables and sintering method

The particulate-reinforced aluminum–matrix composites are interesting due to their attractive physical and mechanical properties over their monolithic counterparts, which are related to their prominent structural differences. The effect of interfacial reaction on the mechanical properties of the Al composites has been attributed to the influence of the reaction product. In this work, the formation of Al4C3 in Al-Gr compounds prepared by high-energy ball milling and sintered by high-frequency induction is compared with a conventional method of sintering: cold compaction and furnace sintering. The conditions related to the generation of this carbide and a precise temperature in which the initial generation of this phase occurs were determined. The different results and the in-situ characterization using HR-TEM showed the substantial reactivity of graphite in the aluminum matrix, leading to the formation of the Al4C3 phase within a few seconds of heating to 250 °C. The conventionally sintered samples displayed the highest number and size of Al4C3 precipitates. In contrast, the heated sample exhibited varied quantities and sizes of these precipitates. Notably, the high-frequency induction sintered samples contained smaller Al4C3 precipitates with a lower number density. Structural, microstructural, and chemical composition results of this phase formed in Al-Gr composites are also shown.

Joining high volume fraction SiC particle reinforced aluminum matrix composites using Bi2O3-B2O3-ZnO-BaO-Na2O glass

This paper designs a bismuthate glass 58Bi2O3-25B2O3-13ZnO-2BaO-2Na2O in mol%(BBZ) and uses it to join 65 % volume fraction SiC particle reinforced aluminum matrix composites (65 vol%SiCp/ZL102) in an atmospheric environment. The thermal properties of BBZ glass were studied, and the effect of the brazing process on the mechanical properties of the joint was explored. The results show that the glass transition temperature of the glass is 344.6 °C, and the two crystallization temperatures are 464.7 °C and 544.3 °C. The oxidation of the parent material can improve the mechanical properties of the joint. The increase in welding temperature and the extension of holding time make the mechanical properties of the joint first increase and then decrease. When brazing at 490 °C for 30 min, the pre-oxidized composite material was brazed, the joint was defect-free, and the shear strength of the joint was 19.4 MPa. The analysis of the shear fracture showed that the fracture mainly occurred in the glass brazing material, which is a brittle fracture.

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.

Damping and mechanical properties of SiC particles reinforced aluminium matrix composites prepared by colloidal dispersion and suction filtration method

In order to uniformly distribute SiCp in the aluminium matrix and prepare SiCp/Al composites with high mechanical and damping properties, a preparation method of colloidal dispersion and suction filtration was developed. It was observed from the microstructure of the composites that the SiCp/Al composites prepared by colloidal dispersion and suction filtration method had good interfacial structures, and the interfacial reaction between SiCp and aluminium matrix was effectively inhibited. Tensile mechanical properties at room temperature and damping properties in the temperature range of 25 °C to 300 °C were tested for the SiCp/Al composites with volume fractions of 5% to 10%. The results showed that SiCp/Al composites have excellent mechanical and damping properties when the volume fraction of SiCp was 7%. This is because SiCp were uniformly distributed in the aluminium matrix, and formed a good interfacial bond with the aluminium matrix, which benefitted both the interfacial slip loss and the strengthening effect of SiCp.

Agglomerating behavior of in-situ TiB2 particles and strength-ductility synergetic improvement of in-situ TiB2p/7075Al composites through ultrasound vibration

Agglomerates of in-situ particles are the key detrimental defects in particulate reinforced aluminum matrix composites (PRAMCs) by acting as Achilles' heel leading to the premature failure of the materials. Effective methods to disperse/eliminate these agglomerates rely on in-depth understanding of the agglomeration mechanism of the in-situ particles. In this work, the agglomerating behavior of TiB2 particles in Al-Ti-B system was investigated through the thermit reactions between mixed fluorides and molten aluminum. The results indicate that the morphological patterns of TiB2 agglomerates are inherited from the preformed Al3Ti intermedium. The formation of flocculent, shell and flaky TiB2 agglomerates are the results of the diffusing boron atoms continuously reacting with Al3Ti. The in-situ Al-TiB2 was used as a precursor to prepare TiB2p/7075 Al composites. In particular, ultrasound vibration treatment was applied to explore if a locally forced oscillation can deagglomerate the TiB2 agglomerates. Microstructural observations strongly support such speculation. Thanks to the deagglomeration and dispersion of TiB2 particles, both the strength and ductility of the PRAMC have been improved drastically. The fracture surface of the composites was transformed from particle debonding to the dominance of ductile fracture.

Phase composition and microstructure of B4C particles reinforced aluminum matrix composites fabricated via direct laser deposition

Phase composition and microstructure of B4C particles reinforced aluminum matrix composites fabricated via direct laser deposition

Investigations on tensile mechanical properties of rigid insulation tile materials at elevated temperatures based on digital image correlation algorithm

This work investigates the tensile mechanical properties of rigid insulation tile (RIT) materials at room temperature (26 °C) and elevated temperatures (700–1000 °C) through experimental and digital image correlation (DIC) methods. Experimental results indicate that the tensile strength of RIT materials changes nonlinearly with increasing temperature and that the primary fracture mode under tension load is fiber root fracture. In terms of the DIC algorithm, this work builds an elevated-temperature DIC test system. A zero-mean Gaussian filtering algorithm and an image gradient difference square sum algorithm (SSDGI) are proposed to improve the precision of the DIC algorithm. The derived tensile stress-strain curve of RIT materials reveals that the elastic modulus changes nonlinearly with increasing temperature. The reliability and precision of the DIC algorithm are confirmed through the tensile test of silicon carbide particle-reinforced aluminum matrix composites. Hence, this work provides guidance for evaluating mechanical properties of RIT materials under elevated temperature environments.

Hot Deformation Behavior and Mechanisms of SiC Particle Reinforced Al-Zn-Mg-Cu Alloy Matrix Composites

A systematic and comprehensive analysis of the hot deformation and mechanisms of SiC particle-reinforced aluminum matrix composites is significant for optimizing the processing of the composites and obtaining the desired components. Based on this, related research on 11 vol% SiCp particle-reinforced 7050Al matrix composites was carried out. Hot compression experiments were carried out on the Gleeble-3500 thermal simulator to study the hot deformation behavior of composites at the temperature of 370–520 °C and strain rate of 0.001–10 s−1. The hyperbolic sine constitutive equation of the material was established, and the processing map was calculated. Combining the typical metallograph and misorientation angle distribution, the microstructure evolution mechanism of composites was analyzed, and the effect of particles on recrystallization behavior was investigated. Under certain process conditions, the dominant deformation mechanism of composites changed from dynamic recovery (DRV) to dynamic recrystallization (DRX), and the grain boundary sliding mechanism began to play a role. In addition, high temperature tensile and elongation at break were tested, and it was found that the dominant form of fracture failure changed from brittle fracture of the particles to ductile fracture of the matrix as the temperature increased.

Effects of solution temperatures on microstructures and mechanical properties of B4C/7A04Al composites: A comparison study with 7A04Al alloys

To prepare particle-reinforced aluminum matrix composites with ultra-high strength, high-strength 7xxx Al alloys are commonly employed as matrices. Heat treatment plays a crucial role in enhancing the mechanical properties of the alloys and their composites, but the influence of solution temperatures on composites based on 7xxxAl alloys remains unexplored. In this study, the effects of solution temperatures on the microstructures and mechanical properties of B4C/7A04Al composites fabricated via powder metallurgy (PM) technology were investigated, as well as those of 7A04Al alloys for comparison. Before solution treatments, the prominent second phases in the composite were MgZn2 phases, while those in the 7A04Al alloy consisted of MgZn2 and Al2CuMg phases. At lower solution temperature (420 °C), MgZn2 phases dissolved completely, whereas Al2CuMg phases persisted. Al2CuMg phases dissolved at 450 °C, and thus the 7A04Al alloy obtained the optimum strength and elongation. Further elevating the solution temperature caused abnormal grain growth (AGG) in the 7A04Al alloy, leading to a deterioration of strength and plasticity. In contrast, at various solution temperatures, the composite exhibited stability in grain size, which could be attributed to the pinning effects of B4C particles and Mg(Al)B2 phases, the reaction products between the boron impurity and the Al matrix. However, at higher solution temperatures (510 °C and 600 °C), the segregation of Mg and O around B4C particles was aggravated, and thus the elongation of the composite deteriorated. Interestingly, the strength remained relatively unaffected due to the strengthening effects of Mg(Al)B2 phases. The results indicate that the composite exhibited a broad range of solution temperature with comparable strength and elongation across a temperature range of 420 °C–470 °C. But for the 7A04Al alloy, the optimal solution temperature is 450 °C.

Tribological and corrosion characteristics of tetra hybrid particulate-reinforced aluminum composites for aerospace and automotive applications

This study investigates Hybrid Particulate-Reinforced Aluminum Matrix Composites (HPRAMCs), a material class known for exceptional physico-mechanical, tribological, and corrosion resistant properties. The research synthesizes HPRAMCs using SiC, Al2O3, graphite (Gr), and sugar cane bagasse ash (SCBA) reinforcements through a powder metallurgy process, followed by sintering at 550°C for 3 h. Comprehensive tests include X-ray diffraction (XRD) for phase analysis, physico-mechanical assessments, tribological evaluations, and corrosion resistance analyses. Notably, secondary reinforcements significantly reduce porosity, with AS4 HPRAMC exhibiting a 0.53% porosity, while AS1 HPRAMC has 1.446%. AS4 HPRAMC displays a remarkable 209.76% increase in compressive strength and a 446.40% boost in material hardness compared to pure aluminum. Secondary reinforcements also improve tribological performance, reducing wear loss by 60.27% and the coefficient of friction by 89.89%. Exceptional corrosion resistance, with an inhibition efficiency of 99.691%, is observed in the AS4 HPRAMC sample, confirmed by scanning electron microscopy (SEM). These findings underline the substantial potential of HPRAMC materials, positioning them as promising candidates for aerostructural components, aircraft systems, automobiles, spacecraft, and high-performance engineering applications.

Effects of laser power on the microstructural evolution and mechanical performance in laser dissimilar welding of TC4 to SiCp/6092Al composite

In this study, an overlap configuration for Ti6Al4V alloy (TC4) and SiC particle reinforced aluminum matrix composites (AMC) was achieved by laser welding process. The influence of laser power on the microstructural evolution, intermetallic compounds formation and mechanical properties of TC4/AMC joints were investigated. The presence of reinforced phase SiC complicated the metallurgical reaction in the molten pool, resulting in the formation of intermetallic compounds, such as Al4C3, TiC, TiAl, and TiAl3. The influence of laser power was more pronounced on the penetration depth compared to its impact on the weld width. The thickness of TiAl intermetallic compounds at the TC4/AMC interface increased as the laser power was raised. Abundant dislocations existed surrounding the TiAl3 phase because of the different thermal-mechanical properties between Al matrix and TiAl3 phase. The tensile shear force of TC4/AMC joints can be considerably improved by reducing the thickness of the TiAl3 phase. The maximum tensile shear force of 1675.6 N for the TC4/AMC joint was obtained at a laser power of 1500 W when the thickness of the TiAl3 layer reached the lowest value of 7.1 μm. The research results have the potential to improve laser welding techniques for TC4/AMC hybrid structures and provide valuable guidance for the design of TC4/AMC welded joints in the future.