SiC Particles Research Articles

Influence of pulse frequency on microstructure, mechanical properties, and corrosion resistance of electrodeposited Ni-SiC composite coatings

The current study explores the effects of SiC co-deposition in Ni matrix during pulse electrodeposition (PED) at various pulse frequencies. X-Ray Diffraction (XRD) analysis indicates that at lower frequencies, the composite coating favours the (111) plane orientation, while at higher frequencies (50 and 100 Hz), it changes toward the (200) plane. Scanning Electron Microscopy (SEM) analysis shows a decrease in SiC particle content with increasing frequency. Coatings deposited at 10 Hz display a compact, uniform structure with higher SiC particle concentration, resulting in smoother surfaces compared to pure Ni coatings. This leads to higher hardness (440 HVN) compared to coatings deposited at higher frequencies (425 HVN and 410 HVN for the 50 Hz and 100 Hz, respectively). Furthermore, the composite coatings exhibit superior corrosion resistance, with reduced electrolyte penetration and localized corrosion relative to pure Ni. Notably, the 10 Hz coating demonstrates a lower corrosion rate of 0.005 mm/year and a higher corrosion protection efficiency of 88 %. Therefore, SiC co-deposition at 10 Hz acts as a protective barrier, inhibiting corrosion progression and enhancing long-term durability against corrosion.

Tribological Properties of Recycled Polyvinyl Butyral (rPVB) and Glass-Fiber-Reinforced Polyamide Blends in Dry and Microabrasive Contacts

As a contribution of recycling of polymers in the automotive industry, recycled polyvinyl butyral (rPVB) from automotive windshields is being explored as a solid lubricant reinforcement for improving lubricity of engineering polymers. This work aims to evaluate the tribological behavior (coefficient of friction [CoF] and wear resistance) of polyamide 6 (PA6) and glass-fiber-reinforced polyamide 6 (PAGF) blended with rPVB as solid lubricant under two-body and three-body abrasive conditions. The different polymer blends were produced by adding recycled polyvinyl butyral (rPVB) into a matrix of either a commercial polyamide 6 (PA6) or a commercial 30% glass-fiber reinforced polyamide 6 (PAGF). The tribological tests were conducted in an instrumented microabrasion tester for generating wear and measuring the coefficient of friction (CoF) in both dry and microabrasion conditions. In the dry condition, rPVB was effective in reducing the CoF for both PA6 and PAGF. Two-body abrasion was found as the predominant wear pattern in the dry condition. On the other hand, in the microabrasion condition, the additions of rPVB were not totally effective since they produced a wear resistance increase for PAGF but a reduction for PA6, which was ascribed to a notable decrease in toughness for PA6 when adding rPVB. Well-defined plowing traces and several SiC particles embedded in the scars were the predominant patterns in all the materials. In both PA6 and PAGF, CoF increased with the rPVB additions.

Vibration and acoustic characteristics of aluminium-silicon carbide metal matrix composite plate under thermal environment

This paper investigates the vibration and acoustic characteristics of an aluminium-silicon carbide (Al-SiC) simply supported composite plate under thermal loads. The vibrational response induced by the temperature rise is analysed using Kirchhoff’s plate theory and the weighted integral (Galerkin) method. Additionally, the plate is acoustically modelled in conjunction with the air medium to investigate its acoustic response. The acoustic far-field radiation equation determines the plate’s sound pressure level (SPL). The findings reveal that the MMC I (65% SiC/A356.2 MMC SiC particulates reinforced, with three different sizes) plate exhibits a lower overall sound pressure level in the lower frequency range than other MMCs. Moreover, replacing the aluminium plate with the MMC I plate reduces the overall sound pressure level by 5.54 dB due to the high stiffness associated with the mixture of silicon carbide reinforcement in the aluminium matrix.

Multidimensional ultrasonic vibration machining modeling of SiCp/Al cutting forces with different volume fractions: Experiments and numerical simulations

The cutting properties of the particles of aluminum-based silicon carbide (SiCp/Al) and the base material are so disparate that it is challenging to ensure the surface quality of machining. The cutting force significantly influences the quality of the machined surface. Therefore, real-time cutting force prediction is paramount for ensuring the workpiece's desired surface quality. This paper presents a 3D ultrasonic milling force model, established from four aspects: cutting formation force, extrusion friction force, SiC particle crushing force, and ultrasonic impact force. The model is based on the ultrasonic action of the cutting process and the unique removal characteristics of the material. A 3D ultrasonic milling system was constructed to experimentally verify the milling force model. The effects of each parameter on the milling force were analyzed through orthogonal experiments, which resulted in the effects of depth of cut, rotational speed, volume fraction, ultrasonic amplitude, and feed rate. The ultrasonic amplitude, feed rate, and other factors were found to influence the milling force to varying degrees. The milling force was observed to be 42.47 %, 22.37 %, 10.85 %, 12.67 %, and 11.64 % affected by the factors mentioned above, respectively. The single-factor experiment was conducted to analyze the cutting force at different machining parameters. The experimental results and the MATLAB numerical simulation results exhibited a similar trend of change. The maximum absolute error between the two was 12.71 %, with an average absolute error of 3.735 %.

ZrB2‐based ultrahigh‐temperature ceramic with various SiC particle size: Microstructure, thermodynamical behavior, and mechanical properties

ZrB₂‐based ultrahigh‐temperature ceramic with various SiC particle size: Microstructure, thermodynamical behavior, and mechanical properties

Research on the microstructure and properties of SiCp-SiO2/6061Al composites based on ball milling time

In this study, SiCp-SiO2/6061Al composites were synthesized by integrating SiC and SiO2 particulates into a 6061Al matrix, followed by ball milling and hot isostatic pressing sintering. The impact of ball milling duration on microstructure, mechanical properties, corrosion resistance, and thermal properties was evaluated. After 10 h of ball milling, reinforcement particles were uniformly dispersed, achieving a material density of over 98 %. Extending milling to 15 h enhanced tensile strength to 253.53 MPa and flexural strength to 433.56 MPa, with a maximum elongation at break of 6.4 %. Uniform SiO2 distribution improved corrosion resistance, evidenced by a self-corrosion potential of −1209 mV and a self-corrosion current density of 53.02 µA·cm−2. After 20 h, the lowest thermal expansion coefficient, 19.87×10−6·K−1, was achieved. However, agglomerated particles after 5 h resulted in inferior thermal properties, including a thermal expansion coefficient of 20.45×10−6·K−1 and thermal conductivity of 94 W·m−1·K−1. The optimal ball milling duration for these composites was determined to be 10 h, balancing performance and cost-effectiveness.

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.

Improving thermal conductivity of Al/SiC composites by post-oxidization of reaction-bonded silicon carbide preforms

High thermal conductivity aluminium-based silicon carbide (Al/SiC) composites were successfully fabricated through post-oxidization of reaction-bonded silicon carbide preforms (RS preforms), utilizing vacuum pressure infiltration technology. The study investigated the regulation of interfacial reactions in conventional sintering and reaction sintering. Conventional sintering introduced a large amount of SiO2, which negatively impacted the thermal conductivity of the Al/SiC composite, but the reaction sintering not. The proposed post-oxidization treatment of RS preforms effectively removed residual carbon from the SiC particle surfaces, thereby forestalling the formation of Al4C3. Furthermore, the post-oxidization treatment effectively formed lightweight SiO2 deposits onto the surface of SiC particles, improving Al-SiC interfacial wettability and reducing thermal resistance, thereby enhancing composite thermal conductivity. Notably, the thermal conductivity of the post-oxidized sample exhibited an increase of 6.5% compared to the untreated sample. The study also evaluated the impact of particle size distribution on volume fraction and thermal properties. The optimized Al/SiC composites yielded thermal conductivity, coefficient of thermal expansion, bending strength, and Young’s modulus values of 237.3 W/m K, 8.5 × 10−6/°C, 325 MPa, and 75.9 GPa, respectively.

Improved slag resistance of ferrotitanium slag based Al2O3-SiC-C castables: The effect of reaction between SiC and TiO2

Ferrotitanium slag is a kind of waste slag produced by smelting ferrotitanium alloy. It has high refractoriness (>1790 ℃) and Al2O3 content (≥70 wt%), which can be used to replace bauxite to prepare Al2O3-SiC-C castables. However, excessive substitution will lead to the decrease of slag resistance of Al2O3-SiC-C castables because of impurities in the ferrotitanium slag. In this paper, the slag resistance of ferrotitanium slag based Al2O3-SiC-C castables was improved by increasing the SiC content. The results showed that the castables with 13 wt% SiC had good mechanical properties. Increasing the amount of SiC was beneficial to improve the slag resistance. SiC content increased from 5 wt% to 22 wt%, the erosion index of dynamic slag resistance decreased from 17.05 % to 11.18 %. During the dynamic slag resistance, the TiO2 in the ferrotitanium slag dissolved in the slag, then the SiC reacted with TiO2 in the slag to form TiC coating on the surface of SiC particles. SiC particles wrapped by TiC widely existed in the reaction layer, which prevented further erosion of the slag. Further, the reaction of SiC with TiO2 to consume TiO2 and generate SiO2 increased the viscosity of the slag in the reaction layer, thus hindering slag penetration.

Microstructural and mechanical properties of Al-Al2O3 micro and nanocomposite fabricated by stir casting

ABSTRACT The current study examines the relationship between the microstructure and tribological characteristics of Al-Si alloy composites reinforced by secondary phase nano SiC particulates synthesis via the stir casting process. The results of wear testing of stir-cast SiC metal matrix composites including up to 12 weight percent fine (75–100 µm) and coarse (125–150 µm) size particles were obtained from cast aluminium alloy. It was discovered via microstructural investigation that the aluminium alloy and SiC particles have good interface bonding. However, at greater amounts (12 wt.%) of fine size reinforcement, clustering of reinforced particles is observed. In addition, results state that finer size particles agglomerate more in the matrix than coarser size particles at greater reinforcement levels. In addition, increasing the amount of SiC particles in the matrix enhanced the hardness of the base alloy. However, when the size of the SiC particles was reduced, the hardness of the composite increased dramatically. Better wear resistance was observed for higher SiC reinforcement levels, while higher forces were also associated with a corresponding increase in wear rate. A combined mode of adhesive and abrasive wear mechanisms is responsible for composite wear, according to a scanning electron microscopy (SEM) investigation of worn surfaces.

On Fused Filament Fabrication of Novel Tape Bandages as Phagocytosis Sensor: Effect of SiC Particle Size in PLA Matrix

On Fused Filament Fabrication of Novel Tape Bandages as Phagocytosis Sensor: Effect of SiC Particle Size in PLA Matrix

Effect of Diffusion on the Ultimate Axial Load of Complex-Shaped Al-SiC Samples: A Molecular Dynamics Study.

Metal matrix composites (MMCs) combine metal with ceramic reinforcement, offering high strength, stiffness, corrosion resistance, and low weight for diverse applications. Al-SiC, a common MMC, consists of an aluminum matrix reinforced with silicon carbide, making it ideal for the aerospace and automotive industries. In this work, molecular dynamics simulations are performed to investigate the mechanical properties of the complex-shaped models of Al-SiC. Three different volume fractions of SiC particles, precisely 10%, 15%, and 25%, are investigated in a composite under uniaxial tensile loading. The tensile behavior of Al-SiC composites is evaluated under two loading directions, considering both cases with and without diffusion effects. The results show that diffusion increases the ultimate tensile strength of the Al-SiC composite, particularly for the 15% SiC volume fraction. Regarding the shape of the SiC particles considered in this research, the strength of the composite varies in different directions. Specifically, the ultimate strength of the Al-SiC composite with 25% SiC reached 11.29 GPa in one direction, and 6.63 GPa in another, demonstrating the material's anisotropic mechanical behavior when diffusion effects are considered. Young's modulus shows negligible change in the presence of diffusion. Furthermore, diffusion improves toughness in Al-SiC composites, resulting in higher values compared to those without diffusion, as evidenced by the 25% SiC volume fraction composite (2.086 GPa) versus 15% (0.863 GPa) and 10% (1.296 GPa) SiC volume fractions.

Microstructural and tribological properties of cold sprayed high content SiCp/Al coating by SiCp mild-oxidation treatment

This paper presents the results of the influence of irregular SiC particles, treated by mild-oxidation at 1100 °C, on deposition behavior (deposit rate, surface finish roughness), and deposition body (microstructure, friction, and wear). Coatings are obtained using the cold-sprayed method, employing a powder mixture comprising 36 vol% irregular SiC powder treated by mild-oxidation and 64 vol% aluminum powder as feedstock. Results show that the silicon carbide particles are treated by mild-oxidation, the external surface of silicon carbide particles is predominantly composed of soft ceramic silica, and the particle edges are passivated. The results indicate that, under identical cold-sprayed process conditions, both the deposition amount of the coating and the retention amount of SiC particles increased. The particle fragmentation and particle distribution of SiC are obviously improved. The coating did not exhibit any harmful phases. Local weak metallurgical bonding is found at the interface of SiCp and Al matrix. Furthermore, the coating's porosity decreased, after SiCp mild-oxidation, the friction coefficient (0.5716) is decreased by 12.9 %, and the wear amount (0.159 mm3/N·m) is decreased by 64.7 %. A dense and uniformly distributed aluminum matrix composite coating with a high SiC particles content is achieved.

Influence of SiC particles on the microstructure and mechanical behaviors of AlMgScZr alloy processed by laser powder bed fusion

Laser powder bed fusion (LPBF) of AlMgScZr alloy has garnered significant attention as a high-strength aluminum alloy. However, its low modulus, Portevin-Le Chatelier (PLC) behavior, and weak strain hardening capability restrict its application in the aerospace sector. In this study, SiC/AlMgScZr composites with different SiC content have been successfully fabricated using LPBF. The inherent bimodal grain structure of AlMgScZr alloy was not completely altered by the addition of SiC particles. However, with increasing SiC content, heat accumulation increased, and the solidification cooling rate decreased. This led to an increase in the size of α-Al grains in the 5 wt% SiC/AlMgScZr composites. Meanwhile, movable dislocations can be efficiently preserved inside the grains, where they effectively accumulate and become entangled. Consequently, the strain hardening capability of the 5 wt% SiC/AlMgScZr composites improved by approximately 58 % compared to AlMgScZr alloy, with a strain hardening index (n) reaching 0.29. Additionally, the addition of SiC particles led to an increase in the elastic modulus (81.0 GPa). Furthermore, the reaction between Mg atoms and SiC particles resulted in the formation of Mg2Si, which altered the distribution of Mg elements and initiated the reactive precipitation of a Mg-rich phase. There is no competition between the diffusive migration of solute atoms and the motion of movable dislocations within the composites. The additional SiC particles effectively eliminated the PLC effect in the LPBF of AlMgScZr alloy. This work provides essential guidance for developing high-strength and high-stiffness aluminum matrix composites with excellent processing properties in LPBF technology.

Enhanced fracture toughness of high entropy boride by adding SiC

The effect of SiC content (10 vol%, 20 vol% and 30 vol%) and sintering temperature (1800 °C, 1900 °C and 2000 °C) on the microstructure and mechanical properties of high entropy boride-silicon carbide (HEB-SiC) composites were systematically investigated in this work. The densification was gradually increased with the increase of SiC content and sintering temperature. More specially, the densification of HEB-30 vol% SiC composite obtained at 2000 °C was as high as 99.1 %. As for the mechanical properties, the dense HEB-30S-2000 composite possessed the highest fracture toughness (5.24 MPa m1/2) and Vickers hardness (28.5 GPa). The above significantly enhanced fracture toughness was closely pertained to the fracture modes adjusting. In details, after the addition of SiC, the branching and bridging of crack, the rupture of large SiC grain, and the deflection of crack existing near the HBE matrix and SiC particles jointly promote the improvement of fracture toughness. Besides, the Vickers hardness increased linearly with the relative density increasing. A simplified equation was established, which could effectually reflect the linear connection between the Vicker hardness and relative density (SiC content) of HEB-SiC composites. It will certainly play an important guiding role in the further development of HEB-SiC composites.

Microstructure and properties of SiC ceramic-modified aluminium alloy fabricated using wire arc additive manufacturing

A method for improving the properties of the deposited metal in wire arc additive manufacturing of Al–Si alloy is proposed here, which introduces SiC ceramic particles into the side-axis wire feed. The effects of SiC ceramic particles on the macroscopic morphology, microstructure and mechanical properties, corrosion resistance, and wear resistance of deposited metals were studied. The results show that the introduction of SiC particles will not affect the surface-forming quality of the deposited metal; this is likely due to the stable droplet transfer and no splashing. The transverse and longitudinal tensile strengths are increased by 10.1 % and 11.3 %, respectively, while the corresponding elongations are increased by 33.1 % and 47.2 %, respectively. Further, the corrosion resistance and wear resistance of Al–Si alloy deposited metals containing SiC are improved. The (100) base surface has strong texture characteristics along the deposition direction X0, and the maximum polar density decreases to 13.63, which indicates that SiC promotes the transformation of columnar crystals to equiaxial crystals. The interface between SiC and Al is non-coherent, and the performance improvement lies in the enhanced dispersion distribution and load transfer of SiC. A ring structure was prepared using double-wire arc additive manufacturing technology, and the feasibility of side-axis wire feeding technology was verified.

Numerical simulation study on hot pressing of ceramic/metal powders

This study utilizes the multi-particle finite element method (MPFEM) to establish 2D and 3D hot pressing models for particle-reinforced aluminum matrix composites. The hot pressing of 6061Al powder and 10 % volume fraction SiCp/6061Al composite powder are simulated under a temperature range of 430–510 °C and pressures ranging from 15 to 30 MPa. The densification mechanism of the composites is elucidated by analyzing the evolution of density and microscopic particle behavior. The analysis reveals that elevating both the pressing temperature and pressure effectively increases the relative density of the powders, with the maximum growth rate occurring at 25 MPa. Notably, the barrier effect created by SiC particles in the 6061Al matrix restricts the plastic deformation and flow of matrix particles, leading to a lower final relative density for the composite powder compared to pure 6061Al powder. Microscopic observations indicate that particle rearrangement dominates in the initial pressing stage, while plastic deformation and particle flow become crucial factors for enhancing relative density in the later stage. Further stress-strain analysis demonstrates that 6061Al particles effectively fill pores through plastic deformation, resulting in stress concentration primarily on the harder SiC particles.

Enhancement of Plain Carbon Steels Corrosion by Heat Treatment of the Direct Electrodeposited Ni-P-SiC Deposit

The current study examined the effects of heat treatment on the microhardness and wear resistance of electrodeposited Ni-P-SiC coatings, as well as the effects of SiC particle concentrations on the coating's metallic continuous phase. Direct electrodeposition onto a low alloy steel electrode (0.40 C) was used to obtain the deposits. A modified Watt bath and pure nickel anode were used, and the material was heat treated for one hour at 400 °C. Using XRD and SEM methods, the Ni-P-SiC deposit was characterized. Additionally, the deposit's microhardness was assessed using the LECO, DM-400, both before and after heat treatment, with a 50g load. The results obtained indicate that the coating's deposition on the surface of low alloy steel and its impacts on the deposit coating crystal plane may be influenced by the applied current density. The SiC dispersion slightly improved as the bath's SiC content rose. The reduction in phosphor content of the deposited Ni-P-SiC coating as a result of the SiC particles being added to the Ni-P electrodeposition bath. The XRD data showed that crystalline Ni and Ni3P are formed as a result of the heat treatment procedure. As the SiC content in the electrodeposition bath and heat treatment procedure rises, so does the microhardness of the Ni-P-SiC deposit. Low alloy steel's resistance to erosion corrosion can be strengthened by the Ni-P-SiC.

Microstructural evolution and phase analysis of SS410–Al2O3–SiC multilayered functionally graded composite fabricated through laser cladding

In the present study, a functionally graded metal-ceramic composite structure comprising SS410, Al2O3, and SiC particles with varying composition, structure and properties in a single deposit was successfully fabricated using direct energy deposition (DED). The composition varied from 90 % SS410 with 10 % (xAl2O3 + ySiC) to 10 % SS410 with 90 % (xAl2O3 + ySiC), where x = 70 % and y = 30 % in a five-layered FGM design. The microstructure, phase evolution and mechanical properties of the components with different composition gradients were characterized by microscopy, energy dispersive spectroscopy, wavelength dispersive spectroscopy, X-ray diffraction and micro hardness. The investigation revealed that complex phases such as C0.12Fe0.79Si0.09, M7C3, Fe3C, and Fe3Si formed as a result of the interaction between SiC and SS410 during the cladding process. Microstructural analysis showed a transition from columnar dendrites at the bottom zone of the cladding to a typical cellular structure and carbide particle agglomerates in the middle zone, with finer grains at the top zone. This gradation in microstructure correlated with an increase in microhardness ranging from 299 HV at the bottom to 966 HV at the top. This enhancement in hardness is primarily attributed to solid solution strengthening from C and Si originating from the decomposition of SiC and the precipitation of intermetallic phases.

Enhanced thermochemical energy storage properties of SiC-doped calcium-based material with steam addition during heat charging process

Thermochemical energy storage based on the reversible carbonation/calcination reaction of CaCO3/CaO is emerging as a promising technology for energy storage in concentrating solar power systems. However, the inherent weak solar absorption capacity of natural calcium-based materials necessitates a substantial enhancement in their solar absorption capability. In this study, dark SiC particles of different sizes were introduced into CaO-based composite particles supplemented with cement and microcrystalline cellulose. The aim was to explore the influence of SiC components on the solar absorptivity, energy storage capacity, thermal conductivity, and mechanical properties of CaO-based particles. The results indicate that doping 10 wt% of SiC with a size of 25 μm in CaO-based particles demonstrated optimal results, corresponding to a 20.3 % increase in the average optical absorption and a 2.86-fold improvement in the thermal conductivity compared to the undoped particles. Furthermore, introducing steam during the decomposition of SiC-doped CaO-based particles significantly enhanced the mechanical properties. The breaking force of SiC-doped CaO-based pellets after 50 runs with 10 vol% steam addition was 1.39 times higher than that of the identical particles without steam treatment.