Silicon Carbide Particles Research Articles

Investigating of epoxy nanocomposites structure and properties that contain both pristine and aminosilane-treated silicon carbide (SiC) particles

This article presents a methodology for functionalization of silicon carbide (SiC) through chemical modification using γ-aminopropyltriethoxysilane (APTES) and its subsequent dispersion in an epoxy composition. The research revealed that functionalizing SiC particles with γ-aminopropyltriethoxysilane (SiC(APTES)) enhanced their chemical compatibility with the epoxy composition, facilitating the dispersion of SiC particles. Furthermore, it was observed that the functionalization of the filler had a profound impact on the structure, curing kinetics, and physical and mechanical properties of epoxy nanocomposites. The addition of SiC(APTES) into the epoxy composition resulted in a significant reinforcement of the material. Specifically, the flexural stress and flexural modulus of elasticity increased by 179% and 74%, respectively, while the impact strength experienced a remarkable improvement of 462%. Additionally, the tensile strength and tensile modulus of elasticity increased by 83% and 70%, respectively, compared to the epoxy composite without SiC. The application of SiC(APTES) also played a crucial role in initiating the polymerization process through the involvement of reactive amino groups, leading to a reduction in the initial curing temperature and an amplification of the thermal effects of the polymerization reaction. Moreover, the presence of functionalized SiC significantly influenced the structure of the epoxy composite, thereby contributing to its enhanced strength. In summary, the inclusion of SiC in the epoxy composition not only bolstered the material but also improved its thermal stability.

Preparation of a graphite / SiC composite casting material and study of its performance

The inferior mechanical properties and thermal conductivity of carbon graphite materials are attributed to the presence of pores and cracks. The integration of graphite with ceramics has been proposed as a method to enhance these properties; however, graphite/ceramic composites fabricated through pressureless sintering often exhibit inadequate integration. In this paper, a diffuse-continuous network dual-reinforced graphite/silicon carbide(SiC) ceramic composite was prepared by integrating the graphite powder micro-thermal press forming technology with the fused deposition modelling(FDM) technology and combining the pressureless sintering and vacuum pressure impregnation processes. It was found that the addition of high purity silicon powder to the material formulation reacts with the resin carbon to form silicon carbide particles (SiC-p), which can play a role in diffusion enhancement. However, the addition of excessive silicon powder can have a detrimental effect, and the performance of diffusion enhanced graphite/silicon carbide composites is positively correlated with the density of billet formation, and the effect of diffusion continuous network dual enhancement is more obvious, and the performance of the composites is better compared to that of single diffusion enhancement. The compressive and flexural strengths of the graphite/SiC composites finally obtained reached 59.47 MPa and 44.25 MPa, respectively, and the thermal conductivity was 43.62 W/m·K, and the porosity and open porosity were 29.62 % and 20.48 %, respectively, which are comparable to those of manmade graphite castings, and have better gas permeability, which is expected to be applied in the casting field.

Vat photopolymerization of silicon carbide strengthened alumina ceramic composites with honeycomb structure for heat insulation and oil/water separation

In this study, the effects of different silicon carbide (SiC) particle sizes on the viscosity and curing behavior of alumina (Al2O3) ceramic suspensions were thoroughly investigated. The findings revealed that increasing the size of SiC particles led to a noticeable decrease in the viscosity of the suspension. The Al2O3 ceramic suspension with 0.6 μm SiC powder demonstrated a shallower cure depth and wider excess width compared to the suspension with 1.0 μm SiC powder. Sintering tests demonstrated that the properties of the SiC–Al2O3 ceramics improved at higher sintering temperatures. Moreover, a high-performance honeycomb ceramic was successfully designed and fabricated with a porosity and compressive strength of 30.8 % and 188 MPa, respectively. Finally, the SiC–Al2O3 honeycomb ceramics were effectively applied in heat insulation and oil-water separation applications, demonstrating their remarkable capabilities.

Study of tribological performance and corrosion resistance of aluminum alloy 6063 composites enhanced with a combination of silicon carbide and tungsten disulfide particles

This research explores the effects of wear on a 6063 aluminum alloy matrix combined with silicon carbide (SiC) and tungsten disulfide (WS2) particulates. Dry friction wear tests were conducted on three materials: pure 6063 aluminum alloy, a composite with 4 wt% SiC and 4 wt% WS2 reinforcement, and another composite with 6 wt% SiC and 4 wt% WS2 reinforcement. These materials were tested against AISI410 stainless steel discs under varying loads (10N, 20N, and 30N) and sliding rates (0.5, 1.0, and 1.5 ms−1) following a Taguchi L27 orthogonal experimental plan. Main effect graphs (S/N ratios) and ANOVA analysis were utilized to determine optimal parameter combinations, and confirmation tests were carried out to validate the Taguchi results. Scanning electron microscope (SEM) images of wear areas showed that incorporating SiC and WS2 significantly enhanced the wear resistance of the aluminum alloy. This indicates that incorporating SiC and WS2 reinforcement has the potential to enhance the wear resistance of aluminum alloys, making them suitable for applications such as piston rings in internal combustion engines, which is in line with the requirements of engine performance. Furthermore, potentiodynamic polarization studies evaluated the corrosion resistance of the Metal Matrix Composites AA6063 in 3.5% NaCl. Results indicated that the AA6063 + 6 wt% SiC + 4 wt% WS2 composite exhibited superior corrosion resistance compared to AA6063 alone.

Effect of Reinforcement on Micro Structural and Compressive Deformation Behavior on Closed Cell AA7075 Aluminium Foam

Effect of Reinforcement on Micro Structural and Compressive Deformation Behavior on Closed Cell AA7075 Aluminium Foam

Impact of Silicon Carbide Particle on the Behavior of Coir Fiber-Incorporated Polypropylene Hybrid Composite

Impact of Silicon Carbide Particle on the Behavior of Coir Fiber-Incorporated Polypropylene Hybrid Composite

Microstructure and Mechanical Properties of Carbon Fiber Phenolic MatrixComposites containing Carbon Nanotubes and Silicon Carbide

A novel class of hybrid composites was prepared containing carbon fibers along with carbon nanotubes and silicon carbide particles in phenolic resin for improved mechanical performance. The loading of carbon fibers was ~60 wt% while carbon nanotubes and silicon carbide particles were reinforced in the fractions of 0.1 wt% and 5 wt%, respectively. Individually reinforced composites containing 0.1 wt% carbon nanotubes and 5 wt% silicon carbide particles were also manufactured for comparison with hybrid composites. Microstructural and mechanical property characterization was performed using electron microscopy and mechanical testing, respectively. Uniform dispersion of nanometer-scale carbon nanotubes and micrometer-scale silicon carbide particles was observed under microscopy. The pooled effect of carbon nanotubes and silicon carbide particles significantly increased the tensile, compressive, and flexural performance of composites while carbon nanotubes offered greater weight fraction value improvement than silicon carbide particles.

Evaluating the Effect of Different Percentage Addition of SiC on Mechanical and Wear Properties of Al6061 Composite

AbstractAluminum 6061 alloy using silicon carbide (SiC) particles as a reinforcement is a promising metal matrix composite (MMC) that has gained significant attention in the automotive and aerospace industries. Till now the effect of the addition of SiC particles in Al6061 composite is not studied in depth and also very few studies are reported the on‐wear properties of Al6061‐SiC composite. So, to further enhance the properties of Al6061 alloy and to study in depth this work is carried out. In this study, MMCs are prepared using the stir casting route with varying weight fractions (5–10 wt%) of SiC particles. The properties of composites including tensile strength, compression strength, and wear are evaluated experimentally. The results demonstrated that the incorporation of SiC particles into the Al alloy matrix leads to a notable improvement in mechanical and wear parameters. The tensile and compression strength of the Al composites increases with an increase in the weight percentage addition of SiC particles (from 5% to 7.5%). At 7.5 wt% addition of SiC, it is found that the particles are uniformly distributed throughout the Al6061 alloy matrix. And also shows higher mechanical and wear properties as compared to 5% and 10% addition.

On the Possibility of Using Secondary Alloys in the Production of Aluminum-Based Metal Matrix Composite

Aluminum-based composites provide tribological performance and thermophysical properties that, combined with being lightweight, are suitable for their application in automotive brake discs. Aluminum alloys allow the use of secondary materials to produce composites, with the drawback of several elements, impurities, and oxides that can harm the mechanical and thermophysical properties. This preliminary study explored the mechanical and thermophysical performance of a composite material produced with a secondary matrix alloy. Overall, the results are promising, with a minimal decrease in mechanical and thermophysical properties despite clustered silicon carbide particles in the composite with the secondary matrix. The challenges in effectively dispersing carbides in the melt seem linked to aluminum oxides, and future microstructural investigations will aim to clarify this aspect.

Wear Behavior of Epoxy Resin Reinforced with Ceramic Nano- and Microparticles.

Cavitation erosion poses a significant challenge in fluid systems like hydraulic turbines and ship propellers due to pulsed pressure from collapsing vapor bubbles. To combat this, various materials and surface engineering methods are employed. In this study, nano and micro scale particles of silicon carbide (SiC) or boron carbide (B4C) were incorporated as reinforcement at 6% and 12% ratios, owing to their exceptional resistance to abrasive wear and high hardness. Microparticles were incorporated to assess the damage incurred during the tests in comparison to nanoparticles. Wear tests were conducted on both bulk samples and coated aluminum sheets with a 1mm of composite. Additionally, cavitation tests were performed on coated aluminum tips until stability of mass loss was achieved. The results indicated a distinct wear behavior between the coatings and the bulk samples. Overall, wear tended to be higher for the coated samples with nanocomposites than bulk, except for the nano-composite material containing 12% SiC and pure resin. With the coatings, higher percentages of nanometric particles correlated with increased wear. The coefficient of friction remained within the range of 0.4 to 0.5 for the coatings. Regarding the accumulated erosion in the cavitation tests for 100 min, it was observed that for all nanocomposite materials, it was lower than in pure resin. Particularly, the composite with 6% B4C was slightly lower than the rest. In addition, the erosion rate was also lower for the composites.

Experimental Investigation of WE43(T6) magnesium metal matrix composites to enhance mechanical properties and EDM process parameters

In recent years, magnesium metal matrix composites (MMCs) are increasingly used in the automotive, aerospace, and biomedical industries due to their superior physical and thermal properties compared to their parent materials. Magnesium metal matrix composites are noteworthy for numerous reasons, including their light weight, high specific modulus, wear resistance, corrosion resistance, high toughness, fracture resistance, thermal stability, and ability to perform at higher temperatures. Our research primarily focuses on enhancing the mechanical properties of the magnesium metal matrix composite (WE43-T6) reinforced by silicon carbide (SiC) and aluminum oxide (Al2O3) particles with a size of 10 μm to 30 μm. The composite was examined using SEM and EDAX to investigate its microstructure and elemental composition. The distribution of the reinforcement particles is well represented in the microstructural analysis. In addition, the present research also focuses on studying MRR, TWR, and surface roughness in EDM machining process using copper, brass, and tungsten carbide electrodes to improve MRR and limit TWR and surface roughness. The results of the study showed that pulse on-time, pulse current, and spindle speed have a significant influence on MRR and TWR. A parametric analysis using a linear regression model was performed to verify the effects of experimental machining performance The experimental results were found to have less than 5% error. The addition of silicon carbide and aluminum oxide particles to magnesium metal matrix composites, makes materials harder and stronger while reducing their weight by 0.98–1.05%.

Silicon carbide nanoparticles featured AZ63/BN alloy nanocomposite made by using liquid stir vacuum die cast: characteristics study

ABSTRACT With the unique class, the reinforcements play a precious role during the composite fabrication, expanding the specific properties. The novel research intensively enhances the micro-structural and mechanical behaviour of magnesium alloy (AZ63/3 wt% boron nitride) nanocomposite featured 2, 4, and 6 wt% of nano-size silicon carbide (SiC) particles via liquid state vacuum stir cast route. The exposure of SiC and BN on composite density, voids contribution, changes in AZ91D microstructure, impact toughness, hardness, and stress-strain individuality of AZ63 alloy nanocomposite is evaluated with ASTM policy. The composite composed with 3 wt% BN and 6 wt% SiC proved their identity. It showed the lower contribution of voids-free homogenous dispersion particle results in a maximum impact strength of 14.7J/mm2, hardness of 74HV, and superb tensile strength of 247MPa. This optimum behaviour will be recommended for automotive roof frame applications.

The evaluation of machining performances and surface roughness of TZM-molybdenum superalloy processed by silicon carbide powder mixed EDM process using RSM and ANOVA

In the present era, the concept of Industry 4.0 plays a significant part in improving the efficiency, quality, and utilization of resources by automation and enabling intelligent operations in manufacturing processes. As a result, there is a requirement to develop an environment that improves efficiency as well as quality in order to accomplish net zero in manufacturing. The objective of powder mixed electric discharge machining (PMEDM) is to enhance the quality of the surface and machining efficiency of traditional electrical discharge machining. The PMEDM method was applied to TZM-molybdenum superalloy in the present investigation by incorporating silicon carbide particles into the dielectric medium. Powder concentration, peak current, pulse on time, pulse off time, and gap voltage were the considered input variables for the investigation. The impacts of the input variables on the surface of the specimen’s roughness and the rate of material removal (MRR) were examined. The experiment model was built using response surface methodology. To find out if the input factors were significant with regard to each response, an analysis of variance (ANOVA) was performed. Powder concentration, pulse current, gap voltage, and pulse on time are found to be the important input variables for both surface roughness and MRR based on ANOVA analysis.

Numerical Analysis and Experimental Study on Side Dam Temperature and Stress Field of Two‐Roll Casting

The side sealing technology is crucial for ensuring the quality and process stability in twin‐roll casting (TRC). Investigating the temperature and stress distribution in side dams under operational conditions is vital, especially in understanding the causes of side dam fractures. Optimal performance of side dam materials is achieved when the boron nitride (BN) matrix is fine and homogeneous, with zirconium dioxide (ZrO2) and silicon carbide (SiC) particles evenly dispersed throughout. The fracture of the side dam after casting is mainly caused by BN interlamellar tear. The coexistence of BN lamellar tearing and BN layer fracture leads to the fracture of the side dam during the casting process. Through finite element simulation, the effects of variables such as pouring temperature, preheating temperature, and side dam thickness on temperature and stress distribution were analyzed. The findings indicate that a preheating temperature range of 1200–1300 °C minimizes thermal stress in the side dam. Building on these findings, a composite structure for the side dam is developed. Both internal and external composite structures have shown significant effectiveness in reducing thermal stress. These results are pivotal in extending the service life of side dams and enhancing the stability of the TRC process.

Preparation of Silicon Carbide Powder from Amorphous Silica and Investigation of Synthesis Mechanism

An innovative process for preparing silicon carbide (SiC) from acid leaching residue of ferronickel slag through a carbon–thermal reduction process was proposed in this study. The results indicate that the acid leaching residue is an ideal silicon source for SiC preparation according to its high amorphous silica content of 84.20% and fine particle size of d50 = 29.16 μm. Compared with carbon black, activated carbon, and graphite, coke is the more appropriate carbon source for SiC preparation. A micron-size SiC powder with grade of 88.90% and an average particle size (d50) of 44.68 μm can be obtained under the following conditions: the mass ratio of coke to leaching residue as 1.2:1, in an air atmosphere, reducing at 1600 °C for 3 h, following by decarbonizing at 700 °C for 4 h. The XRD, SEM and FTIR analyses show that the prepared powder is 3C-SiC and belongs to the β-SiC crystal type. Based on thermodynamic analysis and micromorphology observation, it can be concluded that with amorphous silica as the silicon source, the carbon–thermal synthesis of SiC powder follows both the solid–solid reaction mechanism and the gas–solid mechanism. The SiC created through solid–solid reaction is primarily nucleated in situ on amorphous SiO2, with a size close to that of the original acid-leaching slag, while the SiC generated according to the gas–solid mechanism mainly nucleates heterogeneously on the surface of carbon particles, resulting in a smaller particle size and mostly adhering to the surface of solid–solid nucleated SiC particles. This study provides a feasible method for the effective utilization of amorphous silica, which is also significant for the efficient consumption of the vast acid leaching residue.

Investigation of the microstructure and mechanical properties of an Al/SiC/ZrO2 hybrid composite by spark plasma sintering technique

The quantum of work with silicon carbide (SiC) and zirconium dioxide (ZrO2) in the aluminum hybrid composite material has increased due to the growing demand for lightweight materials for various industrial applications. The aluminum hybrid composite with the wt% of primary reinforcement particles of SiC was kept constant at 5%, and the secondary reinforcement particles of ZrO2 were taken by 5%, 10%, and 15%. The sintering parameters were used as the temperature at 600°C, holding time of 35 minutes, and pressure at 30MPa. In this work, the aluminum composite material reinforced with 5%wt of SiC particles compared the test results with aluminum hybrid composite reinforcement of SiC and ZrO2 nanoparticles. Adding ZrO2 reinforcements enhances the aluminum hybrid composite material's better microstructure, microhardness, tensile strength, compression, and yield strength.

Ultrasonic-Vibration-Superimposed Face Turning of Aluminium Matrix Composite Components for Enhancing Friction-Surface Preconditioning

Aluminium matrix composites (AMCs) represent an important group of high-performance materials. Due to their specific strength and a high thermal conductivity, these composites have been considered for the large-scale production of brake discs. However, preconditioning the friction surfaces is necessary to avoid severe wear of both the brake discs and the brake linings. This can be achieved through controlled friction against commercially available brake-lining materials and the formation of transfer or reactive layers (tribosurfaces). Homogeneous tribosurfaces allow for nearly wear-free brake systems under moderate brake conditions. In this work, preconditioning was carried out with a pin-on-disc tester, aiming for the fast creation of homogeneously formed and stable tribosurfaces. The influence of surface microedges perpendicular to the direction of friction on the machined AMC surfaces on the build-up speed and homogeneity of the tribosurfaces was investigated. The microedges were generated using ultrasonic-vibration-superimposed face turning. Thereby, the vibration direction corresponded to the direction of the passive force. For research purposes, the distance of the microedges was changed by varying the cutting speed and feed. The experiments were carried out using AMC disc specimens with a reinforcement content of a 35% volume proportion of silicon carbide particles. Machining was realised with CVD-diamond-tipped indexable inserts. The evaluation of the generated surfaces before and after preconditioning was achieved using 3D laser scanning microscopy and scanning electron microscopy. It was demonstrated that ultrasonic-vibration-superimposed face turning effectively generated microedges on the AMC surfaces. The results show that larger distances between the microedges enhanced the formation of stable tribosurfaces. Thus, the tribosystem’s steady state was reached quickly. Therefore, the benefits of AMC-friction-surface microstructuring on the generation of tribosurfaces under laboratory conditions were proven. These findings contribute to the development of high-performance AMC brake systems.

Effect of silicon carbide particles on the mechanical, thermal and structural properties of recycled high-density polyethylene

In this research work, recycled high-density polyethylene (rHDPE)/silicon carbide (SiC) composites were produced by melt compounding followed by injection moulding technique. It has been revealed from the mechanical properties that the addition of SiC increases the hardness, density, flexural strength of the composite and tensile strength of the composite. The impact strength at 15 wt-% SiC composite gives the best results. From the thermal analysis, it was observed that the addition of SiC in rHDPE increases the melting point and total enthalpy of crystallisation. The residual value of rHDPE composites increases with the rise in filler loading which enhances the thermal stability of the composites. Melt flow index (MFI) decreases with the increased in silicon carbide. The heat deflection temperature (HDT) increased with the loading of filler content. The contact angle analysis revealed the hydrophilic nature of the composite. MFI reduced with the incorporation of filler content. The SEM images concluded the agglomeration of the composite at higher filler fractions. These results confirm the possibility of using rHDPE/SiC composite to produce various parts for household commodities and structural applications.

Al-5052/SiC + CeO2 hybrid surface composites: Achieving improved microstructural and mechanical behaviour via friction stir processing

In the present work, hybrid surface composites (HSCs) were fabricated using aluminium 5052 alloy as base matrix and silicon carbide (SiC) and cerium oxide (CeO2) as reinforcement particles via friction stir processing (FSP) technique. Varying reinforcement ratios of SiC and CeO2 nano-powders, viz 100:0, 75:25, 50:50, 25:75, and 0:100 was used. Multi-pass FSP was employed to obtain improved dispersion of reinforcement particles. Results revealed the collaborative impact of SiC and CeO2 particles on the mechanical properties of the SCs, shedding light on the optimal ratios for achieving superior mechanical performance. The hybrid ratio of (SiC: CeO2) 75:25 was predominant in tensile strength enhancements with an ultimate tensile strength of 283 MPa compared to 269 MPa of BM while the percentage elongation increased to 21.6 as compared to 18.8 in BM. The average microhardness also improved to 92 HV compared to 85 HV. These results emphasised on the importance of HSC fabricated using 75:25 ratio of SiC:CeO2 reinforcing particles.

Effect of Milling Time and Reinforcement Volume Fraction on Microstructure and Mechanical Properties of SiCp-Reinforced AA2017 Composite Powder Produced by High-Energy Ball Milling.

The influence of milling time and volume fraction of reinforcement on the morphology, microstructure, and mechanical behaviors of SiCp-reinforced AA2017 composite powder produced by high-energy ball milling (HEBM) was investigated. AA2017 + SiCp composite powder with different amounts of SiC particles (5, 10, and 15 vol%) was successfully prepared from gas-atomized AA2017 aluminum alloy powder with a particle size of <100 μm and silicon carbide (SiC) powder particles with an average particle size of <1 μm. An optical microscope (OM), X-ray diffraction (XRD), and scanning electron microscope (SEM) were utilized to characterize the microstructure of the milled composite powder at different milling periods. The results indicated that the SiC particles were homogeneously distributed in the AA2017 matrix after 5 h of HEBM time. The morphology of the particles transformed from a laminar to a nearly spherical shape, and the size of the milled powder particles reduced with increasing the content of SiC particles. The XRD analysis was carried out to characterize the phase constituents, crystallite size, and lattice strain of the composite powders at different milling periods. It was found that with increasing milling time and SiC volume fraction, the crystallite size of the aluminum alloy matrix decreased while the lattice strain increased. The average crystallite sizes were reduced from >300 nm to 68 nm, 64 nm, and 64 nm after 5 h of milling, corresponding to SiC contents of 5, 10, and 15 vol%, respectively. As a result, the lattice strain increased from 0.15% to 0.5%, which is due to significant plastic deformation during the ball milling process. XRD results showed a rapid decrease in crystallite size during the early milling phase, and the minimum grain size was achieved at a higher volume fraction of SiC particles. Microhardness tests revealed that the milling time has a greater influence on the hardness than the amount of SiC reinforcements. Therefore, the composite powder milled for 5 h showed an average microhardness three times higher than that of the unmilled powder particles.