Volume Fraction Of SiC Particles Research Articles

Study of the residual stress distribution in SiCp/Al composites under thermal cycling conditions

In this study, a three-dimensional random representative volume element model was constructed using the finite element method combined with Python script to investigate the residual stress distribution in SiCp/Al composites with varying volume fractions, particle shapes, and particle size under thermal cycling conditions. The model has two different particle morphologies: spheres and irregular polygons. The results show that the irregular polygonal SiC particles exhibit higher residual stresses than spherical particles before and after thermal cycling due to their complex load transfer pathways and higher stress concentration at particle corners, which makes them more consistent with the characterization of SiCp/Al composites under practical application conditions. As the volume fraction of SiC particles increases, the particle spacing decreases, hindering the release of thermal stresses through plastic deformation. Notably, the relief rate of residual stress reached 53% in the 12 vol% SiCp/Al composites, with the stress decreasing from 698 MPa to 328 MPa after 50 thermal cycles. In contrast, the reduction rate for 18 vol% composites is only 13% after thermal cycling. Furthermore, compared to larger particles (7.3 µm, 8.9 µm), the smaller particles (4.3 µm, 5.9 µm) exhibit a more uniform stress distribution and lower thermal stresses before and after thermal cycling. Consequently, our work provides a significant theoretical basis for the design and application of SiCp/Al composites, especially for the application of materials under extreme temperature changes.

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.

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.

Synergistic enhancement of strength and plasticity of SiCp/Al composites by designing and controlling SiCp@MgAl2O4 core-shell micro-interfaces

Building a superior balance of strength and plasticity inversion is a challenge in the development of aluminum matrix composites reinforced with medium volume fraction SiC particles. In this study, we reported an interface design strategy to simultaneously enhance the strength and plasticity of 30 vol% SiCp/Al composite by in-situ generating SiC@MgAl2O4 core-shell micro-nanostructures. The results showed that a uniform MgAl2O4 shell layer with a thickness of ∼300 nm was formed when the Mg content was 4.0 wt%. The MgAl2O4 shell layer formed abundant coherent interfaces with both SiC particles and aluminum alloy matrix, exhibiting powerful interfacial bonding strength. During the deformation process, the effective transmission of load and the delay of fracture achieved a synergistic improvement in both strength and plasticity.

Simultaneously improved modulus, thermal expansion coefficient and wear resistance of a Mg–6Zn–1Gd–0.3Ca matrix composite by adding high volume fraction SiC particles

In this paper, three sizes (5, 20 and 50 μm) SiC particles (SiCp) were selected, and the SiCp/Mg–6Zn–1Gd-0.3Ca (SiCp/ZG61X) composites with ∼50 vol.% were successfully prepared by squeeze casting. The effect of particle size on the properties of the composites was studied, while the wear resistance and the wear mechanism of composites were investigated. The results showed that compared with the matrix alloy, the addition of SiCp can significantly improve the properties of the composites, in which the strength increased from 175.2 to 326.5 MPa and the modulus increased from 45.0 to 159.6 GPa. At the same time, the coefficient of thermal expansion and friction were significantly reduced. In addition, the smaller the particle size, the higher the strength and modulus of the composite. However, for the coefficient of friction and thermal expansion, the larger particle size was conducive to the reduction of the two coefficients. The analysis of friction and wear behavior showed that the wear mechanism of the matrix alloy was mainly abrasive wear and adhesive wear, while the wear mechanism of the composites was abrasive wear and layered wear.

Oxidation mechanism of high-volume fraction SiCp/Al composite under laser irradiation and subsequent machining

Conventional mechanical machining of a composite material comprising an aluminum matrix reinforced with a high volume fraction of SiC particles (hereinafter referred to as an SiCp/Al composite) faces problems such as rapid tool wear, high specific cutting force, and poor surface integrity. Instead, a promising method for solving these problems is laser-induced oxidation-assisted milling (LOAM): under laser irradiation, the local workpiece material reacts with oxygen, thus forming loose and porous oxides that are easily removed. In the present work, the oxidation mechanism of SiCp/Al irradiated by a nanosecond pulsed laser is studied to better understand the laser-induced oxidation behavior and control the characteristics of the oxides, with laser irradiation experiments performed on a 65% SiCp/Al composite with various laser parameters and auxiliary gases (oxygen, nitrogen, and argon). With increasing laser pulse energy density, both the ablated groove depth and the width of the heat-affected zone increase. When oxygen is used as the auxiliary gas, an oxide layer composed of SiO2 and Al2O3 forms, and CO2 is produced and escapes from the material, thereby forming pores in the oxides. However, when nitrogen or argon is used as the auxiliary gas, a recast layer is produced that is relatively difficult to remove. Under laser irradiation, the sputtered material reacts with oxygen to form oxides on both sides of the ablated groove, and as the laser scanning path advances, the produced oxides accumulate to form an oxide layer. LOAM and conventional milling are compared using the same milling parameters, and LOAM is found to be better for reduced milling force and tool wear and improved machined surface quality.

Mechanical and thermal expansion behavior of hybrid aluminum matrix composites reinforced with SiC particles and short carbon fibers

In recent years, the research of hybrid composites reinforced by multiple reinforcements has received increasing attention because these composites have great potential to be tailored for various applications. In the present work, hybrid aluminum (Al) matrix composites reinforced with SiC particles and carbon fibers (SiCp-Cfs/Al composites) were fabricated by the colloidal dispersion and suction filtration method. It was found that SiCp-Cfs/Al composites had a dense structure and the carbon fibers and SiC particles were uniformly distributed in the Al matrix. The mechanical properties of SiCp-Cfs/Al composites with different reinforcement volume fractions were investigated. The results showed that the SiCp-Cfs/Al composites exhibited high tensile strength and elastic modulus (tensile strength 207 MPa and elastic modulus 92 GPa) when the volume fraction of SiC particles was 5% and the volume fraction of carbon fiber was 7%, which were significantly higher than that of SiCp/Al composites with 5% volume fraction of SiC particles (tensile strength 112 MPa and elastic modulus 80 GPa). The homogeneous distribution of carbon fibers and SiC particles in the Al matrix, which serves as co-reinforcing, is responsible for the high tensile strength and elastic modulus of SiCp-Cfs/Al composites. The coefficient of thermal expansion (CTE) of SiCp/Al composites and SiCp-Cfs/Al composites were measured at temperatures ranging from 25 °C and 400 °C. The results showed that the addition of carbon fibers caused the CTE of SiCp-Cfs/Al composites to be much lower than that of SiCp/Al composites.

Establishment of scratching force model for micro-removal of SiCp/Al composites by ultrasonic vibration

In the process of micro-removal machining SiCp/Al, the real-time prediction of cutting force is of great significance to ensure the surface quality of the workpiece and safe production. Based on the two major sources of cutting forces: the elastic-plastic deformation resistance of the machined material and the friction between the tool and the material, this paper established an ultrasonic vibration-assisted scratching force model by considering four aspects: chip formation force, SiC particle breaking force, tool and Al matrix friction force and rolling friction force. The model was experimentally validated by a self-built ultrasonic scratching device, and the effects of scratching speed, SiC particle volume fraction, and ultrasonic amplitude on the scratching force were investigated. The results showed that the scratching force is minimum when the scratching speed is 400 mm/min for both ordinary scratching (OS) and ultrasonic vibration-assisted scratching (UVAS). As the volume fraction of SiC particles increases, the scratching force gradually increases. Under the same experimental conditions, the force of UVAS is much smaller than OS. The maximum error between the experimental value and the predicted value of the model is 33% and gradually decreases with the increase of scratching speed and SiC volume fraction. The overall trend of the two is consistent, which proves the feasibility of the scratching force model. This study can provide some theoretical guidance for the force control when machining SiCp/Al. The ultrasonic vibration-assisted scratching force model was established by considering the chip formation force, SiC particle breaking force, tool matrix friction force, rolling friction force and ultrasonic vibration applied. And the model was verified by experiments. • A new machining process of ultrasonic vibration-assisted scratching was proposed. • An ultrasonic vibration-assisted scratching force model was established. • The experimental values were in good agreement with the model predicted value, which verified the feasibility of the established model.

Heat transfer enhancement through perforated fin made by MMC by reinforcing Aluminium with SiC & Graphite and optimization of design parameters using Taguchi method

This research paper examines the performance of Al-SiC/4%Graphite as a perforated fin material in opposition to traditional materials that is – aluminum, rectangular fin prepared with lateral circular perforations of varying sizes such as 12 mm, 14 mm, 16 mm, and 18 mm (porosity are 0.028, 0.038, 0.050 and 0.064). The perpendicular fragmentary area of the fin was 40x3 mm, the length of the fin is 100 mm, and different velocity of flow rates are 4, 5, 6, and 7 m/s. by applying Taguchi L16 method, the best design constraints and then their levels were studied. Varity of specimens made by Stir Casting with varied Combinations of Sic, 4%(Gr) in Al as Matrix. SiC powder with various volume fractions (5, 10, and 15%) and particle size (150 μm) was mixed with Graphite-4% powder to manufacture Al-4 %Graphite/SiC composite. Results revealed that by increasing the volume fraction of SiC particles, heat transmission of the Al- SiC/4%Graphite nanocomposite was enhanced. With a Combination of Al/15%(SiC)/4%(Gr) high heat transfer coefficient, and heat transfer rate improved compared to conventional Aluminium, for porosity 0.064 friction factor and pressure drop were found to be high. The Optimal results were found for the fin made by Al/15%(SiC)/4%(Gr) when compared with normal fin materials, and it was also found that fin made by Al/15%(SiC)/4%(Gr) has high strength and less weight.

Cutting Force Prediction Model for Elliptical Vibration Cutting SiCp/Al Based on Three-Phase Friction Theory

The friction behavior in the tool-chip interface is an essential issue in aluminum matrix composite material (AMCM) turning operations. Compared with conventional cutting, the elliptical vibration (EVC) cutting AMCM has attractive advantages, such as low friction, small cutting forces, etc. However, the friction mechanism of the EVC cutting AMCM is still inadequate, especially the model for cutting forces analyzing and predicting, which hinders the application of EVC in the processing of AMCM. In this paper, a cutting force prediction model for EVC cutting SiCp/Al is established, which is based on the three-phase friction (TPF) theory. The friction components are evaluated and predicted at the tool-chip interface (TCI), tool-particle interface (TPI) and tool-matrix (TMI), respectively. In addition, the tool-chip contact length and SiC particle volume fraction were defined strictly and the coefficient of friction was predicted. Based on the Johnson-Cook constitutive model, the experiment was conducted on SiCp/Al. The cutting speed and tool-chip contact length were used as input parameters of the friction model, and the dynamic changes of cutting force and stress distribution were analyzed. The results shown that when cutting speed reaches 574 m/min, the tool-chip contact length decreases to 0.378 mm. When the cutting speed exceeds 658 m/min, the cutting force decreases to a minimum of 214.9 N and remains stable. In addition, compared with conventional cutting, the proposed prediction model can effectively reduce the cutting force.

An Experimental Study of The Effects of Ceramic Composition on The Electrical and Thermal Properties of Al/SiC Composites

Al/SiC metal-matrix composites were investigated through Differential Thermal Analysis device as a function of volume fraction of SiC particles and sample temperature ranging 273 K to 373 K. It was found that electrical resistivity increased with increasing sample temperature and volume fraction of SiC. In contrast to electrical resistivity, electrical conductivity decreased with increasing sample temperature and volume fraction of SiC. Electrical conductivity decreased from 1,8x107 1/ohm.m to 2x106 1/ohm.m as the volume fraction of SiC increased to 60%. On the other hand, thermal conductivity decreased with increasing volume fraction of SiC particles, while being almost insensitive to temperature change between 273 K to 373 K. Thermal conductivity decreased from 120 W/mK to 10 W/mK as the volume fraction of SiC increased to 60%.

Microstructure and properties of plasma electrolytic oxidation coating on 55% SiCp/Al matrix composites

Protective coating was successfully prepared on two types of SiC p /Al matrix composites by plasma electrolytic oxidation (PEO) method, where the SiC p /Al matrix composites contains high volume fraction of SiC particles with sizes of 60 μm and 40 μm, respectively. Current-time curves were recorded during the PEO process in a constant voltage mode. The surface and cross-section morphologies, composition and adhesive force of the coatings were characterized by scanning electron microscopy (SEM), X-ray photoelectron spectroscopy (XPS) and X-ray diffraction (XRD), and coating adhesion automatic scratch tester, respectively. The electrochemical corrosion behavior of the substrate and coated composites was investigated in 3.5% NaCl solution by potentiodynamic polarization tests and EIS . The results show that the current change trend and coating morphology features of the two type of composites were consistent. SiC particles at high volume fraction could hinder the formation of the film and the ejection of the melt, resulting in rough, uneven pores with variable sizes, coarse molten particles and micro-cracks on the coatings. There is ablation on 60 μm-SiC/Al coating. The PEO coating was mainly composed of mullite , α-Al 2 O 3 , γ-Al 2 O 3 and amorphous phases. The adhesive force of coating on 40 μm-SiC/Al matrix composite (68.1 N) is better than that of 60 μm-SiC/Al matrix composite (22.0 N). The corrosion resistance of SiC p /Al matrix composite was improved by plasma electrolytic oxidation treatment. • The influence of SiC particles size on plasma electrolytic oxidation is analyzed. • SiC particles hinder the formation of the film and the ejection of the melt. • The large size of SiC particles causes the coating ablation. • SiC particles affect the properties of plasma electrolytic oxidation coating.

Predictive Computational Model for Damage Behavior of Metal-Matrix Composites Emphasizing the Effect of Particle Size and Volume Fraction.

In this paper, an integrated numerical model is proposed to investigate the effects of particulate size and volume fraction on the deformation, damage, and failure behaviors of particulate-reinforced metal matrix composites (PRMMCs). In the framework of a random microstructure-based finite element modelling, the plastic deformation and ductile cracking of the matrix are, respectively, modelled using Johnson–Cook constitutive relation and Johnson–Cook ductile fracture model. The matrix-particle interface decohesion is simulated by employing the surface-based-cohesive zone method, while the particulate fracture is manipulated by the elastic–brittle cracking model, in which the damage evolution criterion depends on the fracture energy cracking criterion. A 2D nonlinear finite element model was developed using ABAQUS/Explicit commercial program for modelling and analyzing damage mechanisms of silicon carbide reinforced aluminum matrix composites. The predicted results have shown a good agreement with the experimental data in the forms of true stress–strain curves and failure shape. Unlike the existing models, the influence of the volume fraction and size of SiC particles on the deformation, damage mechanism, failure consequences, and stress–strain curve of A359/SiC particulate composites is investigated accounting for the different possible modes of failure simultaneously.

Experimental Investigation of In-homogeneity in Particle Distribution During the Processing of Metal Matrix Composites

Particle reinforced metal matrix composites are skilled to fulfill the late needs of cutting edge designing applications, because of its tunable mechanical properties. Stir casting is one of the unmistakable and affordable strategies for preparing of particle reinforced metal matrix composites. However, complete investigation and evaluation of the vortex pressure and the homogenous distribution of particles are still an obstacle for the research community. In this method, vortex pressure and flow pattern are the important factors for the dispersion of particles in the liquid metal. Effectual flow pattern and vortex pressure can be attained by optimizing stir casting parameters such as volume concentration (5%, 10%), stirrer blade angle (45º, 90º), impeller position (20%, 40%) from the base, viscosity of Al melt (1.04 mPa-s, 1.24 mPa-s) and holding time (10 minutes, 15 minutes). In this research, computational fluid dynamics has been used to find the vortex pressure, which influences the particle distribution. A new photographic technique was implemented to find out the flow pattern of the reinforcement particles and the stir casting parameters are optimized using Taguchi method. Optimized parameters have been utilized for the production of PRMMCs. In addition, micro structural image and hardness test confirm the uniform particle distribution of the reinforcement particles. From the outcome of various experimentations, 10 minutes holding time of the stirrer blade with 45º angle which was kept 40% from the base and the viscosity of the Al melt (1.04 mPa-s) with 10% volume fraction of SiC particles shows effective flow pattern and optimum vortex pressure with homogenous distribution of SiC particles.

Synergistic strengthening of FeCrNiCo high entropy alloys via micro-TiC and nano-SiC particles

Adding reinforcing phases is an effective method to improve the mechanical performance of high entropy alloys. The strengthening effect of single reinforcement type has thus been studied to a great extend. Here FeCrCoNi high entropy alloy matrix composites embedded with micro-scale TiC and nano-scale SiC particles were fabricated via vacuum inductive melting method. The combined volume fraction of TiC and SiC particles was 10%, while the volume fraction of each particle was varied namely, 10 : 0, 7: 3, 5 : 5, 3 :7, and 0 : 10. The results show that the composite matrix has FCC structure, and the micro- TiC and nano- SiC particles were developed in the matrix through in-situ reactions. When the volume ratio of TiC and SiC particles is 7: 3, the mechanical properties reach the optimal combination. The yield tensile strength of the composite is 498.0 MPa, which is 207.2% higher than that of the matrix. The percent elongation is 41.2%. The strength increase stems from a synergy of grain refinement, thermal mismatch, solid solution, load bearing effect, and Orowan effect.

Joining high volume fraction SiC particle reinforced aluminum matrix composites (SiCp/Al) by low melting point stannous oxide–zinc oxide–phosphorus pentoxide glass

This study focused on joining high volume fraction SiC particles reinforced aluminum matrix composites (55 vol% SiCp/Al) with 50SnO–20ZnO–30P2O5 (SZP) glass directly in air. Prior to joining, various properties of the SZP glass and its wettability on the composites were investigated. The results showed that the coefficient of thermal expansion of the glass was 10.58 × 10-6/°C (20–369 °C), which closely match with 55 vol% SiCp/Al composites. The glass transition, crystallization, and softening temperature were identified to be 369, 397, and 486 °C, respectively. Subsequent wetting tests confirmed excellent wettability of the glass on the composites. The joint exhibited sound bonding that was free of defects when brazed at 550 °C for 10 min Zn2P2O7 was formed adjacent to the composites due to the crystallization of the glass. The mechanical properties of the joint were proven to be suitable, exhibiting an average shear strength of 55.3 MPa.

Method for preparing micro-nano-particle-reinforced PDMS-based FGM using 3D printing single nozzle

A single nozzle forming micro-nano-particle-reinforced polydimethylsiloxane (PDMS)-based functionally gradient material (FGM) was prepared by 3D printing. In the experiment, SiC and SiO2 particles were selected as the reinforcing phase, and an FGM with a volume fraction increasing from 0% to 20% layer by layer was prepared. The prepared FGM has no pores, shows good interlayer bonding, and contains micro-nano-particles evenly distributed in the layer without agglomeration. The mechanical properties and thermal conductivity of the PDMS-based FGM reinforced by SiC particles changed layer by layer. When the volume fraction of SiC particles reached 20%, the tensile modulus and hardness increased by 83% and 36%, respectively, and the thermal conductivity increased by 21%. SiO2-particle-reinforced PDMS-based FGMs have a lower layer-by-layer elongation rate after fracture than SiC particle-reinforced PDMS-based FGMs. The preparation of the above materials satisfies the actual demand for substrate materials in the field of flexible electronic products. While maintaining flexibility, high reinforced particle content can fully provide protection or heat dissipation for embedded electronic devices.

Microstructure and mechanical properties of in situ (TiC + SiC)/FeCrCoNi high entropy alloy matrix composites

In situ (TiC + SiC) particles (5 vol.% and 10 vol.%, respectively)-reinforced FeCrCoNi high entropy alloy matrix composites were fabricated via vacuum inductive melting method, with equal volume fractions of TiC and SiC particles. X-ray diffraction, scanning electron microscope and energy diffraction spectrum were employed to analyze the microstructure and composition of the samples. The results manifested that the FeCrCoNi matrix is composed of FCC phase, and the in situ particles are homogeneously scattered in the matrix. The presence of reinforcements augmented the ultimate tensile strength from 452 to 783 MPa, and raised the yield strength from 162 to 466 MPa at room temperature, whereas the elongation to fracture was reduced from 70.6% to 28.6%. All the tensile fracture surfaces consisted of numerous tiny dimples, indicating that the composites exhibited ductile fracture. Furthermore, the enhancement of strength ascribes to a combination of thermal mismatch strengthening, load-bearing effect, grain refinement, Orowan strengthening and solid solution strengthening effect, which contribute about 58.0%, 2.4%, 12.3%, 11.1% and 16.2% to the improvement of yield tensile strength, respectively.

Effects of SiC Particle Volume Fraction on Microstructure and Mechancial Properties of SiCp/6061Al Composites

The SiCp/6061Al composites with volume fractions of 10%, 20%, 30% and 40% were prepared by power metallurgy method. The effects of the volume fraction of SiCp on microstructure and mechanical properties were studied by means of phase analysis, microstructure observation, hardness test, friction test, wear and tensile test. The results show that the SiC particles distribute uniformly in the matrix and the interface bonding between the matrix and the reinforcement was exceptional. With the increase of the volume fracture of SiC particles, the distribution uniformity decreases, the hardness increases, the elongation decreases, with the tensile strength and wear resistance were increasing before slowly decrease. If the volume fracture of SiC particles is 30%, the comprehensive mechanical property is best that the hardness is 97.9 HV, the tensile strength 243 MPa, the elongation is 2.9% and wear rate is 1.21 × 10–5 g/m.

Characterization of aluminum based functionally graded composites developed via friction stir processing

Abstract Al/SiC functionally graded material (FGM) was developed through a novel multi-step friction stir processing (FSP) method. SiC particles with a mean size of 27.5 μm were embedded in the groove on the 6082-Al plate. To create a graded structure over a predefined value, FSP was carried out with three tools with different pin lengths and with varying volume fractions of SiC particles. The structure was formed by passing tools with 1−3 passes with a constant rotational and traveling speeds of 900 r/min and 20 mm/min, respectively. The experiments were conducted at room temperature. Microstructural features of functionally graded (FG) samples were examined by using scanning electron microscopy (SEM) and 3D light microscopy. Mechanical properties in terms of wear resistance and microhardness were thoroughly assessed. The results indicate that the increase in FSP pass number causes more uniform SiC particle dispersion. The microhardness values were impacted by the number of passes and improved by 51.54% for Pass 3 when compared to as-received 6082-Al. Wear resistance of Al/SiC FG samples was found to increase as a result of the addition of SiC particles.