Low cycle fatigue behaviour of particulate reinforced metal matrix composites

The low cycle fatigue (LCF) resistance of two different 6061 Al/20 vol% alumina particulate metal matrix composites (MMCs) in a peaked-aged condition has been evaluated under fully reversed strain control testing. Test results were combined with scanning electron and optical microscopy investigations to determine the effects of reinforcement particles and strain amplitude on the LCF behaviour of these MMCs. Both materials show three stages of response to LCF: initial fast hardening or softening in the first few cycles; gradual softening for most of the fatigue life; and a rapid drop in the stress carrying capability prior to failure. Both MMCs exhibit short LCF life which follows a Coffin-Manson relationship. All tested specimens demonstrate ductile fracture morphology at final failure. The experimental results are discussed in respect of strain amplitude, matrix composition and reinforcement shape and crack initiation.     

In situ SEM studies on the effects of particulate reinforcement on fatigue crack growth mechanism of aluminium-based metal-matrix composite

The effects of particulate reinforcement on the fatigue behaviour and fatigue mechanisms of two 6061 aluminium-based metal-matrix composites (MMCs) in three different heattreatment conditions were studied in situ with a scanning electron microscope and compared to the unreinforced alloy in the as-received condition. It was observed that the fatigue properties of the MMCs were influenced by the ceramic particles in two ways: firstly the particles increased the fatigue stress intensity threshold mainly by crack-deflection and crack-closure mechanisms, and secondly, the particles raised the fatigue crack growth rates in the Paris region by providing an easy crack path. The effect of ageing was small on the fatigue stress intensity threshold of MMCs, but for the peak-aged MMCs the fatigue crack growth rates in the Paris region were faster. The mechanism of fatigue crack growth was largely associated with the matrix/particle interface and the linkage with subcracks initiated ahead of the main crack at high applied stress intensity factors.     

Improvement of the bonding interface in hybrid fiber/particle preform reinforced Al matrix composite

The bonding interface between the reinforcement and the matrix alloy in hybrid AZS fiber/SiC particle preform based aluminum metal matrix composites (Al MMCs) has been investigated as a function of reinforced particle size and the binder content. It is observed that high binder and large particle will result in a poor bonding interface. This has deleterious effects on the mechanical properties of the cast MMCs. Estimation of the binder thickness indicates that there exists a critical particle size above which the particles are not appropriate to be used in fabricating the hybrid fiber/particle preform based MMCs.     

Phase-stress partition and residual stress in metal matrix composites

Finite element (FE) modeling based on axisymmetrical cells was performed for relating the phase-stress partition and residual phase stress in metal matrix composites (MMCs) to the reinforcement volume fraction and shape, matrix hardening behavior and applied strain levels. The phase stress is defined as mean effective stresses in the constituent phases. The elastic, plastic phase-stress partition behavior during loading, and the resultant residual stress in matrix followed unloading are delineated. A set of formulas is given for predicting the value of the phase stress in each phase, and residual stress in matrix from the inclusion volume fraction and aspect ratio, as well as matrix hardening exponent and applied strain level.     

The effect of extrusion parameters on the fretting wear resistance of Al-based composites produced via powder metallurgy

The work reported in this paper is aimed at establishing the relationship between processing and the wear resistance of the metal matrix composites (MMCs) based on a novel alloy, Al-20Si-5Fe-3Cu-1Mg. The MMCs were processed via a commercially viable powder metallurgy (PM) route, i.e. through mixing the atomized matrix alloy powder with 10 vol% SiC or Al₂O₃ particles, cold isostatic pressing, degassing and hot extrusion. It has been found that the extrusion window of the MMCs is greatly narrowed due to their increased deformation resistance on one hand and incipient melting of their matrix on the other. For a sound MMC extrudate, a reduction ratio over a critical value must be applied. However, a further rise of this ratio leads to deterioration of local interfacial cohesion between the ceramic phase and the matrix dispersed with a high volume fraction of silicon crystals and intermetallic dispersoids, thus degrading the MMCs in tensile properties. Furthermore, fretting wear tests at room and elevated temperatures and with dry and wet contacts show that the MMCs extruded at a higher reduction ratio has a higher mass loss and an increased friction coefficient. The work points to the direction of further research, i.e. on MMCs containing spherical reinforcement instead of commonly used angular particles.     

内部因素对金属基复合材料磨损性能的影响

综述和分析了金属基复合材料的内部因素对磨损性能的影响。这些因素包括增强体种类，大小、形状和取向，体积分数。分析表明，上述因素通过影响复材料的磨损机制而影响磨损性能，金属基复合材料在各种条件下表现的磨损机制的多样性是造成其磨损性能不稳定的原因。     

The relationships between wear behavior and thermal conductivity of CuSn/M7C3–M23C6 composites at ambient and elevated temperatures

The effect of FeCr (M₇C₃–M₂₃C₆) particles on the wear resistance of a CuSn alloy was investigated under 125 N load, and 300–475 K temperature interval. Sliding tests were performed to investigate the wear behavior of FeCr_p-reinforced CuSn metal–matrix composites (MMCs) against DIN 5401 in a block-on-ring apparatus. The CuSn/FeCr_p MMCs, which were prepared by addition of 5, 10, 15 and 20 vol.% of FeCr_p, were produced by powder metallurgy and the size of the particles was taken as 16 μm. The powders were uniaxially cold compacted by increasing pressure up to 250 Mpa. The dry sliding wear tests were carried out in an incremental manner, i.e. 300 m per increment and 3500 m total sliding length. The wear-test results were used for investigation of the relationship between weight loss, microstructure, surface hardness, friction coefficient, particle content and thermal conductivity. Finally, it was observed that FeCr_p reinforcement is beneficial in increasing the wear resistance of CuSn MMCs. FeCr particles in MMCs also tend to reduce the extent of plastic deformation in the subsurface region of the matrix, thereby delaying the nucleation and propagation of subsurface microcracks     

Spray forming of ultra-fine SiC particle reinforced 5182 Al-Mg

This paper describes the spray forming of SiC particle reinforced Al metal matrix composites (MMCs) with particular emphasis on microstructure characterization of SiC particle distribution. A 5182 Al-Mg alloy was used as matrix material, and SiC particles with a mean diameter of 1.2 m and 2.0 m as reinforcement. The reinforcing particle distribution and microstructural characteristics of MMCs were analyzed in the current study using TEM, SEM and optical microscopy. The distribution of SiC particles in the as-spray deposited and hot-extruded conditions was characterized. SEM results indicate that the SiC particles are homogeneously distributed although some clustering was evident in the matrix. TEM and OM examinations show that most of SiC particles are present intergranularly in the Al matrix. EDS analysis indicated that Mg tends to segregate and form oxide phases in the vicinity of SiC particles and that there is no compositional variation of Mg across grain boundaries in the Al matrix.     

Pressure infiltration processes to synthesize metal matrix composites – A review of metal matrix composites,the technology and process simulation

Metal matrix composites (MMCs) acquire their improved physical and mechanical properties through the careful reinforcement of their matrices by a variety of light but strong and stable reinforcement materials. The pressure infiltration process (PIP) is one of the most important techniques used for making MMCs with a high reinforcement content in which a molten metal or alloy is injected and solidified in a mold packed with continuous or discontinuous reinforcement materials. Several factors affect the quality of MMCs made by this process. These include, but are not limited to, the reinforcement type, preform geometry, applied pressure and pressure control, as well as the transport phenomena of the molten metal. This paper presents a review of the various aspects of MMCs, the process in terms of the technological details, the latest developments in the reinforcement materials used and the simulation models developed for pressure infiltration manufacturing of MMCs.     

Shear lag models for discontinuous composites: fibre end stresses and weak interface layers

A new shear lag (SL) type model for stress transfer in a composite with cylindrical fibres is derived. It accounts for fibre end stresses in an approximate yet realistic manner, and leads to a new formula for predicting the Young’s modulus of the composites. The predictions of this model were found to agree well with data for metal matrix composites (MMCs) with fibres of various aspect ratios. The accuracy and relative simplicity of the new model have been exploited in the development of an approximate analytical model for the stress transfer and macroscopic yield stress of a composite that contains a weak layer in the matrix adjacent to the reinforcement. With the aid of the latter model, the proof stress of MMCs which contain a precipitate free zone (PFZ) around the reinforcement, can be studied; experimental data obtained for aged 8090 MMCs is consistent with the model predictions.     

Magnesium Alloy - SiCp Reinforced Infiltrated Cast Composites

This article relates to the fabrication of magnesium and magnesium alloy with SiC_p reinforced metal matrix composites (MMCs) by a relatively new infiltration route. The preform for the fabrication of MMC was prepared by a mixed particle method where the matrix metal particles are mixed with the required volume percent of reinforcement without the use of any binders. Characterizations of fabricated composites were done by microstructure, microhardness, and wear studies. The studies revealed that an increase in the volume percent of reinforcement had beneficial effect on the microhardness values and wear studies.     

A generalized plane strain technique for estimating effective properties of particulate metal matrix composites using FEM

A procedure to estimate the effective elastic moduli and coefficient of thermal expansion (CTE) of particulate-reinforced metal matrix composites (MMCs) using a two-dimensional finite element method is presented. The actual microstructural geometry of the composites with randomly distributed second-phase particles is incorporated in the model. A generalized plane strain technique, realistically to describe the three-dimensional behaviour, is also incorporated in the model. The elastic moduli and the CTE, estimated using this model, agree favourably with the experimental data. The technique is shown to be superior compared to the conventional two-dimensional plane stress and plane strain approximations. Also, the results indicate that the effect of the shape of the randomly distributed second-phase particles on the effective elastic moduli is insignificant. Although the procedure is demonstrated for particulate MMCs, it can be easily extended to many other materials as well.     

Thermal expansion characteristics of cast Cu based metal matrix composites

Like any other metal/alloy, copper and its alloys also soften at elevated temperatures. Reinforcing with ceramic or carbon fibres is one of the suggested solutions to overcome this. Very limited literature is available on Cu based metal matrix composites (MMCs); none of these pertain to liquid phase fabrication. Hence, a systematic investigation was carried out on MMCs based on copper, with alumino-silicate fibres and carbon fibres as reinforcements. The MMCs thus produced exhibit a uniform distribution of reinforcement in the matrix. Coefficient of thermal expansion (CTE) values are lower than that of pure copper.     

搅拌摩擦加工制备颗粒增强铝基复合材料的研究现状及展望

铝合金作为现代工程和高新技术领域发展的关键材料之一,具有密度小、比强度和比刚度高、耐蚀性好等特点。通过在铝基体中添加增强相颗粒,制备得到的颗粒增强铝基复合材料既有铝合金良好的强度、韧性、易成形性等特点,又有颗粒的高强、高模等优点,是近年来应用最广的一类金属基复合材料。 目前,制备铝基复合材料的方法主要有粉末冶金法、铸造以及超声波法等,但这些方法在制备过程中需要较高的温度,颗粒与金属基体容易发生不良的界面反应,从而影响界面结合效果,降低复合材料的性能。搅拌摩擦加工(FSP)作为一种新型的固相加工技术,可同时实现材料微观组织的细化、致密化和均匀化。目前,FSP直接法已在铝基复合材料制备方面取得应用,主要是将增强相颗粒通过打盲孔或开槽的方式预置在金属基体内再进行FSP,进而制备出高致密度的颗粒增强铝基复合材料。因为FSP过程的温度低,颗粒与铝基体不会发生界面反应,所以该方法也被用于制备具有形状记忆效应(SME)的铝基功能复合材料。 近年研究结果表明,颗粒相对FSP制备的铝基复合材料晶粒细化起到显著作用,这有助于提高复合材料的拉伸强度、显微硬度及疲劳强度等力学性能。随着颗粒含量的增加和颗粒尺寸的减小,复合材料的力学性能得以增强。再者,减小颗粒尺寸有利于改善颗粒与基体之间的结合。另外,通过优化搅拌头的结构、形状和尺寸,以及FSP工艺参数,已经可以实现加工后颗粒相在基体中的均匀分布。 鉴于搅拌摩擦加工(FSP)直接法在制备颗粒增强铝基复合材料方面所具备的短流程、高效能以及基体与增强相颗粒界面无杂质等优势,本文对目前FSP直接法制备颗粒增强铝基复合材料的最新研究现状进行了总结。主要综述了FSP制备颗粒增强铝基复合材料过程中颗粒的含量、类型及尺寸对复合材料组织与力学性能的影响,并对颗粒分布均匀性以及颗粒与铝基体的界面问题做了阐述。文章最后深入分析了当前研究中的不足之处并展望了未来的研究方向。     

Refinement of microstructure and improvement of mechanical properties of Al/Al2O3 cast composite by accumulative roll bonding process

Some important problems associated with cast metal matrix composites (MMCs) include non-uniformity of the reinforcement particles, high porosity content, and weak bonding between reinforcement and matrix, which collectively result in low mechanical properties. Accumulative roll bonding (ARB) process was used in this study as a very effective method for refinement of microstructure and improvement of mechanical properties of the cast Al/10 vol.% Al₂O₃ composite. The average particle size of the Al₂O₃ was 3 μm. The results revealed that the microstructure of the composite after eleven cycles of the ARB had an excellent distribution of alumina particles in the aluminum matrix without any noticeable porosity. The results also indicated that the tensile strength and elongation of the composites increased as the number of ARB cycles increased. After eleven ARB cycles tensile strength and elongation values reached 158.1 MPa and 7.8%, which were 2.54 and 2.36 times greater than those of the as-cast MMC, respectively.     

Dislocation-induced damping in metal matrix composites

The damping response of crystalline metals and alloys is generally associated with the presence of defects in the crystal lattice. The disturbance of these defects, usually in response to an applied cyclic load, dissipates energy, a mechanism known as internal friction. The various defects commonly found in crystalline materials include point defects (e.g. vacancies), line defects (e.g. dislocations), surface defects (e.g. grain boundaries) and volume defects (e.g. inclusions). Among these, dislocations are noteworthy because they play a critical role, not only in the damping response of crystalline materials, but also in the overall mechanical behaviour of the materials. Among the various structural materials actively being developed, metal matrix composites (MMCs) have received considerable attention as a result of their potential to combine reinforcement properties of strength and environmental resistance, with matrix properties of ductility and toughness. Of interest is the generally observed phenomenon that MMCs exhibit unusually high concentrations of dislocations, an observation typically attributed to the difference in coefficient of thermal expansion between matrix and reinforcement. The objectives of the present paper are to provide an overview of the sources of dislocation generation in MMCs, and to provide insight into the effects that dislocations have on the damping response of MMCs. The presence of dislocations in MMCs is highlighted on the basis of transmission electron microscopy studies, and the dislocation damping mechanisms are discussed in light of the Granato-Lücke theory.     

Diamond Turning and Grinding of Aluminum-Based Metal Matrix Composites

This paper reports research results obtained from diamond turning and grinding of aluminum-based MMCs reinforced with either SiC or Al₂O₃ particles. Both polycrystal diamond (PCD) and single crystal diamond (SCD) tools were used for turning the MMCs at depths of cut ranging from 0 to 1.6 um. Diamond grinding wheels were used to grind the MMCs at depths of cut from 0.1 to 1 µm. Besides die depth of cut, ductile-mode turning of the reinforcing particles might also be affected by the orientation of the particles. Grinding using a 3,000-grit diamond wheel at depths of cut of 1 and 0.5 µm produced ductile streaks on the Al₂O₃ particles and the SiC particles, respectively. There was almost no subsurface damage except rare cracked particles. At the same depth of cut, the surfaces ground with the diamond grinding wheel revealed more ductile streaks on the reinforcement ceramic particles than those obtained from SCD turning.     

Thermal residual stresses in metal matrix composites: A review

Recently, metal matrix composites (MMCs) have generated a considerable interest in the materials field because of their attractive physical and mechanical properties. However, during the fabrication of MMCs, thermal residual stresses are reportedly developed in the matrix as a result of the mismatch of the thermal expansion coefficients between the reinforcement and the matrix. It is well established that these residual stresses have a significant effect on the composite properties. For example, due to the presence of thermal residual stresses, it is almost never possible to achieve the maximum elastic response of the composites. In addition, yield stress and fracture toughness of the composites are significantly affected by thermal residual stresses. In this paper, a critical review of the published literature on thermal residual stresses in MMCs and their effect on composite properties are presented. Also, experimental and numerical techniques that are currently available to measure and estimate thermal residual stresses are reviewed and discussed.     

Stiffness of particulate reinforced metal matrix composites with damaged reinforcements

Abstract

During tensile plastic deformation particulate reinforced metal matrix composites (MMCs) undergo reinforcement damage and a parallel reduction in stiffness. An analytical model is developed to calculate this stiffness reduction using the equivalent inclusion technique proposed by Eshelby. The model considers both damaged and undamaged reinforcement particles as ellipsoidal inclusions but with different stiffness tensors. The effect of the aspect ratio of the reinforcing particles has been accounted for in the model. The model is very flexible and can meet different specific damage situations by designing a suitable stiffness tensor for the damaged reinforcements. Finite element analysis is used to modify a numerical stiffness tensor for cracked reinforcement particles. The model is compared with an earlier model of modulus reduction in MMC materials and with a few experimental measurements made on a 15 vol.-%SiC particulate reinforced aluminium alloy 2618 MMC.     

两种Al2O3短纤维增强纯Al复合材料拉伸断裂过程与强化机理研究

选用国产Al₂O₄纤维与英国Saffil纤维怍为增强体,工业纯Al作为基体制成复合材料。在扫描电镜下,进行了微观断裂过程动态观察,并结合强度测定及断口分析探讨了不同情况下的断裂机理。