Studies on Machining Parameters While Milling Particle Reinforced Hybrid (Al6061/Al2O3/Gr) MMC

In this article, response surface methodology has been used for finding the optimal machining parameters values for cutting force, surface roughness, and tool wear while milling aluminum hybrid composites. In order to perform the experiment, various machining parameters such as feed, cutting speed, depth of cut, and weight (wt) fraction of alumina (Al₂O₃) were planned based on face-centered, central composite design. Stir casting method is used to fabricate the composites with various wt fractions (5%, 10%, and 15%) of Al₂O₃. The multiple regression analysis is used to develop mathematical models, and the models are tested using analysis of variance (ANOVA). Evaluation on the effects and interactions of the machining parameters on the cutting force, surface roughness, and tool wear was carried out using ANOVA. The developed models were used for multiple-response optimization by desirability function approach to determine the optimum machining parameters. The optimum machining parameters obtained from the experimental results showed that lower cutting force, surface roughness, and tool wear can be obtained by employing the combination of higher cutting speed, low feed, lower depth of cut, and higher wt fraction of alumina when face milling hybrid composites using polycrystalline diamond insert.     

铝基碳化硅精密铣削刀具磨损实验研究

针对铝基碳化硅切削加工中刀具易磨损、寿命低、切削难度大和加工成本高等问题,选用不同材料的硬质合金铣刀及金刚石铣刀进行切削加工实验,并利用扫描电镜和工具显微镜对高体积分数铝基碳化硅铣削时刀具磨损形态进行了分析研究.研究表明:硬质合金刀具前刀面和刃口磨损主要形式为粘结磨损和微崩刃,后刀面磨损主要为刻划磨损,而金刚石铣刀加工时刀具磨损很小;YG6X铣刀材料微观组织致密,抗磨损能力较强,宜粗加工时选用;金刚石刀体的硬度远大于SiC颗粒,且金刚石与工件的摩擦系数小,金刚石铣刀寿命远大于硬质合金铣刀,宜精加工时选用.     

Studies on wear rate and micro-hardness of the Al/Al2O3/Gr hybrid composites produced via powder metallurgy

Micro-structural characterization of the composites has revealed fairly uniform distribution and some amount of grain refinement in the specimens. Further, it was observed that the micro-hardness improve when increasing the milling time and the reinforcement content due to presence of hard Al₂O₃ particles. Was also observed a low wear rate exhibited by the Al/Al₂O₃/Gr hybrid composites due to presence of Al₂O₃ and Gr which they acted as load bearing elements and solid lubricant respectively. The observed wear rate and micro-hardness have been correlated with microstructural analyses.     

Microstructure and morphology of Mo-based Tm2O3 composites synthesized by ball milling and sintering

Mo-based Tm₂O₃ composites used as neutron absorbers were synthesized by ball milling, cold isostatic pressing and sintering. The size of Mo grain was decreased rapidly in the initial stage and then kept a constant in the later stage. After ball milling for 96 h, the size of Mo grain was up to approximately 8 nm. Ball milling induced Tm₂O₃ to be first fined, nano-crystallized, then transformed to amorphization, and finally dissolved into Mo crystal. The supersaturated nanocrystalline solid solution of Mo (Tm, O) was formed after 96 h of ball milling. Sintering caused Tm and O atoms precipitated from Mo crystal and then formed Tm₂O₃ precipitates that uniformly distributed in the Mo matrix. After sintered for 12–24 h at 1400–1600 °C, only diffraction peaks of Tm₂O₃ and Mo could be observed in the XRD spectrums, which indicated that there was not a chemical reaction between Tm₂O₃ and Mo. The microhardness of sintered bulks increased with increasing ball-milling time, sintering temperature and time, and the chemical content of Tm₂O₃ in the powder mixtures. The evolutionary mechanism of the microstructural characteristics during ball milling and subsequent sintering was discussed.     

Al2O3-TiC/Al2O3-TiC-CaF2复合叠层陶瓷材料摩擦磨损性能

将Al2O3-TiC陶瓷材料与具有固体润滑特性的Al2O3-TiC-CaF2陶瓷材料进行叠层,通过真空热压烧结制备Al2O3-TiC/Al2O3-TiC-CaF2复合叠层陶瓷材料.在环盘式摩擦磨损试验机上进行摩擦磨损实验,研究该材料在不同载荷、转速条件下的摩擦系数和磨损率,分别用SEM及EDS观察材料磨损前后的微观形貌和分析其成分组成,研究其磨损机制.结果表明:在相同载荷条件下,Al2O3-TiC/Al2O3-TiC-CaF2复合叠层陶瓷材料的摩擦系数和磨损率随着转速的升高而下降,在相同转速条件下,其摩擦系数和磨损率随着载荷的增加而下降;Al2O3-TiC/Al2O3-TiC-CaF2复合叠层陶瓷材料的磨损机制主要是磨粒磨损和黏着磨损.     

Effect of ball milling time on the structural characteristics and mechanical properties of nano-sized Y2O3 particle reinforced aluminum matrix composites produced by powder metallurgy route

Mechanical milling presents an effective solution in producing a homogenous structure for composites. The present study focused on the production of 0.5 wt% yttria nanoparticle reinforced 7075 aluminum alloy composite in order to examine the effects of yttria dispersion and interfacial bonding by ball milling technique. The 7075 aluminum alloy powders and yttria were mechanically alloyed with different milling times. The milled composites powders were then consolidated with the help of hot pressing. Hardness, density, and tensile tests were carried out for characterizing the mechanical properties of the composite. The milled powder and the microstructural evolution of the composites were analyzed utilizing scanning and transmission electron microscopy. A striking enhancement of 164% and 90% in hardness and ultimate tensile strength, respectively, were found compared with the reference 7075 aluminum alloy fabricated with the same producing history. The origins of the observed increase in hardness and strength were discussed within the strengthening mechanisms' framework.     

Tribological behavior of ZA27/Al2O3/graphite hybrid nanocomposites

ZA27 alloy composites reinforced with alumina and graphite nanoparticles are a unique class of advanced engineered materials that have been developed to use in tribological applications. In this study, dry sliding wear behavior of ZA27 alloy matrix hybrid nanocomposites has been investigated. Mechanical alloying and hot pressing methods have been used for the fabrication of these composite materials. Sliding wear tests were conducted using a block-on-disc type sliding wear testing apparatus under unlubricated conditions. Scanning electron microscopy analyses have been carried out to examine the wear surfaces. The results showed that the increase of alumina nanoparticle content can positively influence improvement of the tribological behavior of the hybrid nanocomposites.     

不同冷却润滑方式对切削SiCP/Al复合材料刀具磨损的影响

为探究不同冷却润滑方式对切削SiC_P/Al复合材料刀具磨损的影响,进行了干切削（Dry）、微量润滑（MQL）、液氮（LN₂）、切削油（Oil）和乳化液（Emulsion）共五种冷却润滑条件下的车削实验,分析了冷却润滑方式对刀具边界磨损、刀具破损和后刀面磨损的影响。结果表明:MQL和LN₂有更佳的流体冲刷效果,可以将脱落的SiC颗粒及时带离切削区,减少边界磨损; Oil和Emulsion冲刷效果较差,会加剧边界磨损。LN₂的使用会增加刀具受到的热应力和机械冲击,积屑瘤发生完全脱落,造成切削过程不平稳,当切削距离达到1 100 m时,刀具发生破损; Oil切削时,严重的边界磨损导致刀尖部位尺寸减小,强度降低,当切削距离达到825 m时发生了刀具破损。MQL良好的润滑渗透性和LN₂有效的冷却效果可以减少后刀面磨损。因此,MQL兼具冷却、润滑和流体冲刷效果,更加适合作为切削SiC_P/Al复合材料的冷却润滑方式。      

温度对Al2O3/ZrB2/ZrO2复合材料摩擦磨损特性的影响

采用UMT-2多功能摩擦实验机,研究了温度对Al2O3/ZrB2/ZrO2复合刀具材料摩擦磨损性能的影响,并分别使用白光干涉仪和扫描电镜分析实验后磨痕的轮廓和微观形貌。结果表明,常温摩擦时,随着ZrB2/ZrO2含量的增加,AZ系列自润滑陶瓷材料与硬质合金对摩时的摩擦系数逐渐降低。高温摩擦时,随着环境温度的提高,表面摩擦温度不断上升,生成的润滑膜有助于使摩擦系数和磨损率下降。     

Sintering and oxidation in gel-coated SiC w /Al2O3 composites

Boehmite gel-coated SiC whiskers have been studied as discs and as dispersed in gel and commercial alumina. The coated whiskers oxidize and react to some extent in alumina-rich composite compacts when heated in vacuum. In the absence of alumina as matrix, discs of coated whiskers turned brittle on heating above 1600°C. A density of 3.7g/cc was obtained for compacts of SiC whiskers in submicron alumina when sintered pressureless for 2 h at 1600°C. A smooth interface, compatible with the matrix, has resulted in good mechanical properties.     

三维网络Al2O3增强球墨铸铁基复合材料摩擦磨损性能

采用SRV摩擦磨损试验机研究了球墨铸铁及三维网络Al2O3增强球墨铸铁基复合材料的干摩擦磨损性能,测量了球墨铸铁和复合材料在不同摩擦频率及载荷下的摩擦系数和磨损率;用扫描电镜观察磨损表面形貌,并分析了三维网络Al2O3对复合材料磨损机制的影响.结果表明:陶瓷与金属基体之间具有良好界面结合的三维网络Al2O3/球墨铸铁复合材料,其摩擦系数随载荷和摩擦频率的变化保持稳定;复合材料的耐磨性能远优于球墨铸铁,而且随着摩擦频率和载荷的增加,复合材料的抗磨损性能明显提高.这是由于复合材料中陶瓷与金属相之间三维空间结构和良好的界面结合有利于摩擦载荷的传递;金属基体中的石墨减摩作用保持摩擦系数的稳定;三维陶瓷骨架在磨损表面形成硬的微突体并起承载作用,制约了基体的塑性变形和高温软化,有利于磨损表面氧化膜的留存.     

纳米Al2O3颗粒增强新型铜基自润滑复合材料

以Cu-Ni-Y₂O₃-MoS₂-Graphite混合粉为基体,加入质量分数分别为0%、1%、2%、3%、4%的纳米Al₂O₃增强相,采用粉末冶金方法制备纳米Al₂O₃增强新型铜基自润滑复合材料。结果表明：随着铜合金粉末中纳米Al₂O₃颗粒含量的增加 , 所制备自润滑复合材料样品的密度下降,但硬度和压溃强度先上升后下降,在Al₂O₃含量为2%时硬度从HV 23.7增加到HV 35.1,压溃强度从189 MPa提高到276 MPa。由石墨和MoS₂组成的混合固体自润滑材料的摩擦系数小且稳定,约0.12。Al₂O₃质量分数为2%的样品磨损量最小,是未加Al₂O₃试样磨损量的1/7～1/8。铜基体经过镍、纳米Al₂O₃等弥散颗粒强化和固体润滑相石墨和MoS₂的加入,所制备的材料已具有一定的自润滑性能。     

Cyclic oxidation of FeCrAlY/Al2O3 composites

Abstract

Three-ply composites consisting of a FeCrAlY matrix and continuous single crystal Al₂O₃ (sapphire) fibers were cyclically oxidized at 1,000° and 1,100°C for up to 1,000 1-h cycles. FeCrAlY matrix only samples were also fabricated and tested for comparison. Fiber ends were exposed at the ends of the composite samples. Following cyclic oxidation, cracks running parallel to and perpendicular to the fibers were observed on the large surface of the composite. In addition, there was evidence of increased scale damage and spallation around the exposed fiber ends, particularly around the middle ply fibers. This damage was more pronounced at the higher temperature. The exposed fiber ends showed cracking between fibers in the outer plies, occasionally with Fe and Cr-rich oxides growing out of the cracks. Large gaps developed at the fiber–matrix interface around many of the fibers, especially those in the outer plies. Oxygen penetrated many of these gaps resulting in significant oxide formation at the fiber–matrix interface far within the composite sample. Around several fibers, the matrix was also internally oxidized showing Al₂O₃ precipitates in a radial band around the fibers. The results show that these composites have poor cyclic oxidation resistance due to the CTE mismatch and inadequate fiber–matrix bond strength at temperatures of 1,000°C and above.     

Tool wear mechanisms in axial ultrasonic vibration assisted milling in-situ TiB2/7050Al metal matrix composites

The in-situ TiB₂ particle reinforced aluminum matrix composites are materials that are difficult to machine, owing to hard ceramic particles in the matrix. In the milling process, the polycrystalline diamond (PCD) tools are used for machining these materials instead of carbide cutting tools, which significantly increase the machining cost. In this study, ultrasonic vibration method was applied for milling in-situ TiB₂/7050Al metal matrix composites using a TiAlN coated carbide end milling tool. To completely understand the tool wear mechanism in ultrasonic-vibration assisted milling (UAM), the relative motion of the cutting tool and interaction of workpiecetool-chip contact interface was analyzed in detail. Additionally, a comparative experimental study with and without ultrasonic vibration was carried out to investigate the influences of ultrasonic vibration and cutting parameters on the cutting force, tool life and tool wear mechanism. The results show that the motion of the cutting tool relative to the chip changes periodically in the helical direction and the separation of tool and chip occurs in the transverse direction in one vibration period, in ultrasonic vibration assisted cutting. Large instantaneous acceleration can be obtained in axial ultrasonic vibration milling. The cutting force in axial direction is significantly reduced by 42%-57%, 40%-57% and 44%-54%, at different cutting speeds, feed rates and cutting depths, respectively, compared with that in conventional milling. Additionally, the tool life is prolonged approximately 2-5 times when the ultrasonic vibration method is applied. The tool wear pattern microcracks are only found in UAM. These might be of great importance for future research in order to understand the cutting mechanisms in UAM of in-situ TiB₂/7050Al metal matrix composites.The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-020-00294-2     

CuAl_2O_3复合材料中Al_2O_3的长大动力学分析

通过分析铜铝颗粒表面铝与氧的反应,计算铜铝合金中铝的沉淀析出量、铝在铜基体中的扩散速率以及Al2O3颗粒大小,研究了喷射沉积内氧化法制备CuAl2O3复合材料中Al2O3的长大动力学行为。结果表明,在反应合成制备过程中,氧化铝颗粒长大动力学行为满足抛物线规律;铜铝合金表面铝与氧的反应是一种铝扩散控制型反应,该氧化铝颗粒的长大与铝在铜铝合金中的含量、扩散速率和所处位置(晶内、晶界)有关。计算得到的Al2O3颗粒大小与实际获得的氧化铝颗粒大小相吻合。     

Effect of 10Ce-TZP/Al2O3 nanocomposite particle amount and sintering temperature on the microstructure and mechanical properties of Al/(10Ce-TZP/Al2O3) nanocomposites

A zirconia/alumina nanocomposite stabilized with cerium oxide (Ce-TZP/Al₂O₃ nanocomposite) can be a good substitute as reinforcement in metal matrix composites. In the present study, the effect of the amount of 10Ce-TZP/Al₂O₃ particles on the microstructure and properties of Al/(10Ce-TZP/Al₂O₃) nanocomposites was investigated. For this purpose, aluminum powders with average size of 30 μm were ball-milled with 10Ce-TZP/Al₂O₃ nanocomposite powders (synthesized by aqueous combustion) in varying amounts of 1, 3, 5, 7, and 10 wt.%. Cylindrical-shape samples were prepared by pressing the powders at 600 MPa for 60 min while heating at 400–450 °C. The specimens were then characterized by scanning and transmission electron microscopy (SEM and TEM) in addition to different physical and mechanical testing methods in order to establish the optimal processing conditions. The highest compression strength was obtained in the composite with 7 wt.% (10Ce-TZP/Al₂O₃) sintered at 450 °C.     

Slip casting of Al2O3 and Al2O3/ZrO2 composites

Al₂O₃ and Al₂O₃/ZrO₂ composites have been fabricated by slip casting from aqueous suspensions. The physical and structural characteristics of the starting powders, composition of the suspensions, casting behaviour, microstructure of the green and fired bodies and the mechanical properties of the products were investigated. The addition of ZrO₂ to Al₂O₃ leads to a significant increase in fracture toughness when ZrO₂ particles are retained in the tetragonal form (transformation-toughening mechanism) but when microcracking (due to the spontaneous transformation of ZrO₂ from the tetragonal phase to the monoclinic one) is dominant, an excellent toughness value is accompanied by a drastic drop in strength and hardness.     

空心陶瓷／铝基复合材料的阻尼减振性能

采用挤压铸造法制备了70%（体积分数）空心陶瓷/6061Al复合材料．采用弯曲共振法测试了复合材抖的阻尼性能，结果表明．空心陶瓷的加科明显提高了6061Al合金的阻尼性能，且尺寸减小会进一步提高空心陶瓷复合材料的阻尼性能。采用弯曲共振法测得的含较小粒径的空心陶瓷/6061Al复合材料的阻尼为基体6061Al阻尼的5.7倍，这表明空心陶瓷／6061Al复合材料阻尼与材料内部所含孔洞有密切的关系。结各组织观察，本文对相关的阻尼机理进行了探讨。