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.     

Deformation behavior of aluminum alloy matrix composites reinforced with few-layer graphene

Microstructure and mechanical properties of aluminum alloy 2024 (Al2024)/few-layer graphene (FLG) composites produced by ball milling and hot rolling have been investigated. The presence of dispersed FLGs with high specific surface area significantly increases the strength of the composites. The composite containing 0.7 vol.% FLGs exhibits tensile strength of 700 MPa, two times higher than that of monolithic Al2024, and around 4% elongation to failure. During plastic deformation, restricted dislocation activities and the accumulated dislocation at between FLGs may contribute to strengthening of Al2024/FLG composites.     

Microstructure evolution during fabrication and microstructure–property relationships in vapour-grown carbon nanofibre-reinforced aluminium matrix composites fabricated via powder metallurgy

Microstructure evolution of vapour-grown carbon nanofibre (VGCF)-reinforced aluminium matrix composites during fabrication and microstructure–property relationships of these materials were studied. Composites were fabricated using powder metallurgy, i.e. by mixing VGCFs and aluminium powder via ball-milling followed by sintering or hot extrusion. The mixing condition was selected to achieve small powder particle size and homogeneously dispersed VGCFs. Aluminium grains and VGCFs were elongated along the longitudinal direction of aluminium particles in the mixed powder. Detailed observation of the aluminium grains in the composites found grain size and morphology dominated by recrystallization. Apparently, grain growth was inhibited by VGCFs. Theoretical models considering strength increment due to grain refinement resulting from VGCF addition, load bearing of VGCFs, thermal mismatch of VGCFs and aluminium and Orowan effect were developed. Theoretical values coincided well with hardness, yield strength, and ultimate tensile strength of the composites, and thus the models could precisely explain the microstructure–property relationships.     

Thermal conductivity of Cu/diamond composites prepared by a new pretreatment of diamond powder

Cu/diamond composites were fabricated by spark plasma sintering (SPS) after the surface pretreatment of the diamond powders, in which the diamond particles were mixed with copper powder and tungsten powder (carbide forming element W). The effects of the pretreatment temperature and the diamond particle size on the thermal conductivity of diamond/copper composites were investigated. It was found that when 300 μm diamond particles and Cu–5 wt.% W were mixed and preheated at 1313 K, the composites has a relatively higher density and its thermal conductivity approaches 672 W (m K)⁻¹.     

Microstructure and grain growth of the matrix of SiCf/Ti–6Al–4V composites prepared by the consolidation of matrix-coated fibers in the β phase field

The microstructural characteristics in the matrix of SiC_f/Ti–6Al–4V composites prepared by consolidation of the matrix-coated fibers in the high-temperature β single-phase field were investigated using both experimental and modelling methods. Some of the critical microstructure features, like volume fraction of component phases, composition of matrix alloys and matrix morphology were systematically studied, providing valuable insight into the microstructural characteristics in the matrix of SiC_f/Ti–6Al–4V composites. In order to assist in understanding the grain growth occurred in the matrix during consolidation processing, a theoretical model was developed. Excellent agreement between theoretical and experimental results was achieved.     

Mechanical properties of hot pressed SiCp and B4Cp/Alumix 123 composites alloyed with minor Zr

In the present study, effect of Zr addition on the microstructure and wear behavior of aluminum alloy composites (AMCs) reinforced with B4Cp and SiCp particles fabricated via hot pressing were investigated. The samples for the study composed of unreinforced aluminum alloy (Alumix 123) and the composites reinforced with 10% B4Cp and % SiCp were prepared by hot isostatic pressing (HIP) method. Similarly, all the samples alloyed with 0.2% Zr were also produced in order to make a comparison. The produced samples were evaluated for microstructural properties and mechanical tests for hardness, tensile and bending strength were performed. Wear test was carried out at 5 mm/s sliding speed under 3.0 N load for the all kind of hot pressed produced samples. The hot pressed composite microstructures have a more uniform distribution of the reinforcements. After HIP process, the composites were successfully produced with high density (>99%). The addition of Zr increased the yield and tensile strength of the samples. The highest strength value was found for the sample Al 123 matrix alloy with Zr. Evaluation of microstructures showed that copper and zirconium dispersed equally within the matrix microstructure without agglomeration. For the composite samples, Al3Zr, appeared as white precipitate, were inspected around B4C and SiC particles. The composite containing SiC particles and Zr had wear resistance value superior to those of the other counterparts.     

High temperature thermal stability of pure copper and copper–carbon nanotube composites consolidated by High Pressure Torsion

The thermal stability of ultrafine-grained (UFG) microstructures in pure copper samples and copper–carbon nanotube (CNT) composites processed by High Pressure Torsion (HPT) was compared. The UFG microstructure in the sample consolidated from pure Cu powder exhibited better stability than that developed in a casted Cu specimen. The addition of CNTs to the Cu powder further increased the stability of the UFG microstructure in the consolidated Cu matrix by hindering recrystallization, however it also yielded a growing porosity and cracking during annealing. It was shown that the former effect was stronger than the latter one, therefore the addition of CNTs to Cu has an overall benefit to the hardness in the temperature range between 300 and 1000 K. A good agreement between the released heat measured during annealing and the calculated stored energy was found for all samples.     

Interface analysis and wear behavior of Ni particulate reinforced aluminum–silicon composites produced by PM

This study is concerned with the influence of Nickel, as reinforcement, in an aluminum–silicon (AlSi) alloy when regarding wear behavior. For these composites, the effect of Ni content, in the tribopair performance, was evaluated. For this purpose, the pin but also the counterface wear behavior was analyzed.Nickel particulate reinforced aluminum–silicon (AlSi) composites, with 5, 12.5 and 20 wt.% Ni were produced by a hot-pressing route. Microstructural characterization showed a uniform distribution of the Ni particulates in the AlSi matrix. EDS and XRD analyses revealed that the particle/matrix interface was formed by Al₃Ni intermetallic. Reciprocating pin-on-plate wear tests were performed with AlSi and AlSi–Ni pins against a gray cast iron (GCI) counterface. It was observed that the wear behavior of the AlSi–Ni/GCI tribopair is improved when compared with the AlSi/GCI system.     

Load-bearing contribution of multi-walled carbon nanotubes on tensile response of aluminum

We fabricated a uniformly dispersed and aligned multi-walled carbon nanotube reinforced aluminum matrix (Al–MWCNT) composite with minimal work hardening and without interfacial chemical compounds. In this paper, the direct load-bearing contribution of MWCNTs on the Al–MWCNT composite was investigated in detail for various volume fractions of MWCNTs. For up to 0.6 vol% of MWCNTs, the ultimate tensile strength (UTS) of the Al–MWCNT composite increased with the conservation of the remarkable failure elongation of Al. These UTS values are consistent with shear lag model. We also observed an uncommon multi-wall-type failure of MWCNTs during the hot extrusion process. However, owing to the agglomeration of MWCNTs in the Al matrix, the UTS deviated significantly from the shear lag model and the remarkable failure elongation of Al decreased. The possibility of strengthening, without degrading ductility, was demonstrated by exploiting directly the load-bearing ability of individually and uniformly dispersed aligned MWCNTs.     

Assessment of tensile behaviour of an Al–Mg alloy composite reinforced with NiAl and oxidized NiAl powder particles helped by nanoindentation

AA5056 matrix composites have been reinforced with as-received and oxidized NiAl particles and their nanohardness investigated as a function of distance to reinforcement. Results indicate that a non-heat treatable aluminium matrix, as is the present case, does not require that the intermetallic particles are surrounding by a protective Al₂O₃ layer to avoid reactions at matrix-reinforcement interfaces. On the other hand, the quality of the matrix-reinforcement bonding has been quantified by the reinforcement influence distance, defined as the distance from the particle at which the nanohardness of the matrix drops to its asymptotic value.     

Effect of tungsten addition on thermal conductivity of graphite/copper composites

Graphite/copper composites with high thermal conductivity were fabricated by tungsten addition, which formed a thin tungsten carbide layer at the interface. The microstructure and thermal conductivity of the composite material were studied. The results indicated that the insertion of tungsten carbide layer obviously suppressed spheroidization of copper coating on the graphite particles during the sintering process, and decreased the interfacial thermal resistance of the composites. Compared with the graphite/copper composites without tungsten, the thermal conductivity of the obtained composites was increased by 43.6%.     

Investigation of microstructure and mechanical properties of nano MgO reinforced Al composites manufactured by stir casting and powder metallurgy methods: A comparative study

In the present work, Al–nano MgO composites using A356 aluminum alloy and MgO nanoparticles (1.5, 2.5, and 5 vol.%) have been fabricated via stir casting and powder metallurgy (PM) methods. Different processing temperatures of 800, 850, and 950 °C for stir casting and 575, 600, and 625 °C for powder metallurgy were considered. Powder metallurgy samples showed more porosity portions compare to the casting samples which results in higher density values of casting composites (close to the theoretical density) compare to the sintering samples. Introduction of MgO nanoparticles to the Al matrix caused increasing of the hardness values which was more considerable in casting samples. The highest hardness value for casting and sintering samples have been obtained at 850 and 625 °C respectively, in 5 vol.% of MgO. Compressive strength values of casting composites were higher than sintered samples which were majorly due to the more homogeneity of Al matrix, less porosity portions, and better wettability of MgO nanoparticles in casting method. The highest compressive strength values for casting and sintered composites have been obtained at 850 and 625 °C, respectively. Scanning electron microscopy images showed higher porosity portions in sintered composites and more agglomeration and aggregation of MgO nanoparticles in casting samples which was due to the fundamental difference of two methods. Generally, the optimum processing temperatures to achieve better mechanical properties were 625 and 850 °C for powder metallurgy and stir-casting, respectively. Moreover, casting method represented more homogeneous data and higher values of mechanical properties compare to the powder metallurgy method.     

Electrical conductivities of carbon powder nanofillers and their latex-based polymer composites

The electrical conductivity of graphene, multi-wall carbon nanotubes, carbon black nanopowders and graphite powder is characterized using paper-like films and by means of powder compression. The large difference in surface area of these materials results in different packing density and number of contact spots, influencing the macroscopic conductivity of the compacts during powder compression. The results are compared with the percolation threshold and final conductivity of polypropylene (PP) composites, using latex technology for the incorporation of the carbon fillers in the polymer. Even though the PP composites produced in this work exhibit percolation thresholds as low as 0.3 wt.%, the final conductivity for all the composites is below 1.5 S/m. Reasons why the high value of ∼10³ S/m, which is obtained for graphene- and nanotube-based paper films or graphite compacts, is not reached for the composites are investigated.     

A review on basalt fibre and its composites

In recent years, both industrial and academic world are focussing their attention toward the development of sustainable composites, reinforced with natural fibres. In particular, among the natural fibres (i.e. animal, vegetable or mineral) that can be used as reinforcement, the basalt ones represent the most interesting for their properties. The aim of this review is to illustrate the results of research on this topical subject. In the introduction, mechanical, thermal and chemical properties of basalt fibre have been reviewed. Moreover, its main manufacturing technologies have been described. Then, the effect of using this mineral fibre as reinforcement of different matrices as polymer (both thermoplastic and thermoset), metal and concrete has been presented. Furthermore, an overview on the application of this fibre in biodegradable matrix composites and in hybrid composites has been provided. Finally, the studies on the industrial applications of basalt fibre reinforced composites have been reviewed.     

Processing,microstructure and properties of ultrasonically processed in situ MgO–Al2O3–MgAl2O4 dispersed magnesium alloy composites

AZ91 alloy matrix composites are synthesized by in situ reactive formation of hard MgO and Al₂O₃ particles from the addition of magnesium nitrate to the molten alloy. The evolved oxygen from decomposition of magnesium nitrate reacts with molten magnesium to form magnesium oxide and with aluminium to form aluminium oxide. Additionally, these newly formed oxides react with each other to form MgAl₂O₄ spinel. Application of ultrasonic vibrations to the melt increased the uniformity of particle distribution, avoided agglomeration, and decreased porosity in the castings. Ultrasound induced physical phenomena such as cavitation and melt streaming promoted the in situ chemical reactions. Well dispersed, reactively formed hard oxides increased the hardness, ultimate strength, and strain-hardening exponent of the composites. Presence of well-dispersed hard oxide particles and stronger interface resulting from cavitation-enhanced wetting of reactively formed particles in the AZ91 alloy matrix improved the sliding wear resistance of the composites.     

Influence of B4C on the tribological and mechanical properties of Al 7075–B4C composites

In the present investigation, the influence of B₄C on the mechanical and Tribological behavior of Al 7075 composites is identified. Al 7075 particle reinforced composites were produced through casting, K₂TiF₆ added as the flux, to overcome the wetting problem between B₄C and liquid aluminium metal. The aluminium B₄C composites thus produced were subsequently subjected to T6 heat treatment. The samples of Al 7075 composites were tested for hardness, tensile, compression, flexural strengths and wear behavior. The test results showed increasing hardness of composites compared with the base alloy because of the presence of the increased ceramic phase. The wear resistance of the composites increased with increasing content of B₄C particles, and the wear rate was significantly less for the composite material compared to the matrix alloy. A mechanically mixed layer containing oxygen and iron was observed on the surface, and this acted as an effective insulation layer preventing metal to metal contact. The coefficient of friction decreased with increased B₄C content and reached its minimum at 10 vol% B₄C.     

Microstructure and fatigue strength of high-strength Cu–Fe and Cu–V in-situ nanocomposite wires

The results of the quantitative analysis of the microstructure of the Cu–Fe and Cu–V in-situ nanocomposite wires with diameter of 0.44–0.80 mm by transmission electron microscopy are presented. Comparative fatigue tests of Cu–Fe and Cu–V in-situ nanocomposite wires and pure copper samples have been carried out using a dynamic mechanical analyzer (DMA). The in-situ nanocomposites have significantly higher characteristics of low-cycle fatigue failure resistance as compared to that of pure copper. The fatigue crack propagation areas for the nanocomposite conductors and pure copper are characterized by fatigue striations and secondary cracking.     

Size dependent strengthening mechanisms in carbon nanotube reinforced metal matrix composites

The matrix grain size plays a dual role in metal matrix composites (MMCs). Contrary to enhance the strength of matrix, grain refinement can weaken the thermal expansion mismatch strengthening induced by the reinforcement. In this article, a dislocation density based model is developed to describe the factors affecting the strengthening mechanisms in Carbon nanotube (CNT)-reinforced MMCs with different matrix grain sizes. Two kinds of thermal expansion mismatch strengthening mechanisms are considered, i.e., geometrically necessary dislocations (GNDs) are distributed in entire matrix and GNDs are limited in dislocation punched zones (DPZs). In addition, comparisons between the predictions and some available experimental results are also performed.     

Investigation of mechanical and tribological behaviors of multilayer graphene reinforced Ni3Al matrix composites

Multilayer graphene (MLG) shows an attractive prospect for the demanding engineering applications. This paper reports the mechanical and tribological properties of MLG reinforced Ni₃Al matrix composites (NMCs) under dry sliding at varying sliding speed. The hardness and elastic modulus of the NMCs are significantly influenced with MLG content. It is found that the hardness and elastic modulus of the NMCs are found to be increased by increasing MLG content up to 1.0 wt.%, while decreased when MLG content is above 1.0 wt.%. Tribological experiments suggest that MLG can dramatically improve the wear resistance and decrease the friction coefficient of the NMCs. Such marked improvement of wear resistance is attributed to the reinforcing mechanisms of MLG, such as crack deflection and pull-out, and reduction of friction coefficient is related to the formation of a tribofilm on the sliding contact surface.     

Effect of mullite particles on the mechanical strength and chemical durability of vitrified CBN composites

The effects of mullite particles on the mechanical strength and chemical durability of vitrified CBN composites were investigated. Incorporating mullite particles to vitrified CBN composites contributes to an obvious improvement of the mechanical strength and the chemical durability of vitrified bond. The enhancement of the mechanical strength may be ascribed to the observed mechanisms including crack deflection and crack pinning. The improvement of chemical durability may be ascribed to the resistance of mullite particles to the dissolution of binders.