Hybrid composites – Metallic and ceramic reinforcements influence on mechanical and wear behavior

This experimental study is concerned with the influence of metallic (Ti) and ceramic (SiC) reinforcements in an aluminumfsilicon (AlSi) alloy, when regarding tensile properties and wear behavior. Several micron sized particulate reinforced composites were produced by hot-pressing technique: AlSi–SiC and AlSi–Ti composites and AlSi-(Ti–SiC) hybrid composites.Regarding tensile properties, all composites presented higher ultimate tensile strength (UTS) than the AlSi matrix, with the highest UTS being attained by a hybrid composite (AlSi-11.25%Ti–5%SiC).Regarding wear behavior, reciprocating pin-on-plate wear tests were performed for unreinforced AlSi; AlSi–Ti composites and AlSi-(Ti–SiC) hybrid composite against a gray cast iron (GCI) counterface. The wear mechanisms for all the tested tribopairs are presented and discussed. It was observed that the wear behavior of the AlSi–Ti/GCI and also AlSi-(Ti–SiC)/GCI tribopairs are improved when compared with the AlSi/GCI system. AlSi-11.25%Ti-5%SiC hybrid composite exhibited the highest improvement in wear rate.     

Synthesis and processing of ceramic–metal composites by reactive metal penetration

Molten aluminum reduces and penetrates silicate ceramics to produce a metal–ceramic composite which yields an Al₂O₃ skeleton infiltrated with a solidified Al–Si alloy. Penetration experiments have been used to study the influence of p(O₂), temperature and substrate composition on penetration kinetics and composite microstructure. The limiting kinetic step for Al penetration is the chemical reaction between Al and the ceramic. For dense substrates the maximum reaction rates are observed between 1000–1200°C and are independent of p(O₂). For porous substrates it is necessary to reach a critical temperature or p(O₂), before infiltration starts. Increasing the Si concentration in the molten Al results in the reduction of the reaction rates.     

Thermal and mechanical properties of EPDM/PP + thermal shock-resistant ceramic composites

Dynamic vulcanizate blends of polypropylene (PP) and ethylene–propylene-diene rubber (EPDM) were filled with 5 wt% of micro-scale ceramic powder. To overcome the difficulty of particles dispersion and adhesion, the filler was modified through grafting using three kinds of organic molecules. A combination of Raman data with thermogravimetric analysis (TGA) results prove that grafting of organic macromolecules onto ceramic surfaces takes place. Dynamic mechanical analysis (DMA) has been performed from −100 to +50 °C; addition of the ceramic increases the storage modulus E′, more so for modified filler. Compared to PP and thermoplastic vulcanizate (TPV), a higher thermal expansion is seen after addition of the ceramic filler, a result of creation of more free volume. The tensile modulus of the composites is about 1.2 times that of pure TPV, an increase in the rigidity clearly caused by the ceramic. Fracture surfaces show weak bonding of filler particles to the matrix. In the sample containing modified filler the tensile deformation is going through the polymer matrix. The brittleness, B, decreases upon surface modification of the ceramic. The highest value of B is seen for the PP + unmodified ceramic while lower B values are obtained for TPV and its composites.     

Microstructure and mechanical properties of zirconia-toughened lithium disilicate glass–ceramic composites

The lithium disilicate glass–ceramics composites reinforced and toughened by tetragonal zirconia (3Y-TZP) were prepared by hot-pressing at 800 °C with varying zirconia content from 0 to 30 wt.%. In the case of the composites of small zirconia content (below 10 wt.%), zirconia acted as nucleation agent primarily, and the microstructure was refined continuously. The morphology of Li₂Si₂O₅ crystals transformed from rod-shaped to spherical structure, and the mechanical properties decreased inevitably. For the composites of large zirconia content (from 15 wt.% to 30 wt.%), however, zirconia restrained the phase separation of glass. The morphology of Li₂Si₂O₅ crystals transformed to rod-shaped structure again. The mechanical properties of the composite at zirconia content of 15 wt.% increased up to 340 MPa and 3.5 MPa m^1/2 which were much higher than those of zirconia-free glass–ceramics. The improved properties were attributed mainly to compressive stress reinforcement, phase transformation and bridging toughening mechanisms.     

Preparation and characterisation of ceramic-faced metal–ceramic interpenetrating composites for impact applications

This article accesses the impact performance of ceramic-faced, metal–ceramic interpenetrating composites (IPCs) produced in situ from infiltrating ceramic foams with a molten aluminium–magnesium alloy. The approach had two variations, viz., the production of a metal bond between a ceramic front face and backing IPC and the creation of a ceramic bond. The impact performance of metal-bonded IPCs was evaluated using both split Hopkinson’s pressure bar (SHPB) and depth of penetration (DoP) techniques. With a 4-mm thick Al₂O₃ front face and an 8-mm thick IPC backing, the DoP was zero. In one case, a sample survived fundamentally intact with only spall damage to the dense Al₂O₃ front face. The resulting damage was thoroughly assessed using a range of techniques, including polarized light microscopy, scanning electron microscopy (SEM), 3D MicroCT and transmission electron microscopy (TEM). The metal phase deformed as a result of the formation of large numbers of dislocations, whilst the ceramic phase accommodated the deformation via localised cracking. Metal bridges across the cracks formed, increasing the damage tolerance of the IPCs. The metal bond between the ceramic front face and the IPC was also observed to withstand the impact of the armour piercing rounds without any sign of debonding occurring.     

Microstructure and mechanical properties of nanolayered W/W–C thin films

The present study reports on the mechanical and structural properties of W/W–C multilayered thin films with bilayer periods Λ ranging from 2.5 to 100 nm. Films were grown by reactive sputtering radio frequency on Si (100) substrate. X-ray diffraction (XRD), grazing incidence X-ray diffraction (GIXRD) and X-ray reflectivity were used to globally characterise the multilayers structure. Hardness and Young modulus have been determined using nanoindentation with a Berkovich tip. The XRD and the GIXRD diagrams revealed the presence of three phases: WC_1−x randomly oriented, W₂C with (100) preferred orientation and W with (110) preferred orientation. An increase in hardness is observed with decreasing period Λ, reaching a maximum value of ~26 GPa at Λ = 2.5 nm.     

Oxidation behavior of green coke-based carbon–ceramic composites incorporating micro- and nano-silicon carbide

The oxidation resistance of the carbon–ceramic composites developed using green coke-based carbon and carbon black as carbon source, boron carbide, and micro- and nano-silicon carbide was carried out in the temperature range of 800 to 1,200 °C. Silicon carbide particulate as such and silicon carbide obtained by the reaction of green coke and silicon provided micro silicon carbide while silicon and carbon black and sol–gel silica and carbon black used as silicon carbide precursors led to the formation of nano-silicon carbide. The oxidation resistance of these composites at 800 to 1,200 °C for 10 h showed that the size of the silicon carbide influenced the oxidation resistance. The weight gain due to protective coating formed on oxidation was higher in composites containing nano-silicon carbide as compared to the composites containing micro silicon carbide.     

Damage accumulation and mechanical properties of particle-reinforced metal–matrix composites during hydrostatic extrusion

The effects of hydrostatic extrusion on particle cracking and on the subsequent tensile properties of some prototypical particle-reinforced metal–matrix composites are investigated. In most cases, tensile failure occurs through a plastic instability in accordance with the Considere criterion for necking. The corresponding failure strain is therefore dictated by the global flow and hardening characteristics of the composites, as influenced by the intrinsic flow properties of the matrix as well as the extent and rate of particle cracking. Such cracking leads to significant reductions in the hardening rate and thus causes a reduction in the failure strain relative to that of the neat matrix alloy. Extrusion prior to tensile testing has the effect of saturating the flow stress of the matrix and limiting the tensile ductility to low values, largely because of the very low hardening rate of the matrix. Particle cracking during extrusion causes a further reduction in ductility. The dominant role of the matrix hardening is demonstrated through re-tempering treatments of extruded billets prior to tensile testing. A micromechanical model of particle cracking is developed, taking into account the effects of both the hydrostatic and the deviatoric stress components in axisymmetric loadings. The model is used to rationalize the observed trends in damage accumulation with particle content, particle type, and loading configuration (tension vs. extrusion).     

Development and mechanical properties of metal–particulate glass matrix composites from recycled glasses

The great number of glasses available from recycling activity and vitrification treatment of industrial wastes leads to the need for new applications, with the development of new materials, such as low-cost composite materials from a powder technology route. In the present work a variety of recycled glasses is investigated, in order to obtain aluminium reinforced glass matrix composites via cold-pressing and viscous flow sintering. A good compatibility between lead silicate glasses from cathode ray tubes dismantling and aluminium reinforcement is found to be effective. Composites exhibiting good mechanical properties were developed from these materials. A particular attention was due to fracture toughness (K_IC) determination. The absolute K_IC of glass matrix composites value remains low, but a notable increment in relation to unreinforced matrix is observed.     

Microstructure and mechanical behavior assessment of Al–Cu composites fabricated through stir casting

In this work, Al–Cu composite metallic materials are produced by dispersing copper particulates in an aluminum matrix using stir casting technique. In order to know the effect of reinforcement content, composites with varying weight fractions were fabricated. For comparison purpose, Al–Cu alloy is also fabricated and investigated. Increased densities have been observed with increasing particulate contents. Homogenization treatment has improved the hardness to a larger extent for both alloy and composites, particularly for rich composites. Composite with lean mixture of reinforcements has shown improvement in specific strength, whereas drop in specific strength has been observed for rich mixture of reinforcements. However, hardness is improved from 5% to 15% reinforcement content. Drop in strain has been observed for higher reinforcement composites. Response to cold upsetting is noticeable for lean composite which is on par with the alloy.     

Coupling in situ experiments and modeling – Opportunities for data fusion,machine learning,and discovery of emergent behavior

This paper reviews recent studies, that not only includes both experiments and modeling components, but celebrates a close coupling between these techniques, in order to provide insights into the plasticity and failure of polycrystalline metals. Examples are provided of studies across multiple-scales, including, but not limited to, density functional theory combined with atom probe tomography, molecular dynamics combined with in situ transmission electron miscopy, discrete dislocation dynamics combined with nanopillars experiments, crystal plasticity combined with digital image correlation, and crystal plasticity combined with in situ high energy X-ray diffraction. The close synergy between in situ experiments and modeling provides new opportunities for model calibration, verification, and validation, by providing direct means of comparison, thus removing aspects of epistemic uncertainty in the approach. Further, data fusion between in situ experimental and model-based data, along with data driven approaches, provides a paradigm shift for determining the emergent behavior of deformation and failure, which is the foundation that underpins the mechanical behavior of polycrystalline materials.     

Effects of interphase strength on the damage modes and mechanical behaviour of metal–matrix composites

A numerical version of the generalized self-consistent method previously developed by the authors is combined with the Gurson model to undertake a parametric investigation of the damage mechanisms and their relations with the macroscopic tensile properties of SiC reinforced aluminium, for three different interphase strengths. The results show that the interphase strength is a governing factor for damage propagation in the composite. Thus, transformation of the failure mechanism from reinforcement fracture to void nucleation and growth can be achieved by reducing the interphase bond strength, although the strengthening effects on the composite decrease unfavourably.     

Fabrication and machining of ceramic composites — A review on current scenario

Ceramic matrix composites (CMCs) are the best-suited material for various engineering application due to their superior properties. The different processing methods involved in the fabrication and machining of these CMCs are a center for attraction to researchers and industrial society. This review article primarily focuses on the development of different processing methods and machining methods for ceramic matrix composites since the last few years. Out of these fabrication methods, powder metallurgy emerged as a most promising and cost-effective technique. In addition, electric discharge machining (EDM) has proved to be time saving, cost effective, and capable of machining complex shapes in composites. At the end, challenges in the processing and machining of ceramic matrix composites have been identified from the literature, and further benefits of microwave sintering and electric discharge machining of materials have been addressed in the paper.     

Flexural creep behavior of discontinuous thermoplastic composites: Non-linear viscoelastic modeling and time–temperature–stress superposition

Flexural creep behavior of nylon 6/6, polypropylene and high-density polyethylene long fiber thermoplastic (LFT) composites was studied according to ASTM D-2990. Neat polymers were tested for baseline data and compared with the 40 wt.% E-glass reinforced LFTs, all processed by compression molding. All materials exhibited non-linear viscoelasticity and showed a succession in creep resistance consistent with static flexural yield strength. A four parameter empirical model used for short fiber thermoplastics (SFT), proposed by Hadid et al., was found to provide an excellent fit to the experimental data. Time-compliance data from flexural creep and dynamic mechanical analysis (DMA) were combined to utilize short-term flexural creep tests to predict lifetime of the composites. A time–temperature–stress superposition (TTSSP) procedure was used, where stress-based vertical shifts were applied in addition to horizontal shifts used in a traditional time–temperature superposition (TTSP). Master curves obtained by this method projected the long-term creep properties, the order of creep resistance being consistent with the flexural creep data.     

Micromechanical modeling and experimental characterization on viscoelastic behavior of 1–3 active composites

A study on the temperature-dependent viscoelastic behavior of (1–3 active composites) 1–3 piezocomposites and bulk piezoceramic subjected to electromechanical loading is carried out. The temperature-dependent effective properties are obtained experimentally using resonance based measurement technique. Experiments are also preformed for various fiber volume fractions of 1–3 piezocomposites subjected to constant compressive prestress and cyclic electric field at elevated temperature to understand the time-dependent behavior. Based on the measurements it is observed that the viscoelastic behavior has a significant influence on the electromechanical responses of 1–3 piezocomposites. Hence a viscoelastic based numerical model (unit cell approach) is proposed to predict the time-dependent effective properties of 1–3 piezocomposites. The evaluated effective properties are incorporated in a finite element based 3-D micromechanical model to predict the time-dependent thermo-electro-mechanical behavior of 1–3 piezocomposites and compared with the experimental observations.     

Influence of the elastic stress relaxation on the microstructures and mechanical properties of metal–matrix composites

Role of the residual stresses on the mechanical properties of metal–matrix composites is studied. It is shown that the stress relaxation can be responsible for the morphologies and spatial distribution of precipitates. Direct measurements of the residual stress is also emphasized and the influence of dislocations in the accommodation process and during interface crossing is exemplified.     

Morphology and mechanical behavior of 1,2 polybutadiene — natural rubber blends

The effect of a thermoplastic rubber, 1,2 polybutadiene, on the mechanical behavior of natural rubber (NR) at different compositions has been studied. The morphology of the blends was studied by dynamic mechanical analysis and by solvent extraction of NR. The mechanical properties such as tensile strength, tear strength and hardness are found to increase with increasing 1,2 polybutadiene content in the blend. 50/50 blend has been found to exhibit the highest elongation. The abrasion resistance decreases with increasing NR content but the decrease is faster beyond 50% by weight of NR. The tear and abrasion fracture surfaces as revealed by scanning electron microscopy complement the quantitative results obtained by standard testing methods. The blends are found to exhibit higher hysteresis loss than either of the components at low strain level. The mechanical properties have also been correlated to the morphology of the blends.     

Ceramic–metal and ceramic–polymer composites prepared by a biomimetic process

A biomimetic process was developed to prepare apatite–metal and apatite–polymer composites. A variety of metals and organic polymers incorporated surface functional groups such as Si–OH, Ti–OH or Ta–OH to induce formation of a biologically active bonelike apatite by chemical treatment or physical adsorption. Subsequent immersion in a simulated body fluid (SBF) with ion concentrations nearly equal to those of human blood plasma or 1.5 SBF led to the formation of a dense and uniform bonelike apatite layer on the surface. Apatite–metal and apatite–polymer composites prepared in this way are believed to be very useful as artificial bone substitutes.     

Wear behavior and mechanical performance of metal injection molded Fe–2Ni sintered components

The microstructure, mechanical properties, and wear behavior of two key components of a hinge fabricated from a metal injection molding process that was then sintered and heat treated under various conditions were analyzed using an optical microscope, a pin-on-disk tester, an open-closed reciprocal wear tester, and a scanning electron microscope. Optical photomicrograph revealed a serious decarburization in the sintered component, suggesting that an increase in carbon content would be necessary to improve mechanical properties. At the initial stage of the open-closed reciprocal wear test, the obverse inclined planes of both components exhibited plastic deformation and depression. As the number of test cycles increased, an increase in cold welding, metal adhesion, spalling, delamination, and surface fatigue was observed, triggering a decrease in metal thickness, which in turn altered the shape of the components. In this study, the optimal parameters to satisfy commercial application requirements were obtained when the components were carburized at 870 °C for 30 min, quenched in oil, and finally tempered at 250 °C for 1 h.     

Aluminium nitride–molybdenum ceramic matrix composites: influence of molybdenum concentration on the mechanical properties

Aluminium nitride–molybdenum ceramic matrix composites are produced by hotpressing a mixture of two powders. Mechanical properties of a series of samples are measured in order to study the effect of molybdenum phase on the behaviour of composite. Three-point bend strength increases from a value of 270 MPa for pure aluminium nitride to 571 MPa for a composite containing 40% by volume of metallic phase. Fracture toughness measured by the single-edged precracked beam (SEPB) technique, is also increased as a function of molybdenum concentration. From 2.3 MPam^1/2 for pure AlN we obtain a value of 6.9 MPam^1/2 in the case of composite containing 40% by volume of metallic phase. This very important increase in the mechanical properties of AIN-Mo composites is attributed to higher mechanical properties of molybdenum and an adherent interface between AIN and Mo grains. This revised version was published online in November 2006 with corrections to the Cover Date.