A parametric study on the buckling of functionally graded material plates with internal discontinuities using the partition of unity method

In this paper, the effect of local defects, viz., cracks and cutouts on the buckling behaviour of functionally graded material plates subjected to mechanical and thermal load is numerically studied. The internal discontinuities, viz., cracks and cutouts are represented independent of the mesh within the framework of the extended finite element method and an enriched shear flexible 4-noded quadrilateral element is used for the spatial discretization. The properties are assumed to vary only in the thickness direction and the effective properties are estimated using the Mori-Tanaka homogenization scheme. The plate kinematics is based on the first order shear deformation theory. The influence of various parameters, viz., the crack length and its location, the cutout radius and its position, the plate aspect ratio and the plate thickness on the critical buckling load is studied. The effect of various boundary conditions is also studied. The numerical results obtained reveal that the critical buckling load decreases with increase in the crack length, the cutout radius and the material gradient index. This is attributed to the degradation in the stiffness either due to the presence of local defects or due to the change in the material composition. (C) 2013 Elsevier Masson SAS. All rights reserved.

Low-Wear High-Friction Behavior of Copper Matrix Composites Dispersed With an In Situ Polymer Derived Ceramic

We show that copper-matrix composites that contain 20 vol. % of an in situ processed, polymer-derived, ceramic phase constituted from Si-C-N have unusual friction-and-wear properties. They show negligible wear despite a coefficient of friction (COF) that approaches 0.7. This behavior is ascribed to the lamellar structure of the composite such that the interlamellar regions are infused with nanoscale dispersion of ceramic particles. There is significant hardening of the composite just adjacent to the wear surface by severe plastic deformation.

Carbon-Nanohorn-Reinforced Polymer Matrix Composites: Synergetic Benefits in Mechanical Properties

Mechanical properties of single-walled carbon nanohoms (SWNH) and SWNH plus few-layer graphene (EG)-reinforced poly(vinyl alcohol) (PVA) matrix composites have been measured using the nanoindentation technique. The elastic modulus (E) and hardness (H) of PVA were found to improve by similar to 315% and similar to 135%, respectively, upon the addition of just 0.4 wt % SWNH. These properties were found to be comparable to those obtained upon the addition of 0.2 wt % single-walled nanotubes (SWNT) to PVA. Furthermore, upon binary addition of 0.2 wt % EG and 0.4 wt % SWNH to PVA, benefits in the form of similar to 400% and similar to 330% synergy in E and H, respectively, were observed, along with an increased resistance to viscoelastic deformation. The reasons for these improvements are discussed in terms of the dimensionality of nanocarbon, the effectiveness of nanocarbon and polymer matrix interaction, and the influence of nanocarbon on the degree of crystallinity of the polymer. The results from SWNH reinforcement in this study demonstrate the scope for a novel and, in contrast to SWNT composites, a commercially feasible opportunity for strengthening polymer matrices.

MACHINING OF MMCs: A REVIEW

Over the last few decades, Metal Matrix Composites (MMCs) have emerged as a material system offering tremendous potential for future applications. The primary advantages offered by these materials are their improved mechanical properties, particularly in the areas of wear, strength and stiffness. Of the MMCs, Aluminum matrix composites have grown in prominence due to their low density, low melting point and low cost. However, machining these materials remains a challenging task mainly due to the high abrasiveness of the reinforcing phases. Conventional machining processes such as turning, milling or drilling are adopted for machining MMCs. In this article, the existing and ongoing developments in machining MMCs vis-a-vis tool life, tool wear, machinability and understanding chip formation mechanism have been highlighted. Most of the studies discussed in this review will focus on Aluminum matrix composites. Certain areas of machining studies which have hitherto not been investigated have also been detailed.

Dry sliding wear behavior of Al2O3 fiber reinforced aluminum composites

Dry sliding wear behavior of die-cast ADC12 aluminum alloy composites reinforced with short alumina fibers were investigated by using a pin-on-disk wear tester. The Al2O3 fibers were 4 mu m in diameter and were present in volume fractions (T-f)ranging from 0.03 to 0.26, The length of the fiber varied from 40 to 200 mu m. Disks of aluminum-alumina composites were rubbed against a pin of nitrided stainless steel SUS440B with a load of 10 N at a sliding velocity of 0.1 m/s. The unreinforced ADC 12 aluminum alloy and their composites containing low volume fractions of alumina (V-f approximate to 0.05) showed a sliding-distance-dependent transition from severe to mild wear. However, composites containing high volume fractions of alumina ( V-f > 0.05) exhibited only mild wear for all sliding distances. The duration of occurrence of the severe wear regime and the wear rate both decrease with increasing volume fraction. In MMCs the wear rate in the mild wear regime decreases with increase in volume fraction: reaching a minimum value at V-f = 0.09 Beyond V-f = 0.09 the wear rate increasesmarginally. On the other hand, the wear rate of the counterface (steel pin) was found to increase moderately with increase in V-f. From the analysis of wear data and detailed examination of (a) worn surfaces, (b) their cross-sections and (c) wear debris, two modes of wear mechanisms have been identified to be operative, in these materials and these are: (i) adhesive wear in the case of unreinforced matrix material and in MMCs with low Vf and (ii) abrasive wear in the case of MMCs with high V-f. (C) 2000 Elsevier Science Ltd. All rights reserved.

Microstructure control and wear of Al2O3-SiC-(Al,Si) composites made by melt oxidation

Ceramic matrix composites of Al2O3-SiC-(Al,Si) have been fabricated by directed melt oxidation of aluminum alloys into SiC particulate preforms. The proportions of Al2O3, alloy, and porosity in the composite can be controlled by proper selection of SLC particle size and the processing temperature. The wear resistance of composites was evaluated in pin-on-disk experiments against a hard steel substrate. Minimum wear rate comparable to conventional ceramics such as ZTA is recorded for the composition containing the highest fraction of alloy, owing to the development of a thin and adherent tribofilm with a low coefficient of friction.

Reactive hot pressing of ZrB2-ZrCx ultra-high temperature ceramic composites with the addition of SiC particulate

Starting with non-stoichiometric Zr-B4C powder mixture ZrB2-ZrC matrix composites with SiC particulate addition have been made. It was found that variable amounts (5-25 vol%) of SiC could be incorporated and reactively hot pressed (RHPed) to relative densities of 97-99% at 1400-1500 degrees C. This technique has the potential to fabricate ZrB2-based matrices at low temperatures with a variety of reinforcements whose composition and volume fraction are not limited by stoichiometric considerations. The hardness of the composites is in the range of 17-22 GPa. (C) 2010 Elsevier Ltd. All rights reserved.

The effect of SiC particles on the size and morphology of eutectic silicon in cast A356/SiCp composites

Properties of cast aluminium matrix composites are greatly influenced by the nature of distribution of reinforcing phase in the matrix and matrix microstructural length scales, such as grain size, dendrite arm spacing, size and morphology of secondary matrix phases, etc. Earlier workers have shown that SIC reinforcements can act as heterogeneous nucleation sites for Si during solidification of Al-Si-SiC composites. The present study aims at a quantitative understanding of the effect of SiC reinforcements on secondary matrix phases, namely eutectic Si, during solidification of A356 Al-SiC composites. Effect of volume fraction of SiC particulate on size and shape of eutectic Si has been studied at different cooling rates. Results indicate that an increase in SiC volume fraction leads to a reduction in the size of eutectic Si and also changes its morphology from needle-like to equiaxed. This is attributed to the heterogeneous nucleation of eutectic Si on SiC particles. However, SiC particles are found to have negligible influence on DAS. Under all the solidification conditions studied in the present investigation, SiC particles are found to be rejected by the growing dendrites. (C) 1999 Elsevier Science Ltd. All rights reserved.

Interfacial Stresses in Shape Memory Alloy Reinforced Composites

Debonding of Shape Memory Alloy (SMA) wires in SMA reinforced polymer matrix composites is a complex phenomenon compared to other fabric fiber debonding in similar matrix composites. This paper focuses on experimental study and analytical correlation of stress required for debonding of thermal SMA actuator wire reinforced composites. Fiber pull-out tests are carried out on thermal SMA actuator at parent state to understand the effect of stress induced detwinned martensites. An ASTM standard is followed as benchmark method for fiber pull-out test. Debonding stress is derived with the help of non-local shear-lag theory applied to elasto-plastic interface. Furthermore, experimental investigations are carried out to study the effect of Laser shot peening on SMA surface to improve the interfacial strength. Variation in debonding stress due to length of SMA wire reinforced in epoxy are investigated for non-peened and peened SMA wires. Experimental results of interfacial strength variation due to various L/d ratio for non-peened and peened SMA actuator wires in epoxy matrix are discussed.

Effects of Interface Treatment on the Fatigue Behavior of Shape Memory Alloy Reinforced Polymer Composites

Interfacial properties of Shape Memory Alloy (SMA) reinforced polymer matrix composites can be enhanced by improving the interfacial bonding. This paper focuses on studying the interfacial stresses developed in the SMA-epoxy interface due to various laser shot penning conditions. Fiber-pull test-setup is designed to understand the role of mechanical bias stress cycling and thermal actuation cycling. Phase transformation is tracked over mechanical and thermal fatigue cycles. A micromechanics based model developed earlier based on shear lag in SMA and energy based consistent homogenization is extended here to incorporate the stress-temperature phase diagram parameters for modeling fatigue.

Quantitative In Situ Analysis of Deformation in Sliding Metals: Effect of Initial Strain State

Using in situ, high-speed imaging of a hard wedge sliding against pure aluminum, and image analysis by particle image velocimetry, the deformation field in sliding is mapped at high resolution. This model system is representative of asperity contacts on engineered surfaces and die-workpiece contacts in deformation and machining processes. It is shown that large, uniform plastic strains of 1-5 can be imposed at the Al surface, up to depths of 500 mu m, under suitable sliding conditions. The spatial strain and strain rate distributions are significantly influenced by the initial deformation state of the Al, e.g., extent of work hardening, and sliding incidence angle. Uniform straining occurs only under conditions of steady laminar flow in the metal. Large pre-strains and higher sliding angles promote breakdown in laminar flow due to surface fold formation or flow localization in the form of shear bands, thus imposing limits on uniform straining by sliding. Avoidance of unsteady sliding conditions, and selection of parameters like sliding angle, thus provides a way to control the deformation field. Key characteristics of the sliding deformation such as strain and strain rate, laminar flow, folding and prow formation are well predicted by finite element simulation. The deformation field provides a quantitative basis for interpreting wear particle formation. Implications for engineering functionally graded surfaces, sliding wear and ductile failure in metals are discussed.

Structure and properties of fibre reinforced zn-27% al alloy based cast MMCs

Metal matrix composites (MMCs) based on a zinc-27% aluminium alloy (ZA-27) were produced using a pressure infiltration technique. Preforms of alumina fibres and aluminosilicate fibres were used for reinforcement. Uniform distribution of fibres and satisfactory interfacial bonding were achieved. UTS, specific strength, hardness and wear resistance were improved significantly by the alumina fibre reinforcement, but UTS decreased when using aluminosilicate fibres for reinforcement mainly due to unavoidable clustering of particles in the fibre preforms. Structure-property relations have been analysed in all cases.

Novel materials synthesis by mechanical alloying/milling

An account is given of the research that has been carried out on mechanical alloying/milling (MA/MM) during the past 25 years. Mechanical alloying, a high energy ball milling process, has established itself as a viable solid state processing route for the synthesis of a variety of equilibrium and non-equilibrium phases and phase mixtures. The process was initially invented for the production of oxide dispersion strengthened (ODS) Ni-base superalloys and later extended to other ODS alloys. The success of MA in producing ODS alloys with better high temperature capabilities in comparison with other processing routes is highlighted. Mechanical alloying has also been successfully used for extending terminal solid solubilities in many commercially important metallic systems. Many high melting intermetallics that are difficult to prepare by conventional processing techniques could be easily synthesised with homogeneous structure and composition by MA. It has also, over the years, proved itself to be superior to rapid solidification processing as a non-equilibrium processing tool. The considerable literature on the synthesis of amorphous, quasicrystalline, and nanocrystalline materials by MA is critically reviewed. The possibility of achieving solid solubility in liquid immiscible systems has made MA a unique process. Reactive milling has opened new avenues for the solid state metallothermic reduction and for the synthesis of nanocrystalline intermetallics and intermetallic matrix composites. Despite numerous efforts, understanding of the process of MA, being far from equilibrium, is far from complete, leaving large scope for further research in this exciting field.