Seizure resistance of cast aluminium alleys containing dispersed graphite particles of differing sizes

The seizure resistance of cast graphite-aluminium composite alloys containing graphite particles of various sizes was studied using a Hohman wear tester. If the graphite content is more than 2% these alloys can be selfmated without seizure under conditions of boundary lubrication. The size and shape of the graphite particles had no significant effect on seizure resistance. Owing to the extensive deformation and fragmentation of graphite, the low yield strength of the aluminium matrix and the low flow stress of the graphite particles, a continuous layer of graphite is formed on the mating surfaces even after a short running-in period. This layer persisted even after extensive wear deformation.

Computer techniques towards the automatic characterization of graphite particles in metallographic images of industrial materials

The automatic characterization of particles in metallographic images has been paramount, mainly because of the importance of quantifying such microstructures in order to assess the mechanical properties of materials common used in industry. This automated characterization may avoid problems related with fatigue and possible measurement errors. In this paper, computer techniques are used and assessed towards the accomplishment of this crucial industrial goal in an efficient and robust manner. Hence, the use of the most actively pursued machine learning classification techniques. In particularity, Support Vector Machine, Bayesian and Optimum-Path Forest based classifiers, and also the Otsu's method, which is commonly used in computer imaging to binarize automatically simply images and used here to demonstrated the need for more complex methods, are evaluated in the characterization of graphite particles in metallographic images. The statistical based analysis performed confirmed that these computer techniques are efficient solutions to accomplish the aimed characterization. Additionally, the Optimum-Path Forest based classifier demonstrated an overall superior performance, both in terms of accuracy and speed. © 2012 Elsevier Ltd. All rights reserved.

The machinability of a cast aluminium alloy-graphite particle composite

The microstructure of a cast Al---Si alloy-graphite particle composite is examined using optical and analytical scanning electron microscopy. Specimens containing different percentages of graphite were machined by orthogonal planning with 25° and 45° rake angle tools at both 6.5 and 13.2 m min−1. The machining forces are reported and the chip-rake-face friction coefficients and shear flow stresses are calculated. It is shown that the reduction in machining forces with increasing graphite content is due mostly to a decrease in the shear flow stress rather than to lower chip-rake-face friction. Both the polished and the machined surfaces of the composite are rougher than those of the simple alloy, apparently owing to the greater porosity, the tearing out of graphite particles, or the opening of cracks at the graphite particles in the wake of the tool.

Performance of an Al-Si-graphite particle composite piston in a diesel engine

Al-Si-graphite particle composite alloy pistons containing different percentages of about 80 μm uncoated graphite particles were successfully cast by foundry techniques. Tests with a 5 hp single-cylinder diesel engine show that Al-Si-graphite particle composite pistons can withstand an endurance test of 500 h without any apparent deterioration and do not seize during the running-in period. The use of the Al-Si-3% graphite particle composite piston also results in (a) up to 3% reduction in the specific fuel consumption, (b) considerable reduction in the wear of all four piston rings, (c) a reduction in piston wear, (d) a 9% reduction in the frictional horsepower losses of the engine as determined by the motoring test and (e) a slight increase in the exhaust gas temperature. These reductions (a)–(d) appear to be due to increased lubrication from the graphite particles which are smeared on the bearing surface, the higher damping capacity of the composite pistons and the reduced coefficient of thermal expansion of the composite pistons. Preliminary results indicate that aluminum-graphite particle composite alloy is a promising material for automotive pistons.

Mechanism of improvement in oil spreadability of aluminium alloy-graphite particle composites

The spreadability of SAE-30 oil on Al-12 Si base (LM-13) alloy containing dispersed graphite particles about 50 μm average size in its matrix is found to be greater than on either LM-13 with no graphite or brass. It is also found that the spreadability on LM-13 base alloys increase with increasing volume of graphite dispersion in the matrix of these alloys. Further increases in the spreadability of oil on machined LM-13-graphite particle composite test surfaces occur if these are rubbed initially against control discs of either LM-13 or grey cast iron. The formation of a triboinduced graphite-rich layer, confirmed by esca, appears to be responsible for the improved oil spreadability on the rubbed test surfaces of LM-13 base alloys as compared to the as-machined test surfaces prior to rubbing. The triboinduced layer of graphite is apparently responsible for the observed reduction in the friction, wear and seizing tendency of triboelements made from aluminium alloy-graphite particle composites.

The UPAL process: a direct method of preparing cast aluminium alloy-graphite particle composites

A direct method of preparing cast aluminium alloy-graphite particle composites using uncoated graphite particles is reported. The method consists of introducing and dispersing uncoated but suitably pretreated graphite particles in aluminium alloy melts, and casting the resulting composite melts in suitable permanent moulds. The optical pretreatment required for the dispersion of the uncoated graphite particles in aluminium alloy melts consists of heating the graphite particles to 400° C in air for 1 h just prior to their dispersion in the melts. The effects of alloying elements such as Si, Cu and Mg on the dispersability of pretreated graphite in molten aluminium have also been reported. It was found that additions of about 0.5% Mg or 5% Si significantly improve the dispersability of graphite particles in aluminium alloy melts as indicated by the high recoveries of graphite in the castings of these composites. It was also possible to disperse upto 3% graphite in LM 13 alloy melts and retain the graphite particles in a well distributed fashion in the castings using the pre-heat-treated graphite particles. The observations in this study have been related to the information presently available on wetting between graphite and molten aluminium in the presence of different elements and our own thermogravimetric analysis studies on graphite particles. Physical and mechanical properties of LM 13-3% graphite composite made using pre-heat-treated graphite powder, were found to be adequate for many applications, including pistons which have been successfully used in internal combustion engines.

Improved damping capacity and machinability of graphite particle-aluminum alloy composites

The damping capacity of cast graphitic aluminum alloy composites has been measured using a torsion pendulum at a constant strain amplitude. It was found that flake-graphite particles dispersed in the matrix of aluminum alloys increased the damping capacity; the improvement was greater, the higher the amount of graphite dispersed in the matrix. At sufficiently high graphite contents the damping capacity of graphitic aluminum composites approaches that of cast iron. The ratio between the damping capacity and the density of graphitic aluminum alloys is higher than cast iron, making them very attractive as light-weight, high-damping materials for possible aircraft applications. Machinability tests on graphite particle-aluminum composites, conducted at speeds of 315 sfm and 525 sfm, showed that the chip length decreased with the amount of graphite of a given size. When the size of graphite was decreased, at a given machining speed, the chip length decreased. Metallographic examination shows that graphite particles act as chip breakers, and are frequently sheared parallel to the plane of the

Production of cast aluminium-graphite particle composites using a pellet method

Copper- and nickel-coated graphite particles can be successfully introduced into aluminium-base alloy melts as pellets to produce cast aluminium-graphite particle composites. The pellets were made by pressing mixtures of nickel- or copper-coated graphite particles and aluminium powders together at pressures varying between 2 and 20 kg mm–2. These pellets were dispersed in aluminium alloy melts by plunging and holding them in the melts using a refractory coated mild steel cone, until the pellets disintegrated and the powders were dispersed. The optimum pressure for the preparation of pellets was 2 to 5 kg mm–2 and the optimum size and percentage of aluminium powder were 400 to 1000mgrm and 35 wt% respectively. Under optimum conditions the recovery of the graphite particles in the castings was as high as 96%, these particles being pushed into the last freezing interdendritic regions. The tensile strength and the hardness of the graphite aluminium alloys made using the pellet method are comparable to those of similar composites made using gas injection or the vortex method. The pellet method however has the advantage of greater reproducibility and flexibility. Dispersion of graphite particles in the matrix of cast aluminium alloys using the pellet method increases their resistance to wear.

Effects of infiltration pressure on mechanical properties of Al–12Si/graphite composites for piston engines

In this work results for the flexural strength and the thermal properties of interpenetrated graphite preforms infiltrated with Al-12wt%Si are discussed and compared to those for packed graphite particles. To make this comparison relevant, graphite particles of four sizes in the range 15–124 μm, were obtained by grinding the graphite preform. Effects of the pressure applied to infiltrate the liquid alloy on composite properties were investigated. In spite of the largely different reinforcement volume fractions (90% in volume in the preform and around 50% in particle compacts) most properties are similar. Only the Coefficient of Thermal Expansion is 50% smaller in the preform composites. Thermal conductivity of the preform composites (slightly below 100 W/m K), may be increased by reducing the graphite content, alloying, or increasing the infiltration pressure. The strength of particle composites follows Griffith criterion if the defect size is identified with the particle diameter. On the other hand, the composites strength remains increasing up to unusually high values of the infiltration pressure. This is consistent with the drainage curves measured in this work. Mg and Ti additions are those that produce the most significant improvements in performance. Although extensive development work remains to be done, it may be concluded that both mechanical and thermal properties make these materials suitable for the fabrication of piston engines.

Wear resistance of cast graphitic aluminium alloys

Wear rates of several cast aluminium base alloys have been measured for lubricated rubbing against a rotating hardened steel disk. Wear rates of cast graphitic aluminium-silicon-nickel alloys were lower than those of pure Al, Al-Si and Al-Si-Ni alloys especially above pressures of 0.02 kg/mm2. The high wear resistance is attributed to the presence of graphite particles in the matrix which act as a solid lubricant. Additions of nickel alone to Al-Si alloys decrease the wear resistance. Graphitic aluminium-silicon-nickel alloys containing above 2% graphite can be mated unlubricated against the rotating steel disk after a one minute lubricated run-in period. Graphite particles may be potentially suitable to replace part of all of the tin in aluminium-tin bearing alloys.

Wear resistance of cast graphitic aluminium alloys

Wear rates of several cast aluminium base alloys have been measured for lubricated rubbing against a rotating hardened steel disk. Wear rates of cast graphitic aluminium-silicon-nickel alloys were lower than those of pure Al, Al-Si and Al-Si-Ni alloys especially above pressures of 0.02 kg/mm2. The high wear resistance is attributed to the presence of graphite particles in the matrix which act as a solid lubricant. Additions of nickel alone to Al-Si alloys decrease the wear resistance. Graphitic aluminium-silicon-nickel alloys containing above 2% graphite can be mated unlubricated against the rotating steel disk after a one minute lubricated run-in period. Graphite particles may be potentially suitable to replace part of all of the tin in aluminium-tin bearing alloys.

A binderless, bulk modified, renewable surface amperometric sensor for NADH and ethanol

Graphite particles are exfoliated and subsequently functionalized with toluidine blue. The resulting covalently modified graphite particles are restacked without any binder to form a surface-renewable, bulk-modified electrode. Electrocatalytic oxidation of NADH and its application in the amperometric biosensing of ethanol using alcohol dehydrogenase enzyme have been demonstrated with this material.

Structural studies of excimer laser-induced percolative phase transition on polyimide thin film surfaces

The behavior of electrical conductivity for excimer laser irradiated polyimide films in the vicinity of the critical number of laser shots was described by three-dimensional percolative phase transition model. It is: found that electrical conductivity changed more rapidly than that predicted by the percolation model. Thus, the change in microstructure with increasing number of laser shots was analyzed by FT-IR Raman spectrometry and laser desorption time-of-flight mass spectrometry. It is demonstrated that not only the number but also the average size of graphite particles on the irradiated polyimide film surfaces increased with increasing number of laser shots. These results were helpful to better understand the critical change in electrical conductivity on the irradiated polyimide film surfaces. (C) 2001 Elsevier Science B.V. All rights reserved.

Cost-effective composite electrode for the fast voltammetric screening and determination of riboflavin (B2) and pyridoxine (B6) in pharmaceuticals

Different solid composites made by mechanical dispersions of graphite particles into heated paraffin (from 65 to 80% graphite, in mass) were prepared and assessed in order to optimize their use in electrochemical and electroanalytical procedures for bioanalysis. Besides these, composites were also evaluated by thermoanalytical techniques aiming to study their conservation and long-term stability (over eight months without special care), among others. Best results were found at 80% m/m graphite in paraffin. Such electrode combines low-cost, stability, sensitivity, ease of maintenance and clearance, besides the possibilities of manufacture in many different forms and shapes (with or without modifications) and applicability in a wide range of pH. Electrochemical studies by different voltammetric techniques involving vitamins from complex B (riboflavin and pyridoxine) leaded to a better understanding about their electrooxidative processes onto carbon-composite electrodes, specially regarding reversibility and pH-dependence. Data were also acquired and optimized with analytical purposes, being square-wave voltammetry in pH 4.2 chosen by its many advantages. Good linearity between peak responses as function of concentration were reached from 5 to 43 μmol L-1 for riboflavin (peak at -0.257 V) and up to 8.5 × 10-4 mol L -1 for pyridoxine (peak at +1.04 V), best studied conditions; limits of detection (at an S/N of 3) for both analites showed to be circa 1.0 mol L-1. Different commercial samples were analyzed for riboflavin (EMS® complex B syrup) and pyridoxine (Citoneurin 5000 Merck® ampoules) providing 96.6% and 98.7% recoveries, respectively.

In-plane thermal conductivity modeling of carbon filled liquid crystal polymer based resins

Adding conductive carbon fillers to insulating thermoplastic resins increases composite electrical and thermal conductivity. Often, as much of a single type of carbon filler is added to achieve the desired conductivity, while still allowing the material to be molded into a bipolar plate for a fuel cell. In this study, varying amounts of three different carbons (carbon black, synthetic graphite particles, and carbon fiber) were added to Vectra A950RX Liquid Crystal Polymer. The in-plane thermal conductivity of the resulting single filler composites were tested. The results showed that adding synthetic graphite particles caused the largest increase in the in-plane thermal conductivity of the composite. The composites were modeled using ellipsoidal inclusion problems to predict the effective in-plane thermal conductivities at varying volume fractions with only physical property data of constituents. The synthetic graphite and carbon black were modeled using the average field approximation with ellipsoidal inclusions and the model showed good agreement with the experimental data. The carbon fiber polymer composite was modeled using an assemblage of coated ellipsoids and the model showed good agreement with the experimental data.