Analysis of Semi-solid Processing for Metal Matrix Composite Synthesis Using Factorial Design

The main goal in this work is to conduct a quantitative analysis of the mechanical stir casting process for obtaining particulate metal matrix composites. A combined route of stirring at semi-solid state followed by stirring at liquid state is proposed. A fractional factorial design was developed to investigate the influence and interactions of factors as: time, rotation, initial fraction and particle size, on the incorporated fraction. The best incorporations were obtained with all factors at high levels, as well as that very long stirring periods have no strong influence being particle size and rotation the most important factors on the incorporated fraction. Particle wetting occurs during stirring at semisolid state, highlighting the importance of the interactions between particles and the alloy globularized phase. The role of the alloying element Mg as a wettability-promoting agent is discussed. The shear forces resulting from the stirring system is emphasized and understood as the effect of rotation itself added to the propeller blade geometry.

High temperature, low cycle fatigue of a hybrid particulate/fiber aluminum metal-matrix composite

The effect of shot particles on the high temperature, low cycle fatigue of a hybrid fiber/particulate metal-matrix composite (MMC) was studied. Two hybrid composites with the general composition A356/35%SiC particle/5%Fiber (one without shot) were tested. It was found that shot particles acting as stress concentrators had little effect on the fatigue performance. It appears that fibers with a high silica content were more likely to debond from the matrix. Final failure of the composite was found to occur preferentially in the matrix. SiC particles fracture progressively during fatigue testing, leading to higher stress in the matrix, and final failure by matrix overload. A continuum mechanics based model was developed to predict failure in fatigue based on the tensile properties of the matrix and particles. By accounting for matrix yielding and recovery, composite creep and particle strength distribution, failure of the composite was predicted.

Effect of thermal residual stresses on fatigue crack opening and propagation behavior in an Al/SiCp metal matrix composite

The effects of a thermal residual stress field on fatigue crack growth in a silicon carbide particle-reinforced aluminum alloy have been measured. Stress fields were introduced into plates of material by means of a quench from a solution heat-treatment temperature. Measurements using neutron diffraction have shown that this introduces an approximately parabolic stress field into the plates, varying from compressive at the surfaces to tensile in the center. Long fatigue cracks were grown in specimens cut from as-quenched plates and in specimens which were given a stress-relieving overaging heat treatment prior to testing. Crack closure levels for these cracks were determined as a function of the position of the crack tip in the residual stress field, and these are shown to differ between as-quenched and stress-relieved samples. By monitoring the compliance of the specimens during fatigue cycling, the degree to which the residual stresses close the crack has been evaluated. © 1995 The Minerals, Metals & Material Society.

Effect of thermal and mechanical processing on tensile properties of powder formed 2124 aluminium and 2124 Al-SiC p metal matrix composite

The aging responses of 2124 Al-SiC p metal matrix composite (MMC) and unreinforced matrix alloy are studied and related to variations in tensile properties. The MMC is aged from Wo starting conditions: (i) stretched and naturally aged and (ii) re-solution treated. Accelerated aging occurs in both MMC conditions compared with unreinforced alloy. Tensile strengths and elastic moduli are improved in the MMC compared with the alloy, but ductility is reduced. Stretched MMC exhibits higher strength but lower ductility and modulus than re-solutioned MMC. The re-solutioned MMC fails by microvoid coalescence in low aging conditions, and by void nucleation and shear in high aging conditions. Failure of the stretched MMC initiates at the surface at specimen shoulders, illustrating the increased notch sensitivity of this condition, and propagates via a zigzag shear fracture mode. Zigzag facet size increases on gross aging. Particle fracture occurs during tensile failure, but also before testing as a result of the manufacturing process. © 1995 The Institute of Materials.

Comparison of the ageing behaviour of PM 2124 Al alloy and Al-SiCp metal-matrix composite

The ageing response of 2124 Al-SiC particulate metal-matrix composite (MMC) and unreinforced alloy has been examined using hardness measurements and Arrhenius analysis. The formation of phases during precipitation has been studied using differential scanning calorimetry (DSC). The MMC exhibits accelerated ageing compared to unreinforced alloy, due to enhanced S′ formation. The activation energy for diffusion is lower in the MMC than in the unreinforced alloy. DSC scans show Guinier-Preston B (GPB) zone nucleation to occur at a lower temperature in the MMC, whilst the total volume of GPB zones formed is smaller than in the unreinforced alloy. A model has been proposed to explain the GPB zone formation behaviour, in which ease of GPB zone nucleation varies within the MMC, as a function of ageing time and of position within the matrix. S′ formation is enhanced in the MMC because of improved diffusion and a large increase in density of heterogeneous nucleation sites compared to the unreinforced alloy. © 1994 Chapman & Hall.

Crack closure and residual stress effects in fatigue of a particle-reinforced metal matrix composite

A study of the influence of macroscopic quenching stresses on long fatigue crack growth in an aluminium alloy-SiC composite has been made. Direct comparison between quenched plate, where high residual stresses are present, and quenched and stretched plate, where they have been eliminated, has highlighted their rôle in crack closure. Despite similar strength levels and identical crack growth mechanisms, the stretched composite displays faster crack growth rates over the complete range of ΔK, measured at R = 0.1, with threshold being displaced to a lower nominal ΔK value. Closure levels are dependent upon crack length, but are greater in the unstretched composite, due to the effect of surface compressive stresses acting to close the crack tip. These result in lower values of ΔKeff in the unstretched material, explaining the slower crack growth rates. Effective ΔKth values are measured at 1.7 MPa√m, confirmed by constant Kmax testing. In the absence of residual stress, closure levels of approximately 2.5 MPa√m are measured and this is attributed to a roughness mechanism.

The effect of microstructure on the fracture toughness of a metal-matrix composite

The fracture behaviour and plane strain fracture toughness, KIC, of four 8090-based metal-matrix composites containing 20 weight % SiC particles, 3, 6 and 23 μm in diameter, has been evaluated as a function of matrix ageing condition. Toughness values are found to be almost independent of reinforcement size. Ageing at 170°C results in a monotonic decrease in toughness with increasing strength up to the peak condition, with no subsequent recovery in toughness on overageing. However, unlike reinforced 8090, the composites are not found to be susceptible to intergranular embrittlement on overageing. The observed trends are found to be independent of reinforcement size. These findings are explained in terms of the strength, work hardening behaviour and nature and distribution of void-nucleating particles in the matrix. © 1993.

Stratified Sampling Applied to Estimation of the Volumetric Fraction of Alumina in Cast Metal Matrix Composites

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Continuous production of metal matrix composites from the semisolid state

Continuous strip metal matrix composite (MMC) casting of 0.3 mm diameter hard-drawn stainless steel (316L) wire in a quasi-eutectic SnPb (64Sn36Pb) matrix was performed by a two-roll melt drag processing (TRMDping) method, with the wire being dragged through a semisolid puddle with a fibre contact time of approximately 0.2 s. A slag weir placed at the nozzle contained two wire guide holes: one located near the upper roll, and the other located between the rolls. A successful continuous composite strip casting with good fibre alignment was achieved by inserting and embedding the wire into the matrix using the guide hole between the rolls. Degeneration of eutectic/dendrite structures led to the formation of globular structures. The occurrence and formation mechanisms of cracks, de-lamination and voids in the matrix were discussed. TRMDping is economically viable and has significant benefits over other MMC fabrication methods. © (2013) Trans Tech Publications, Switzerland.

Finite element analysis of mechanical properties in discontinuously reinforced metal matrix composites with ultrafine microstructure

This investigation focused on the finite element analyses of elastic and plastic properties of aluminium/alumina composite materials with ultrafine microstructure. The commonly used unit cell model was used to predict the elastic properties. By combining the unit cell model with an indentation model, coupled with experimental indentation measurements, the plastic properties of the composites and the associated strengthening mechanism within the metal matrix material were investigated. The grain size of the matrix material was found to be an important factor influencing the mechanical properties of the composites studied. (C) 1997 Elsevier Science S.A.

A graphical tool for the tomographic characterisation of microstructural features on metal matrix composites

Research on the micro-structural characterization of metal-matrix composites uses X-ray computed tomography to collect information about the interior features of the samples, in order to elucidate their exhibited properties. The tomographic raw data needs several steps of computational processing in order to eliminate noise and interference. Our experience with a program (Tritom) that handles these questions has shown that in some cases the processing steps take a very long time and that it is not easy for a Materials Science specialist to interact with Tritom in order to define the most adequate parameter values and the proper sequence of the available processing steps. For easing the use of Tritom, a system was built which addresses the aspects described before and that is based on the OpenDX visualization system. OpenDX visualization facilities constitute a great benefit to Tritom. The visual programming environment of OpenDX allows an easy definition of a sequence of processing steps thus fulfilling the requirement of an easy use by non-specialists on Computer Science. Also the possibility of incorporating external modules in a visual OpenDX program allows the researchers to tackle the aspect of reducing the long execution time of some processing steps. The longer processing steps of Tritom have been parallelized in two different types of hardware architectures (message-passing and shared-memory); the corresponding parallel programs can be easily incorporated in a sequence of processing steps defined in an OpenDX program. The benefits of our system are illustrated through an example where the tool is applied in the study of the sensitivity to crushing – and the implications thereof – of the reinforcements used in a functionally graded syntactic metallic foam.

Abrasion wear resistance of different artificial teeth opposed to metal and composite antagonists

One of the most important properties of artificial teeth is the abrasion wear resistance, which is determinant in the maintenance of the rehabilitation's occlusal pattern. OBJECTIVES: This in vitro study aims to evaluate the abrasion wear resistance of 7 brands of artificial teeth opposed to two types of antagonists. MATERIAL AND METHODS: Seven groups were prepared with 12 specimens each (BIOLUX & BL, TRILUX & TR, BLUE DENT & BD, BIOCLER & BC, POSTARIS & PO, ORTHOSIT & OR, GNATHOSTAR & GN), opposed to metallic (M & nickel-chromium alloy), and to composite antagonists (C & Solidex indirect composite). A mechanical loading device was used (240 cycles/min, 4 Hz speed, 10 mm antagonist course). Initial and final contours of each specimen were registered with aid of a profile projector (20x magnification). The linear difference between the two profiles was measured and the registered values were subjected to ANOVA and Tukey's test. RESULTS: Regarding the antagonists, only OR (M = 10.45 ± 1.42 µm and C = 2.77 ± 0.69 µm) and BC (M = 6.70 ± 1.37 µm and C = 4.48 ± 0.80 µm) presented statistically significant differences (p < 0.05). Best results were obtained with PO (C = 2.33 ± 0.91 µm and M = 1.78 ± 0.42 µm), followed by BL (C = 3.70 ± 1.32 µm and M = 3.70 ± 0.61 µm), statistically similar for both antagonists (p>0.05). Greater result variance was obtained with OR, which presented the worse results opposed to Ni-Cr (10.45 ± 1.42 µm), and results similar to the best ones against composite (2.77 ± 0.69 µm). CONCLUSIONS: Within the limitations of this study, it may be concluded that the antagonist material is a factor of major importance to be considered in the choice of the artificial teeth to be used in the prosthesis.

Freeform fabrication of aluminum metal-matrix composites

A series of metal-matrix composites were formed by extrusion freeform, fabrication of a sinterable aluminum alloy in combination with silicon carbide particles and whiskers, carbon fibers, alumina particles, and hollow flyash cenospheres. Silicon carbide particles were most successful in that the composites retained high density with up to 20 vol% of reinforcement and the strength approximately doubles over the strength of the metal matrix alone. Comparison with simple models suggests that this unexpectedly high degree of reinforcement can be attributed to the concentration of small silicon carbide particles around the larger metal powder. This fabrication method also allows composites to be formed with hollow spheres that cannot be formed by other powder or melt methods.

Development of a new pultrusion equipment to manufacture thermoplastic matrix composite profiles

This paper describes the design and manufacture of a low-cost full scale pultrusion prototype equipment and discusses the production and obtained mechanical properties of polypropylene/glass (GF/PP) reinforced composite ba rs fabricated by using the prototype equipment. Three different GF/PP pre-impregnated ra w-materials, a commercial GF/PP comingled system from Vetrotex, a GF/PP powder coat ed towpreg [1-3] and, a GF/PP pre- consolidated tape (PCT) produced in our laboratorie s, were used in the production of composite bars that were subsequently submitted to mechanical testing in order to determine the relevant mechanical properties and quantify the consolidation quality. Samples of the different composite profiles were also observed und er SEM microscopy.