Controlled Size Characterization Process for In-Situ TiB2 Particles from Al Matrix Composites Using Nanoparticle Size Analysis

The wide size range and high tendency to agglomerate of in-situ TiB2 particles in reinforced Al matrix composites introduce great difficulties in their size characterization. In order to use a nanoparticle size analyzer (NSA) to obtain the precise size distribution of TiB2 particles, a controlled size characterization process has been explored. First, the extraction and drying processes for TiB2 particles were optimized. In the extraction process, alternated applications of magnetic stirring and normal ultrasound treatments were proven to accelerate the dissolution of the Al matrix in HCl solution. Furthermore, freeze-drying was found to minimize the agglomeration tendency among TiB2 particles, facilitating the acquisition of pure powders. Such powders were quantitatively made into an initial TiB2 suspension. Second, the chemical and physical dispersion technologies involved in initial TiB2 suspension were put into focus. Chemically, adding PEI (M.W. 10000) at a ratio of mPEI/mTiB2 = 1/30 into the initial suspension can greatly improve the degree of TiB2 dispersion. Physically, the optimum duration for high-energy ultrasound application to achieve TiB2 dispersion was 10 min. Overall, the corresponding underlying dispersion mechanisms were discussed in detail. With the combination of these chemical and physical dispersion specifications for TiB2 suspension, the bimodal size distribution of TiB2 was able to be characterized by NSA for the first time, and its number-average diameter was 111 ± 6 nm, which was reduced by 59.8% over the initial suspension. Indeed, the small-sized and large-sized peaks of the TiB2 particles characterized by NSA mostly match the results obtained from transmission electron microscopy and scanning electron microscopy, respectively.

Probabilistic Relative Entropy in Homogenization of Fibrous Metal Matrix Composites (MMCs)

The main aim of this work is to deliver uncertainty propagation analysis for the homogenization process of fibrous metal matrix composites (MMCs). The homogenization method applied here is based on the comparison of the deformation energy of the Representative Volume Element (RVE) for the original and for the homogenized material. This part is completed with the use of the Finite Element Method (FEM) plane strain analysis delivered in the ABAQUS system. The probabilistic goal is achieved by using the response function method, where computer recovery with a few FEM tests enables approximations of polynomial bases for the RVE displacements, and further-algebraic determination of all necessary uncertainty measures. Expected values, standard deviations, and relative entropies are derived in the symbolic algebra system MAPLE; a few different entropy models have been also contrasted including the most popular Kullback-Leibler measure. These characteristics are used to discuss the influence of the uncertainty propagation in the MMCs' effective material tensor components, but may serve in the reliability assessment by quantification of the distance between extreme responses and the corresponding admissible values.

Sintering Temperature Effect of Near-Zero Thermal Expansion Mn3Zn0.8Sn0.2N/Ti Composites

Metal matrix composites with near-zero thermal expansion (NZTE) have gained significant popularity in high-precision industries due to their excellent thermal stability and mechanical properties. The incorporation of Mn3Zn0.8Sn0.2N, which possesses outstanding negative thermal expansion properties, effectively suppressed the thermal expansion of titanium. Highly dense Mn3Zn0.8Sn0.2N/Ti composites were obtained by adjusting the fabrication temperature. Both composites fabricated at 650 °C and 700 °C exhibited NZTE. Furthermore, finite element analysis was employed to investigate the effects of thermal stress within the composites on their thermal expansion performance.

Advancements in SiC-Reinforced Metal Matrix Composites for High-Performance Electronic Packaging: A Review of Thermo-Mechanical Properties and Future Trends

With the advancement of semiconductor technology, chip cooling has become a major obstacle to enhancing the capabilities of power electronic systems. Traditional electronic packaging materials are no longer able to meet the heat dissipation requirements of high-performance chips. High thermal conductivity (TC), low coefficient of thermal expansion (CTE), good mechanical properties, and a rich foundation in microfabrication techniques are the fundamental requirements for the next generation of electronic packaging materials. Currently, metal matrix composites (MMCs) composed of high TC matrix metals and reinforcing phase materials have become the mainstream direction for the development and application of high-performance packaging materials. Silicon carbide (SiC) is the optimal choice for the reinforcing phase due to its high TC, low CTE, and high hardness. This paper reviews the research status of SiC-reinforced aluminum (Al) and copper (Cu) electronic packaging materials, along with the factors influencing their thermo-mechanical properties and improvement measures. Finally, the current research status and limitations of conventional manufacturing methods for SiC-reinforced MMCs are summarized, and an outlook on the future development trends of electronic packaging materials is provided.

Effect of Boron on the Microstructure, Superplastic Behavior, and Mechanical Properties of Ti-4Al-3Mo-1V Alloy

The decrease of superplastic forming temperature and improvement of post-forming mechanical properties are important issues for titanium-based alloys. Ultrafine-grained and homogeneous microstructure are required to improve both processing and mechanical properties. This study focuses on the influence of 0.01-2 wt.% B (boron) on the microstructure and properties of Ti-4Al-3Mo-1V (wt.%) alloys. The microstructure evolution, superplasticity, and room temperature mechanical properties of boron-free and boron-modified alloys were investigated using light optical microscopy, scanning electron microscopy, electron backscatter diffraction, X-ray diffraction analysis, and uniaxial tensile tests. A trace addition of 0.01 to 0.1 wt.% B significantly refined prior β-grains and improved superplasticity. Alloys with minor B and B-free alloy exhibited similar superplastic elongations of 400-1000% in a temperature range of 700-875 °C and strain rate sensitivity coefficient m of 0.4-0.5. Along with this, a trace boron addition provided a stable flow and effectively reduced flow stress values, especially at low temperatures, that was explained by the acceleration of the recrystallization and globularization of the microstructure at the initial stage of superplastic deformation. Recrystallization-induced decrease in yield strength from 770 MPa to 680 MPa was observed with an increase in boron content from 0 to 0.1%. Post-forming heat treatment, including quenching and ageing, increased strength characteristics of the alloys with 0.01 and 0.1% boron by 90-140 MPa and insignificantly decreased ductility. Alloys with 1-2% B exhibited an opposite behavior. For the high-boron alloys, the refinement effect of the prior β-grains was not detected. A high fraction of borides of ~5-11% deteriorated the superplastic properties and drastically decreased ductility at room temperature. The alloy with 2% B demonstrated non-superplastic behavior and low level of strength properties; meanwhile, the alloy with 1% B exhibited superplasticity at 875 °C with elongation of ~500%, post-forming yield strength of 830 MPa, and ultimate tensile strength of 1020 MPa at room temperature. The differences between minor boron and high boron influence on the grain structure and properties were discussed and the mechanisms of the boron influence were suggested.

Impact of Particle Size Distribution in the Preform on Thermal Conductivity, Vickers Hardness and Tensile Strength of Copper-Infiltrated AISI H11 Tool Steel

Spontaneous infiltration of a porous preform by a metallic melt provides the potential of generating metal matrix composites (MMCs) with tailored combinations of material properties at low cost. The bulk of tool inserts for injection molding must sustain high mechanical and thermal loads and simultaneously exhibit high thermal conductivity for efficient temperature control of the mold insert. To fulfill these contradictory requirements, AISI H11 tool steel preforms were infiltrated by liquid copper. The impact of the fine powder fraction (0 wt.% to 15 wt.%) blended to a coarse H11 powder in the preform on thermal conductivity, Vickers hardness and tensile strength was elucidated. The thermal conductivity of the composites could be enhanced by a factor of 1.84 (15 wt.% fine powder) and 2.67 (0 wt.% fine powder) with respect to the sintered H11 tool steel. By adding 15 wt.% fine powder to the coarse host powder, the tensile strength and Vickers hardness of the copper-infiltrated steel were 1066.3 ± 108.7 MPa and 366 ± 24 HV1, respectively, whereas the H11 tool steel yielded 1368.5 ± 89.3 MPa and 403 ± 17 HV1, respectively. Based on the results obtained, an appropriate particle size distribution (PSD) may be selected for preform preparation according with the requirements of a future mold insert.

Effects of Heat Treatment on the Interface Microstructure and Mechanical Properties of Friction-Stir-Processed AlCoCrFeNi/A356 Composites

Equiatomic AlCoCrFeNi high-entropy alloy (HEA) has gained significant interest in recent years because of its excellent mechanical properties. A356 aluminum alloy reinforced by AlCoCrFeNi HEA particles was fabricated by friction stir processing (FSP) and subsequent heat treatment. Solution and aging treatments were specially performed for the composites to control the interface microstructure, and interfacial microstructure and tensile properties were explored at different conditions. The interface between the matrix and HEA particles showed a dual-layered core-shell structure and the thickness of the shell region increased with the solution time. The microstructure located in the shell layers consisted of a solid solution with increasing aluminum content, in which a radial-shaped solid solution phase formed in the region close to the core of the HEA particle and scattered solid solution grains with high Ni content formed in the region close to the matrix alloy. The gradient of composition and microstructure across the HEA/Al interface can be obtained through heat treatment, and an optimal interface bonding state and mechanical property were obtained after solution treatment for 2 h. Compared with FSPed A356 aluminum alloy, the FSPed composite enhanced the tensile stress by 60 MPa and the stain by 5% under the optimized conditions. The overgrowth of the shell layer decreased both the tensile strength and the ductile greatly due to the formation of a radial-shaped solid solution phase in the shell region.

The Microzone Structure Regulation of Diamond/Cu-B Composites for High Thermal Conductivity: Combining Experiments and First-Principles Calculations

The interface microzone characteristics determine the thermophysical properties of diamond/Cu composites, while the mechanisms of interface formation and heat transport still need to be revealed. Here, diamond/Cu-B composites with different boron content were prepared by vacuum pressure infiltration. Diamond/Cu-B composites up to 694 W/(mK) were obtained. The interfacial carbides formation process and the enhancement mechanisms of interfacial heat conduction in diamond/Cu-B composites were studied by HRTEM and first-principles calculations. It is demonstrated that boron can diffuse toward the interface region with an energy barrier of 0.87 eV, and these elements are energetically favorable to form the B₄C phase. The calculation of the phonon spectrum proves that the B₄C phonon spectrum is distributed in the range of the copper and diamond phonon spectrum. The overlapping of phonon spectra and the dentate structure together enhance the interface phononic transport efficiency, thereby improving the interface thermal conductance.

Microstructure and Nanoindentation Behavior of FeCoNiAlTi High-Entropy Alloy-Reinforced 316L Stainless Steel Composite Fabricated by Selective Laser Melting

Selective laser melting (SLM) is one of the metal additive manufactured technologies with the highest forming precision, which prepares metal components through melting powders layer by layer with a high-energy laser beam. The 316L stainless steel is widely used due to its excellent formability and corrosion resistance. However, its low hardness limits its further application. Therefore, researchers are committed to improving the hardness of stainless steel by adding reinforcement to stainless steel matrix to fabricate composites. Traditional reinforcement comprises rigid ceramic particles, such as carbides and oxides, while the research on high entropy alloys as reinforcement is limited. In this study, characterisation by appropriate methods, inductively coupled plasma, microscopy and nanointendation assay, showed that we successfully prepared the FeCoNiAlTi high entropy alloy (HEA)-reinforced 316L stainless steel composites using SLM. When the reinforcement ratio is 2 wt.%, the composite samples show higher density. The SLM-fabricated 316L stainless steel displays columnar grains and it varies to equiaxed grains in composites reinforced with 2 wt.% FeCoNiAlTi HEA. The grain size decreases drastically, and the percentage of the low angle grain boundary in the composite is much higher than in the 316L stainless steel matrix. The nanohardness of the composite reinforced with 2 wt.% FeCoNiAlTi HEA is twice as high as the 316L stainless steel matrix. This work demonstrates the feasibility of using a high-entropy alloy as potential reinforcement in stainless steel systems.

Latest Developments to Manufacture Metal Matrix Composites and Functionally Graded Materials through AM: A State-of-the-Art Review

Multi-material structure fabrication has the potential to address some critical challenges in today's industrial paradigm. While conventional manufacturing processes cannot deliver multi-material structures in a single operation, additive manufacturing (AM) has come up as an appealing alternative. In particular, laser-directed energy deposition (L-DED) is preferred for multi-material AM. The most relevant applications envisioned for multi-material L-DED are alloy design, metal matrix composites (MMC), and functionally graded materials (FGM). Nonetheless, there are still some issues that need to be faced before multi-material L-DED is ready for industrial use. Driven by this need, in this literature review, the suitability of L-DED for multi-material component fabrication is first demonstrated. Then, the main defects associated with multi-material L-DED and current opportunities and challenges in the field are reported. In view of the industrial relevance of high-performance coatings as tools to mitigate wear, emphasis is placed on the development of MMCs and FGMs. The identified challenges include-but are not limited to-tightly controlling the composition of the multi-material powder mixture injected into the melt pool; understanding the influence of the thermal history of the process on microstructural aspects, including the interactions between constituents; and studying the in-service behaviours of MMCs and FGMs with regard to their durability and failure modes.

Macro- and Microstructure of In Situ Composites Prepared by Friction Stir Processing of AA5056 Admixed with Copper Powders

This paper is devoted to using multi-pass friction stir processing (FSP) for admixing 1.5 to 30 vol.% copper powders into an AA5056 matrix for the in situ fabrication of a composite alloy reinforced by Al-Cu intermetallic compounds (IMC). Macrostructurally inhomogeneous stir zones have been obtained after the first FSP passes, the homogeneity of which was improved with the following FSP passes. As a result of stirring the plasticized AA5056, the initial copper particle agglomerates were compacted into large copper particles, which were then simultaneously saturated by aluminum. Microstructural investigations showed that various phases such as α-Al(Cu), α-Cu(Al) solid solutions, Cu₃Al and CuAl IMCs, as well as both S and S'-Al₂CuMg precipitates have been detected in the AA5056/Cu stir zone, depending upon the concentration of copper and the number of FSP passes. The number of IMCs increased with the number of FSP passes, enhancing microhardness by 50-55%. The effect of multipass FSP on tensile strength, yield stress and strain-to-fracture was analyzed.

Metallic Glass-Reinforced Metal Matrix Composites: Design, Interfaces and Properties

When metals are modified by second-phase particles or fibers, metal matrix composites (MMCs) are formed. In general, for a given metallic matrix, reinforcements differing in their chemical nature and particle size/morphology can be suitable while providing different levels of strengthening. This article focuses on MMCs reinforced with metallic glasses and amorphous alloys, which are considered as alternatives to ceramic reinforcements. Early works on metallic glass (amorphous alloy)-reinforced MMCs were conducted in 1982-2005. In the following years, a large number of composites have been obtained and tested. Metallic glass (amorphous alloy)-reinforced MMCs have been obtained with matrices of Al and its alloys, Mg and its alloys, Ti alloys, W, Cu and its alloys, Ni, and Fe. Research has been extended to new compositions, new design approaches and fabrication methods, the chemical interaction of the metallic glass with the metal matrix, the influence of the reaction products on the properties of the composites, strengthening mechanisms, and the functional properties of the composites. These aspects are covered in the present review. Problems to be tackled in future research on metallic glass (amorphous alloy)-reinforced MMCs are also identified.

Scientific Advancements in Composite Materials for Aircraft Applications: A Review

Recent advances in aircraft materials and their manufacturing technologies have enabled progressive growth in innovative materials such as composites. Al-based, Mg-based, Ti-based alloys, ceramic-based, and polymer-based composites have been developed for the aerospace industry with outstanding properties. However, these materials still have some limitations such as insufficient mechanical properties, stress corrosion cracking, fretting wear, and corrosion. Subsequently, extensive studies have been conducted to develop aerospace materials that possess superior mechanical performance and are corrosion-resistant. Such materials can improve the performance as well as the life cycle cost. This review introduces the recent advancements in the development of composites for aircraft applications. Then it focuses on the studies conducted on composite materials developed for aircraft structures, followed by various fabrication techniques and then their applications in the aircraft industry. Finally, it summarizes the efforts made by the researchers so far and the challenges faced by them, followed by the future trends in aircraft materials.

Mechanical and Electrical Properties of Graphene Oxide Reinforced Copper-Tungsten Composites Produced via Ball Milling of Metal Flakes

Copper-tungsten (Cu-W) composites are widely used in high-power and -temperature electrical applications. The combination of these metals, however, leads to compromised physical and electrical properties. Herein, we produce Cu-W-graphene oxide (Cu-W-GO) composites to address this challenge. To ensure uniform density composites, the as-received metal powders were flattened into a flake morphology by ball milling and then mixed with up to 0.5 wt.% GO flakes. The green forms were processed using spark plasma sintering. The GO was found to be well-dispersed amongst the metallic phases in the final composite. The addition of GO reduced the relative density of the composites slightly (4.7% decrease in relative density at 0.5 wt% GO loading for the composites processed at 1000 °C). X-ray diffraction confirmed good phase purity and that no carbide phases were produced. GO was found to improve the mechanical properties of the Cu-W, with an optimal loading of 0.1 wt.% GO found for ultimate compression strength and strain to failure, and 0.3 wt.% optimal loading for the 0.2% offset yield strength. Significantly, the electrical conductivity increased by up to 25% with the addition of 0.1 wt.% GO but decreased with higher GO loadings.

Casting and Characterization of A319 Aluminum Alloy Reinforced with Graphene Using Hybrid Semi-Solid Stirring and Ultrasonic Processing

Advanced metallurgical processing techniques are required to produce aluminum matrix composites due to the tendency of the reinforcement particles to agglomerate. In this study, graphene nano-platelet reinforcement particles were effectively incorporated into an automotive A319 aluminum alloy matrix using a liquid metallurgical route. Due to its low density, it is a highly difficult task to produce an aluminum matrix composite reinforced with graphene. Hence, this study explored a novel approach to prevent particle floating to the melt surface and agglomeration. This was achieved via a hybrid semi-solid stirring of A319, followed by ultrasonic treatment of the liquid melt using a sonication probe. The microstructure and graphene particles were characterized using optical microscopy and scanning electron microscopy. Furthermore, the interfacial products produced with the incorporation of graphene in liquid aluminum were analyzed with X-ray diffraction. The tensile test results exhibited 10, 11 and 32% improvements in ultimate tensile strength, yield strength, and ductility of A319 reinforced with 0.05 wt.% addition of graphene. Analysis of strengthening models demonstrated primary contribution from Hall-Petch followed by CTE mismatch and load bearing mechanism. The results from this research enable the potential for using cost-effective, efficient and simple liquid metallurgy methods to produce aluminum reinforced graphene composites with improved mechanical properties.

Investigation of Mechanical and Tribological Behaviors of Aluminum Based Hybrid Metal Matrix Composite and Multi-Objective Optimization

Aluminum metal matrix composites are potential materials for aerospace and automobile industrial applications due to their enhanced mechanical and tribological properties. Aluminum reinforced with silicon carbide particles has been developed with enhanced mechanical and tribological behavior, but it lacks wettability between matrix and reinforcement causing weak bonding, which reduces the degree of enhancement. The objectives of this study were to fabricate aluminum-based metal matrix composites with enhanced wettability at varying stirring speeds (350, 450, 550 rpm), stirring time (5, 10, 15 min), weight percentage of SiC (0, 5, 10 wt.%), and weight percentage of MoS₂ (0, 2, 4 wt.%). Nine samples were fabricated using stir casting based on Taguchi L9 orthogonal array. Hardness, tensile strength, and wear rate of the developed composite were investigated and analyzed as a single response characteristic using Taguchi's signal-to-noise ratio and as a multi-response characteristic using hybrid Taguchi-grey relational analysis (HTGRA). The results revealed that the addition of SiC in the composite produced better hardness, tensile strength, and wear rate. The addition of MoS₂ in the composite showed better hardness and tensile strength only up to 2 wt.% of MoS₂, and in the case of wear rate, the addition of MoS₂ in the composite up to 4% showed better wear resistance. Al-SiC-MoS₂ hybrid composite shows better enhancement in hardness, tensile strength, and wear resistance than the Al-SiC composite.

Sensitivity Analysis of Reinforced Aluminum Based Metal Matrix Composites

Metal matrix composites (MMCs) have wide applications due to being lightweight, their high strength, and immense resistance to wear. To explore new generation materials like aluminum-based metal matrix composites (AMCs) for wide engineering applications, the present work aimed at investigating the effect of changes in composition, sintering time, and temperature on the hardness and surface roughness of AMCs containing SiC and ZrSiO₄ in wt % of 5, 20, 30, and 40 binary and hybrid sample pallets. The samples have been prepared by powder metallurgy (PM) method under 1000 psi pressure. After compaction, the above pallets sintered at different temperatures ranging from 500 °C to 1100 °C with an increment of 200 °C and 15 min intervals for four levels of temperature and time, respectively. Afterwards, sensitivity analysis has been done by investigating the effect of chemical composition, sintering time, and sintering temperature of the binary and hybrid composites on hardness and surface roughness. Morphological studies on the composites were carried out using field emission scanning electron microscope (FESEM) with energy dispersive spectroscopy (EDS). It has been observed that hardness is increased by increasing the sintering temperature in the case of SiC, whereas surface roughness did not change much by changing the composition. Additionally, a rise in temperature lead to liquid-state sintering. SEM images obtained during the elemental analysis showed that porosity is generated within the samples after sintering due to the higher melting point of reinforcements compared to a base metal, i.e., aluminum. Mathematical equations have also been developed via regression analysis using Minitab and excel for the confirmation and validation of experimental data. Analysis of Variance (ANOVA) has also been done, and its tables are shown and discussed in the paper. Hence, the most optimized findings relating the changes in the composition of reinforcements, sintering temperature, and sintering time (input variables) with porosity, hardness, and surface roughness have been presented in the current study.

Manufacturing of Aluminum Matrix Composites Reinforced with Carbon Fiber Fabrics by High Pressure Die Casting

Aluminum matrix composites reinforced with carbon fiber have been manufactured for the first time by infiltrating an A413 aluminum alloy in carbon fiber woven using high-pressure die casting (HPDC). Composites were manufactured with unidirectional carbon fibers and with 2 × 2 twill carbon wovens. The HPDC allowed full wetting of the carbon fibers and the infiltration of the aluminum alloy in the fibers meshes using aluminum at 680 °C. There was no discontinuity at the carbon fiber-matrix interface, and porosity was kept below 0.1%. There was no degradation of the carbon fibers by their reaction with molten aluminum, and a refinement of the microstructure in the vicinity of the carbon fibers was observed due to the heat dissipation effect of the carbon fiber during manufacturing. The mechanical properties of the composite materials showed a 10% increase in Young’s modulus, a 10% increase in yield strength, and a 25% increase in tensile strength, which are caused by the load transfer from the alloy to the carbon fibers. There was also a 70% increase in elongation for the unidirectionally reinforced samples because of the finer microstructure and the load transfer to the fibers, allowing the formation of larger voids in the matrix before breaking. The comparison with different mechanical models proves that there was an effective load transference from the matrix to the fibers.

Tribocorrosion-Resistant Ti40Nb-TiN Composites Having TiO2-Based Nanotubular Surfaces

A novel multifunctional material was developed by hard TiN particle reinforcement addition to a β-type Ti40Nb alloy, followed by surface functionalization, yielding the formation of a nanotubular layer. Corrosion and tribocorrosion behaviors were investigated in a phosphate-buffered saline solution at body temperature. The results revealed that the Ti40Nb-TiN composites presented similar ipass and E(i=0) values together with relatively similar Rox and Cox. However, its tribocorrosion resistance drastically improved (wear volume is almost 15 times lower than an unreinforced alloy) as a consequence of the load-carrying effect given by the reinforcement phases. The corrosion and tribocorrosion behaviors were further improved through surface functionalization as observed by significantly lower ipass and higher Rox values and almost undetectable wear volume loss from tribocorrosion tests due to the formation of a well-adhered anatase-rutile TiO2-based nanotubular layer.

Influencing the Size and Shape of High-Energy Ball Milled Particle Reinforced Aluminum Alloy Powder

High-energy ball milling represents an efficient process for producing composite powders consisting of ceramic particles dispersed in a metallic matrix. However, collision events, plastic deformations, and cold welding during the milling lead to a flake or block-like shape of the resulting composite powders. Further consolidation of such irregularly shaped powders by powder bed-based additive manufacturing technologies can be challenging because of their low flowability and low bulk density. In this work, different approaches, including milling process parameters (speed, process control agent atmosphere) and post-treatments (mechanical and thermal), are investigated on their suitability to influence the particle shape, especially concerning the roundness of the composite powders consisting of the aluminum alloy AlSi10Mg with 5 vol% SiC and Al₂O₃ reinforcement. It is found that milling with menthol as a process control agent leads to the finest composite powder compared to other milling parameters, with the lowest particle roundness of 0.39 (initial powders 0.84). No success in rounding the milled composite powder could be achieved through mechanical post-treatment in a planetary ball mill. On the other side, the thermal spraying of, e.g., SiC reinforced AlSi10Mg powder resulted in a 77–82% relative roundness. A remarkable change in the microstructure and the shape of the composite powders could also be observed after heat treatment in tube furnaces at a temperature above the melting point of AlSi10Mg. The best result in terms of improved roundness (relative to around 85%) was obtained for Al₂O₃ reinforced at 600 °C. A further increase of the temperature to 700 °C resulted in a moderate coarsening of powders with Al₂O₃ and extensive sintering of powders with SiC, presumably due to a different distribution inside the matrix.

Dimensional Stability of Mirror Substrates Made of Silicon Particle Reinforced Aluminum

In the present study, the thermal cycling stability of mirrors made of silicon particle reinforced aluminum compounds, containing an amount of 42 ± 2 wt.% silicon particles, is investigated with respect to thermal loading. The compound is processed by single-point diamond turning to optical mirrors that were subsequently thermally cycled in a temperature range between 40 °C to −60 °C and between 20 °C and −196 °C, respectively. The residual shape change of the optical surface was analyzed using Fizeau interferometry at room temperature. The change of shape deviation of the mirrors is compared with dilatometric studies of cylinders using the same temperature regime. Due to different coefficients of thermal expansion of the two constituents of the compound, thermal mismatch stresses in the ductile aluminum matrix and the brittle silicon particles are induced by the investigated thermal loads. The plasticity that occurs causes the formation of dislocations and stacking faults as substantiated by Transmission Electron Microscopy. It could be shown that the silicon particles lead to the cold working process of the reinforced aluminum matrix upon thermal cycling. By using interferometry, a higher dimensional stability of mirrors made of silicon particle reinforced aluminum due to thermal loads is demonstrated.

Use of Fumed Silica Nanostructured Additives in Selective Laser Melting and Fabrication of Steel Matrix Nanocomposites

The advancement of additive manufacturing (AM) for metal matrix nanocomposites (MMNCs) is gaining enormous attention due to their potential improvement of physical and mechanical performance. When using nanostructured additives as reinforcements in 3D printed metal composites and with the aid of selective laser melting (SLM), the mechanical properties of the composites can be tailored. The nanostructured additive AEROSIL^® fumed silica is both cost-effective and beneficial in the production of MMNCs using SLM. In this study, both hydrophobic and hydrophilic fumed silicas were shown to successfully achieve homogenous blends with commercial 316L stainless steel powder. The powder blends, which exhibited better flow, were then used to fabricate samples using SLM. The samples’ microstructure demonstrated that smaller grains were present in the composites, resulting in improvements in mechanical properties by grain refinement compared to those of 316L stainless steel samples.

Structure and Thermal Expansion of Cu-90 vol. % Graphite Composites

Copper-graphite composites are promising functional materials exhibiting application potential in electrical equipment and heat exchangers, due to their lower expansion coefficient and high electrical and thermal conductivities. Here, copper-graphite composites with 10-90 vol. % graphite were prepared by hot isostatic pressing, and their microstructure and coefficient of thermal expansion (CTE) were experimentally examined. The CTE decreased with increasing graphite volume fraction, from 17.8 × 10^-6 K^-1 for HIPed pure copper to 4.9 × 10^-6 K^-1 for 90 vol. % graphite. In the HIPed pure copper, the presence of cuprous oxide was detected by SEM-EDS. In contrast, Cu-graphite composites contained only a very small amount of oxygen (OHN analysis). There was only one exception, the composite with 90 vol. % graphite contained around 1.8 wt. % water absorbed inside the structure. The internal stresses in the composites were released during the first heating cycle of the CTE measurement. The permanent prolongation and shape of CTE curves were strongly affected by composition. After the release of internal stresses, the CTE curves of composites did not change any further. Finally, the modified Schapery model, including anisotropy and the clustering of graphite, was used to model the dependence of CTE on graphite volume fraction. Modeling suggested that the clustering of graphite via van der Waals bonds (out of hexagonal plane) is the most critical parameter and significantly affects the microstructure and CTE of the Cu-graphite composites when more than 30 vol. % graphite is present.

Investigation of the Tribological Characteristics of Aluminum 6061-Reinforced Titanium Carbide Metal Matrix Composites

The current trend in the materials engineering sector is to develop newer materials that can replace the existing materials in various engineering sectors in order to be more and more efficient. Therefore, the present research work is aimed at fabricating and determining the physical, mechanical, and dry sliding wear properties of titanium carbide (TiC)-reinforced aluminum alloy (Al6061) metal matrix composites (MMCs). For the study, the Al6061-TiC microparticle-reinforced composites were fabricated via the liquid metallurgy route through the stir casting method, where the reinforcement of the TiC particles into the Al6061 alloy matrix was added in the range of 0 to 8.0 wt.%, i.e., in the steps of 2.0 wt.%. The synthesis procedure followed the investigation of the various mechanical properties of Al6061-TiC MMCs, such as the density and structure, as well as mechanical and dry wear experimentation. The tests performed on the casted Al6061, as well as its TiC composites, were in harmony with ASTM standards. As per the experimental outcome, it can be confirmed that the increase in the weight percentage of TiC into the Al6061 alloy substantially increases the density, hardness, and tensile strength, at the expense of the percentage of elongation. In addition, the dry wear experiments, performed on a pin-on-disc tribometer, showed that the Al6061-TiC MMCs have superior wear-resistance properties, as compared to those of pure Al6061 alloy. Furthermore, optical micrograph (OM), powdered X-ray diffraction (XRD), energy dispersive spectroscopy (EDS), and scanning electron microscopy (SEM) analyses were employed for the developed Al6061-TiC MMCs before and after the fracture and wear test studies. From the overall analysis of the results, it can be observed that the Al6061-TiC composite material with higher TiC reinforcement displays superior mechanical characteristics.

On the Hardness and Elastic Modulus of Phases in SiC-Reinforced Al Composite: Role of La and Ce Addition

The use of silicon carbide particles (SiCp) as reinforcement in aluminium (Al)-based composites (Al/SiCp) can offer high hardness and high stiffness. The rare-earth elements like lanthanum (La) and cerium (Ce) and transition metals like nickel (Ni) and copper (Cu) were added into the matrix to form intermetallic phases; this is one way to improve the mechanical property of the composite at elevated temperatures. The α-Al₁₅(Fe,Mn)₃Si₂, Al₂₀(La,Ce)Ti₂, and Al₁₁(La,Ce)₃, π-Al₈FeMg₃Si₆ phases are formed. Nanoindentation was employed to measure the hardness and elastic modulus of the phases formed in the composite alloys. The rule of mixture was used to predict the modulus of the matrix alloys. The Halpin–Tsai model was applied to calculate the elastic modulus of the particle-reinforced composites. The transition metals (Ni and Cu) and rare-earth elements (La and Ce) determined a 5–15% increase of the elastic modulus of the matrix alloy. The SiC particles increased the elastic modulus of the matrix alloy by 10–15% in composite materials.

High-Temperature Compressive Response of SiCp/6092Al Composites under a Wide Range of Strain Rates

The high-temperature dynamic compressive properties of a 30 vol.% SiC_p/6092Al composite, fabricated using powder metallurgy, were experimentally investigated using the split Hopkinson pressure bar system with an electric furnace. Three different ambient temperatures, namely, room temperature, 200 °C, and 350 °C, were adopted, and the dynamic tests of the composite specimens were conducted at strain rates ranging from 1500 to 4500 s^-1. The experimental results showed that the flow stress of the composite was generally insensitive to strain rates at room temperature. However, the composite started exhibiting different strain-rate-dependent behaviors as the temperature increased, and the flow stress nonlinearly varied with increasing temperature. In addition, the microscopic images of the specimens showed that the microscopic failure mechanisms of the composite were greatly influenced by the ambient temperature and strain rate. Specifically, the percentage of failed particles decreased with rising temperature and the dominating failure mode of particles changed significantly as the strain rate increased.

Experimental Investigation of Surface Roughness in Milling of DuralcanTM Composite

In today’s developing aircraft and automotive industry, extremely durable and wear-resistant materials, especially in high temperatures, are applied. Due to this practical approach, conventional materials have been superseded by composite materials. In recent years, the application of metal matrix composites has become evident in industry 4.0. A study has been performed to analyze the surface roughness of aluminum matrix composites named Duralcan^® during end milling. Two roughness surface parameters have been selected: arithmetical mean roughness value Ra and mean roughness depth Rz regarding the variable cutting speed. Due to the classification of aluminum matrix composites as hard-to-cut materials concerning excessive tool wear, this paper describes the possibility of surface roughness prediction using machine learning algorithms. In order to find the best algorithm, Classification and Regression Tree (CART) and pattern recognition models based on artificial neural networks (ANN) have been compared. By following the obtained models, the experiment shows the effectiveness of roughness prediction based on verification models. Based on experimental research, the authors obtained the coefficient R² for the CART model 0.91 and the mean square error for the model ANN 0.11.

Microstructure and Hardness of Spark Plasma Sintered Inconel 625-NbC Composites for High-Temperature Applications

The study focuses on obtaining Inconel 625-NbC composites for high-temperature applications, e.g., jet engines, waste-to-energy combusting systems or gas engine turbines, and characterizing them in terms of their microstructure and hardness improvement. Synthesis was performed utilizing Spark Plasma Sintering (SPS) at 1150 °C under the load of 45 MPa in medium vacuum (under 10-3 MPa) for a total time of 60 min. Four sets of samples with different Inconel 625 to NbC weight ratios were prepared (5, 10, 20, and 30 wt.%), followed by a reference sample containing no ceramic reinforcement. Obtained materials were hot-rolled at 1150 °C with a 10% reduction step and later cut and polished to perform characterization utilizing scanning electron microscopy (SEM) equipped with energy dispersive spectroscopy (EDS) module and microhardness testing device equipped with Vickers indenter. Hardness was improved proportionally to NbC addition achieving an increase of up to 20% of reference values. Additional heat treatment was conducted on the hot-rolled samples at 1200 °C in an argon atmosphere to further observe the interaction between reinforcement and alloy. Their microstructure revealed the coarsening of precipitates within the metal matrix and partial reinforcement dissolution, which proved to be crucial to obtaining the highest quality composites with homogenous hardness improvement.

Analyzing the Effect of Particle Shape on Deformation Mechanism during Cutting Simulation of SiC P/Al Composites

To analyze the effect of particle shape on deformational behavior in the cutting simulation process for metal matrix composites (MMCs), two 2D mesoscopic-based finite element (FE) models reinforced with randomly distributed circular and irregular polygonal particles were developed. Different material properties (metal matrix phase, particle reinforced phase) and the properties of the particle-matrix interface were comprehensively considered in the proposed FE model. Systematic cutting experiments were conducted to compare the differences between two modeling approaches with respect to particle fracture, chip formation, cutting force and surface integrity. The results show that the irregular polygonal particle model is closer to the microstructure of MMCs, and is better able to reflect the deformation behavior of particles. The simulation model with irregular polygonal particles is even able to capture more details of the impact caused by particles, reflecting variations in the cutting force in the actual cutting process. The initiation and propagation of microcracks is mainly determined on the basis of particle geometry and further affects chip formation. Both models are able to correctly reflect surface defects, but the irregular polygonal particle model provides a more comprehensive prediction for the subsurface damage of MMCs.

Mechanical Robustness of Metal Nanocomposites Rendered by Graphene Functionalization

Nanocarbon materials, such as graphene, carbon nanotubes, and their derivatives, are considered highly effective reinforcing agents in metals. Copious experimental and computational observations suggest that the nature of the interfaces may significantly affect the mechanical behavior of nanocarbon-metal composites, while the exact correlation between the interfacial structure and the deformation and failure mechanisms of the composite remains elusive. Using a nanolaminated graphene-aluminum (Al) composite as the model material, we designed and created composites with distinct interfacial structures and bonding states via graphene functionalization. The mechanical behavior of the composites was strongly affected by the structure of the functionalized graphene (FG)/Al interface, and the optimum strength-ductility synergy came from the composite with the intermediate extent of functionalization. Complementing experimental results with molecular dynamics and phase-field simulation efforts, we interpreted these results by the combined effects of the intrinsic strength of FG nanosheets and the FG/Al interfacial bonding state.

Al Matrix Composites Reinforced by Ti and C Dedicated to Work at Elevated Temperature

In this paper, the applicability of aluminium matrix composites to high-temperature working conditions (not exceeding the Al melting point) was evaluated. The behaviour of Al-Ti-C composites at elevated temperatures was described based on microstructural and phase composition observations for composites heated at temperatures of 540 and 600 °C over differing time intervals from 2 to 72 h. The materials investigated were aluminium matrix composites (AMC) reinforced with a spatial carbon (C) structure covered by a titanium (Ti) layer. This layer protected the carbon surface against contact with the aluminium during processing, protection which was maintained for the material’s lifetime and ensured the required phase compositions of Al₄C₃ phase limitation and AlTi₃ phase creation. It was also proved that heat treatment influenced not only phase compositions but also the microstructure of the material, and, as a consequence, the properties of the composite.

Selective Laser Melting of Al-Based Matrix Composites with Al2O3 Reinforcement: Features and Advantages

Aluminum matrix composites (AMC) are of great interest and importance as high-performance materials with enhanced mechanical properties. Al₂O₃ is a commonly used reinforcement in AMCs fabricated by means of various technological methods, including casting and sintering. Selective laser melting (SLM) is a suitable modern method of the fabrication of net-shape fully dense parts from AMC with alumina. The main results, achievements, and difficulties of SLM applied to AMCs with alumina are discussed in this review and compared with conventional methods. It was shown that the initial powder preparation, namely the particle size distribution, sphericity, and thorough mixing, affected the final microstructure and properties of SLMed materials drastically. The distribution of reinforcing particles tends to consolidate the near-melting pool-edges process because of pushing by the liquid-solid interface during the solidification process that is a common problem of various fabrication methods. The achievement of an homogeneous distribution was shown to be possible through both the thorough mixing of the initial powders and the precise optimization of SLM parameters. The strength of the AMCs fabricated by the SLM method was relatively low compared with materials produced by conventional methods, while for superior relative densities of more than 99%, hardness and tribological properties were obtained, making SLM a promising method for the Al-based matrix composites with Al₂O₃.

In Situ Formation of ZrB2 and Its Influence on Wear and Mechanical Properties of ADC12 Alloy Mixed Matrix Composites

In this work, aluminium alloy ADC12 reinforced with various amounts of ZrB₂ (0 wt.%, 3 wt.%, 6 wt.%, 9 wt.%) were synthesized by an in-situ reaction of molten aluminium with inorganic salts K₂ZrF₆ & KBF_4. XRD, EDAX, and SEM techniques are used for the characterization of the fabricated composite. XRD analysis revealed the successful in situ formation of ZrB₂ in the composite. From the SEM images, it was concluded that the distribution of reinforcement was homogeneous in the composites. A study of mechanical and tribological properties under the dry sliding condition of ZrB₂-reinforced ADC12 alloy has also been carried out. It is seen that there is an increase in tensile strength by 18.8%, hardness by 64.2%, and an increase in wear resistance of the material after reinforcement. The ductility of the material decreased considerably with an increase in the amount of reinforcement. The composite’s impact strength decreased by 27.7% because of the addition of hard ZrB₂ particulates.

Effect of Variation of SiC Reinforcement on Wear Behaviour of AZ91 Alloy Composites

In this investigation, the extensive wear behaviour of materials was studied using SiC reinforced magnesium alloy composites fabricated through the stir casting process. The wear properties of AZ91 alloy composites with a small variation (i.e., 3%, 6%, 9% and 12%) of SiC particulates were evaluated by varying the normal load with sliding velocity and sliding distance. The worn surfaces were examined by scanning electron microscope to predict the different wear mechanisms on the pin while sliding on the hard disk in the dry sliding wear test condition. The microhardness of the SiC reinforced AZ91 composites was found to be more than the un-reinforced AZ91 alloy. Pins tested at load 19.62 N, and 2.6 m/s exhibited a series of short cracks nearly perpendicular to the sliding direction. At higher speed and load, the oxidation and delamination were observed to be fully converted into adhesion wear. Abrasion, oxidation, and delamination wear mechanisms were generally dominant in lower sliding velocity and lower load region, while adhesion and thermal softening/melting were dominant in higher sliding velocity and loads. The wear rate and coefficient of friction of the SiC reinforced composites were lower than that of the unreinforced alloy. This is due to the fact of higher hardness exhibited by the composites. The wear behaviour at the velocity of 1.39 m/s was dominated by oxidation and delamination wear, whereas at the velocity of 2.6 m/s the wear behaviour was dominated by abrasion and adhesion wear. It was also found that the plastic deformation and smearing occurred at higher load and sliding velocity.

Ultrafine-Grained Ti-31Mo-Type Composites with HA and Ag, Ta2O5 or CeO2 Addition for Implant Applications

Ultrafine-grained Ti31Mo alloy and Ti31Mo5HA, Ti31Mo5HA-Ag (or Ta₂O₅, CeO₂) composites with a grain size of approximately 2 μm were produced by the application of mechanical alloying and powder metallurgy. Additionally, the surface of the Ti31Mo alloy was modified. In the first stage, the specimens were immersed in 5M NaOH for 24 h at 60 °C. In the second stage, hydroxyapatite (HA) was deposited on the sample surface. The cathodic deposition at −5 V vs. open circuit potential (OCP) in the electrolyte containing 0.25M CaNa₂-EDTA (di-calcium ethylenediaminetetraacetic acid), 0.25M K₂HPO₄ in 1M NaOH at 120 °C for 2 h was applied. The bulk Ti31Mo alloy is a single β-type phase. In the alkali-modified surface titanium oxide, Ti₃O is formed. After hydrothermal treatment, the surface layer mostly consists of the Ca₁₀(PO₄)₆(OH)₂ (81.23%) with about 19% content of CaHPO₄·2H₂O. Using optical profiler, roughness 2D surface topography parameters were estimated. The in vitro cytocompatibility of synthesized materials was studied. The cell lines of normal human osteoblasts (NHost) and human periodontal ligament fibroblasts (HPdLF) was conducted in the presence of tested biomaterials. Ultrafine-grained Ti-based composites altered with HA and Ag, Ta₂O₅ or CeO₂ have superior biocompatibility than the microcrystalline Ti metal. NHost and HPdLF cells in the contact with the synthesized biomaterial showed stable proliferation activity. Biocompatibility tests carried out indicate that the ultrafine-grained Ti31Mo5HA composites with Ag, Ta₂O_5, or CeO₂ could be a good candidate for implant applications.

Investigation of Formation Behaviour of Al-Cu Intermetallic Compounds in Al-50vol%Cu Composites Prepared by Spark Plasma Sintering under High Pressure

Al-Cu matrix composites with excellent mechanical and thermal properties are among the most promising materials for realising high performance in thermal management systems. However, intermetallic compounds (ICs) formed at the Al/Cu interfaces prevent direct contact between the metals and severely deteriorate the thermal conductivity of the composite. In this study, we systemically investigated the formation behaviour of Al-Cu ICs as a function of compaction pressure at a low temperature of 380 °C. The phases of the Al-Cu ICs formed during sintering were detected via X-ray diffraction, and the layer thickness and average area fraction of each IC at different compaction pressures were analysed via micro-scale observations of the cross-sections of the Al-Cu composites. The ICs were partially formed along the Al/Cu interfaces at high pressures, and the formation region was related to the direction of applied pressure. The Vickers hardness of the Al-Cu composites with ICs was nearly double those calculated using the rule of mixtures. On the other hand, the thermal conductivity of the composites increased with compaction pressure and reached 201 W·m^-1·K^-1. This study suggests the possibility of employing Al-Cu matrix composites with controlled IC formation in thermal management applications.

A Review on AA 6061 Metal Matrix Composites Produced by Stir Casting

In recent years, many alloys as well as composites of aluminium were developed for enhanced material performance. AA 6061 is an aluminium alloy that has extensive applications due to its superior material characteristics. It is a popular choice of matrix for aluminium matrix composite (AMC) fabrication. This study provides a review on AA 6061 aluminium alloy matrix composites produced through the stir-casting process. It focusses on conventional stir-casting fabrication, process parameters, various reinforcements used, and the mechanical properties of the AA 6061 composites. Several research studies indicated that the stir-casting method is widely used and suitable for fabricating AA 6061 composites with reinforcements such as SiC, B₄C, Al₂O₃, TiC, as well as other inorganic, organic, hybrid, and nanomaterials. The majority of the studies showed that an increase in the reinforcement content enhanced the mechanical and tribological properties of the composites. Furthermore, hybrid composites showed better material properties than single reinforcement composites. The usage of industrial and agricultural residues in hybrid composites is also reported. Future studies could focus on the fabrication of AA 6061 nanocomposites through stir casting and their material characterisation, since they have great potential as advanced materials.

Composite and Surface Functionalization of Ultrafine-Grained Ti23Zr25Nb Alloy for Medical Applications

In this study, the ultrafine-grained Ti23Zr25Nb-based composites with 45S5 Bioglass and Ag, Cu, or Zn additions were produced by application of the mechanical alloying technique. Additionally, the base Ti23Zr25Nb alloy was electrochemically modified in the two stages of processing: electrochemical etching in the solution of H₃PO₄ and HF followed by electrochemical deposition in Ca(NO₃)₂, (NH₄)₂HPO₄, and HCl. The in vitro cytocompatibility studies were also done with comparison to the commercially pure titanium. The established cell lines of Normal Human Osteoblasts (NHost, CC-2538) and Human Periodontal Ligament Fibroblasts (HPdLF, CC-7049) were used. The culture was conducted among the tested materials. Ultrafine-grained titanium-based composites modified with 45S5 Bioglass and Ag, Cu, or Zn metals have higher biocompatibility than the reference material in the form of a microcrystalline Ti. Proliferation activity was at a stable level with contact with studied materials. In vitro evaluation research showed that the ultrafine-grained Ti23Zr25Nb-based composites with 45S5 Bioglass and Ag, Cu, or Zn additions, with a Young modulus below 50 GPa, can be further used in the biomedical field.

Effect of SiC Reinforcement and Its Variation on the Mechanical Characteristics of AZ91 Composites

In this study, the processing of SiC particulate-strengthened magnesium alloy metal matrix composites via vacuum supported inert atmosphere stir casting process is presented. The effects of small variations in the SiC particulate (average size 20 µm) reinforcement in magnesium alloy AZ91 were examined. It was found that with the addition of SiC particulate reinforcement, the hardness improved considerably, while the ultimate tensile and yield strength improved slightly. The density and porosity of the magnesium alloy-based composites increased with the increase in the wt.% of SiC particulates. The tensile and compressive fracture study of the fabricated composites was also performed. The tensile fractures were shown to be mixed-mode fractures (i.e., ductile and cleavage). The fractured surface also disclosed tiny dimples, micro-crack, and cleavage fractures which increases with increasing reinforcement. For the compression fracture, the surface microstructural studies of AZ91 displayed major shear failure and demonstrated the greater shear bands when compared to AZ91/SiC composites, which instead revealed rough fracture surfaces with mixed-mode brittle and shear features.

Corrosion-Resistant Steel-MgO Composites as Refractory Materials for Molten Aluminum Alloys

In this study, a novel metal matrix composite based on 60 vol% 316L stainless steel and 40 vol% MgO manufactured by powder metallurgy technology was developed. The corrosion resistance of the developed steel–MgO composite material against molten aluminum alloy AlSi7Mg0.3 was investigated by means of wettability tests and long-term crucible corrosion tests. The wettability tests were carried out using the sessile drop method with the capillary purification technique in a hot-stage microscope (HSM). Static corrosion tests were performed in molten aluminum alloy at 850 °C for 168 h to evaluate the impact of pre-oxidation of the composite surface on the corrosion resistance. The pre-oxidation of steel–MgO composites was carried out at 850 and 1000 °C for 24 h, based on preliminary investigations using thermogravimetry (TG) and dilatometry. The influence of the pre-oxidation on the composite structure, the corrosion resistance, and the phase formation at the interface between the steel–MgO composite and aluminum alloy was analyzed using SEM/EDS and XRD. The impact of the steel–MgO composite material on the composition of the aluminum alloy regarding the type, size, and quantity of the formed precipitations was investigated with the aid of ASPEX PSEM/AFA and SEM/EBSD. It was revealed that the pre-oxidation of the steel–MgO composite at 1000 °C induced the formation of stable MgO-FeO solid solutions on its surface, leading to a significant increase of long-term corrosion resistance against the liquid aluminum alloy.

Decision Support System in the Field of Defects Assessment in the Metal Matrix Composites Castings

This paper presented a new approach to decision making support of defects assessment in metal matrix composites (MMC). It is a continuation of the authors’ papers in terms of a uniform method of casting defects assessment. The idea of this paper was to design an open-access application (follow-up system called Open Atlas of Casting Defects (OACD)) in the area of industry and science. This a new solution makes it possible to quickly identify defect types considering the new classification of casting defects. This classification complements a classical approach by adding a casting defect group called structure defects, which is especially important for metal matrix composites. In the paper, an application structure, and the possibility of its use in casting defects assessment were introduced.

3D Printing of Continuous Fiber Reinforced Low Melting Point Alloy Matrix Composites: Mechanical Properties and Microstructures

A novel 3D printing route to fabricate continuous fiber reinforced metal matrix composite (CFRMMC) is proposed in this paper. It is distinguished from the 3D printing process of polymer matrix composite that utilizes the pressure inside the nozzle to combine the matrix with the fiber. This process combines the metallic matrix with the continuous fiber by utilizing the wetting and wicking performances of raw materials to form the compact internal structures and proper fiber-matrix interfaces. CF/Pb50Sn50 composites were printed with the Pb50Sn50 alloy wire and modified continuous carbon fiber. The mechanical properties of the composite specimens were studied, and the ultimate tensile strength reached 236.7 MPa, which was 7.1 times that of Pb50Sn50 alloy. The fracture and interfacial microstructure were investigated and analyzed. The relationships between mechanical properties and interfacial reactions were discussed. With the optimized process parameters, several composites parts were printed to demonstrate the advantages of low cost, short fabrication period and flexibility in fabrication of complex structures.

Heating Conditions Influence on Solidification of Inconel 625-WC System for Additive Manufacturing

In this study, an Inconel 625-tungsten carbide (WC) composite system was investigated by means of microstructure changes affected by both heating rate and WC content. In order to investigate how the system behaves while exposed to fast thermal processing, controlled melting using a differential thermal analysis (DTA) apparatus was performed on the powders. Two WC powders with different average grain size were used to obtain six compositions of Inconel 625-WC powder mixtures (10, 20, and 30 wt.% WC). They were analyzed under 10 and 30 °C/min heating rate in order to obtain composite samples. Results from DTA together with SEM/energy-dispersive X-ray spectroscopy (EDS) microstructural observations allowed observing material changes during solidification. Because of the extensive microsegregation of alloying elements to liquid and their reactions with C, which derived from dissolved WC, the formation of secondary phases with improved microhardness was possible. The collected results provide a better understanding of material behavior during intensive thermal processing which can be useful when designing materials for the laser additive manufacturing technique.

Recent Developments towards Commercialization of Metal Matrix Composites

Metal matrix composites (MMCs) are promising alternatives to metallic alloys. Their high strength-to-weight ratios; high temperature stabilities; and unique thermal, electrical, and chemical properties make them suitable for automotive, aerospace, defense, electrical, electronic, energy, biomedical, and other applications. The wide range of potential combinations of materials allows the properties of MMCs to be tailored by manipulating the morphology, size, orientation, and fraction of reinforcement, offering further opportunities for a variety of applications in daily life. This Special Issue, “Metal Matrix Composites”, addresses advances in the material science, processing, material modeling and characterization, performance, and testing of metal matrix composites.

Metal Matrix Composites Synthesized by Laser-Melting Deposition: A Review

Metal matrix composites (MMCs) present extraordinary characteristics, including high wear resistance, excellent operational properties at elevated temperature, and better chemical inertness as compared to traditional alloys. These properties make them prospective candidates in the fields of aerospace, automotive, heavy goods vehicles, electrical, and biomedical industries. MMCs are challenging to process via traditional manufacturing techniques, requiring high cost and energy. The laser-melting deposition (LMD) has recently been used to manufacture MMCs via rapid prototyping, thus, solving these drawbacks. Besides the benefits mentioned above, the issues such as lower ultimate tensile strength, yield strength, weak bonding between matrix and reinforcements, and cracking are still prevalent in parts produced by LMD. In this article, a detailed analysis is made on the MMCs manufactured via LMD. An illustration is presented on the LMD working principle, its classification, and dependent and independent process parameters. Moreover, a brief comparison between the wire and powder-based LMDs has been summarized. Ex- and in-situ MMCs and their preparation techniques are discussed. Besides this, various matrices available for MMCs manufacturing, properties of MMCs after printing, possible complications and future research directions are reviewed and summarized.

Nano-Indentation Properties of Tungsten Carbide-Cobalt Composites as a Function of Tungsten Carbide Crystal Orientation

Tungsten carbide-cobalt (WC-Co) composites are a class of advanced materials that have unique properties, such as wear resistance, hardness, strength, fracture-toughness and both high temperature and chemical stability. It is well known that the local indentation properties (i.e., nano- and micro-hardness) of the single crystal WC particles dispersed in such composite materials are highly anisotropic. In this paper, the nanoindentation response of the WC grains of a compact, full-density, sintered WC-10Co composite material has been investigated as a function of the crystal orientation. Our nanoindentation survey has shown that the nanohardness was distributed according to a bimodal function. This function was post-processed using the unique features of the finite mixture modelling theory. The combination of electron backscattered diffraction (EBSD) and statistical analysis has made it possible to identify the orientation of the WC crystal and the distinct association of the inherent nanoindentation properties, even for a small set (67) of nanoindentations. The proposed approach has proved to be faster than the already existing ones and just as reliable, and it has confirmed the previous findings concerning the relationship between crystal orientation and indentation properties, but with a significant reduction of the experimental data.

Corrosion Behavior of Pressure Infiltration Diamond/Cu Composites in Neutral Salt Spray

Diamond particle-reinforced copper matrix composites (Diamond/Cu) are recognized as promising electronic packaging materials due to their excellent thermophysical properties. It is necessary to investigate the reliability of Diamond/Cu composites under extreme environmental conditions. The corrosion behavior of Diamond/Cu composites was studied in a 5 wt% NaCl neutral salt spray. Surface morphology, thermal conductivity, bending strength, corrosion rate, and corrosion depth resulting from corrosion were researched in this paper. The results showed that the corrosion phenomenon mainly occurs on the copper matrix, and the diamond and interface products do not corrode. The corrosion mechanism of Diamond/Cu composites was micro-galvanic corrosion. The corrosion product formed was Cu₂Cl(OH)₃. The salt spray environment had a great influence on the composite surface, but the composite properties were not significantly degenerated. After a 168-h test, the bending strength was unaltered and the thermal conductivity of gold-plated composites showed a slight decrease of 1-2%. Surface gold plating can effectively improve the surface state and thermal conductivity of Diamond/Cu composites in a salt spray environment.

Homogenization and Localization of Ratcheting Behavior of Composite Materials and Structures with the Thermal Residual Stress Effect

In this contribution, the ratcheting behavior and local field distribution of unidirectional metal matrix composites are investigated under cyclic loading. To that end, we extended the finite-volume direct averaging micromechanics (FVDAM) theory by incorporating the rule of nonlinear kinematic hardening. The proposed method enables efficient and accurate simulation of the ratcheting behavior of unidirectional composites. The local satisfaction of equilibrium equations of the FVDAM theory facilitates quick and rapid convergence during the plastic iterations. To verify the proposed theory, a finite-element (FE) based unit cell model is constructed with the same mesh discretization. The remarkable correlation of the transverse response and local field distribution generated by the FVDAM and FE techniques demonstrates the effectiveness and accuracy of the proposed models. The stress discontinuities along the fiber/matrix interface that are generic to the finite-element theory are absent in the FVDAM prediction. The effects of thermal residual stresses induced during the consolidation process, as well as fiber orientations, are revealed. The generated results indicate that the FVDAM is well suited for simulating the elastic-plastic ratcheting behavior of metal matrix composites, which will provide the conventional finite-element based technique with an attractive alternative.

Tribological Properties of Single (AlSi7/SiCp, AlSi7/GCsf) and Hybrid (AlSi7/SiCp + GCsf) Composite Layers Formed in Sleeves via Centrifugal Casting

When designing the composition and structure of a composite material intended for tribological cooperation, many external and structural factors must be considered. The aim of this research was to compare the tribological properties (wear resistance and friction coefficient) of AlSi7Mg1Sr0.03/SiC_p and AlSi7Mg1Sr0.03/GC_sf single-reinforced composite layers with AlSi7Mg1Sr0.03/SiC_p + GC_sf hybrid composite layer formed in sleeves via vertical centrifugal casting. Profilometry enabled quantitative and qualitative analyses to be performed on the wear traces formed on investigated surfaces. The results show that a hybrid composite layer containing spherical glassy carbon particles had a significantly lower and more stable coefficient of friction (μ) and a higher wear resistance compared with single composite layers. The obtained effect was related to the mechanism of vitreous carbon consumption, which was crushed during operation, and then introduced between the cooperating friction surfaces. In this way, it acted as a solid lubricant, which stabilized the coefficient of friction and reduced the wear process.

Effect of Extrusion Temperature on the Microstructure and Mechanical Properties of SiCnw/2024Al Composite

In the present research work, the effect of extrusion temperature from 480 to 560 °C on the microstructure and mechanical behavior of the SiCnw/2024Al composite (15 vol.%) has been explored. It has been found that extrusion at higher temperature (above 520 °C) was beneficial for the densification of the composite, while the residual average length and alignment of the SiC nanowires were also increased with the extrusion temperature. Moreover, higher extrusion temperature was helpful for the mechanical strength of the SiCnw/2024Al composite, and the peak-aged SiCnw/2024Al composite extruded at 560 °C revealed the highest strength (709.4 MPa) and elastic modulus (109.8 GPa).