Abstract
SiC particle-reinforced aluminum matrix composites have high specific strength, high specific modulus, high wear resistance, and excellent corrosion resistance, which are one of the best materials for replacing traditional steel due to the lightweight design they offer in mechanical structures. They have broad application prospects in the automotive, machinery, aviation, and electronic packaging fields. Therefore, they have received much attention from scientific research workers in all fields. This research summarized the fabrication technology, properties, and reinforcement mechanisms of SiC particle-reinforced aluminum matrix composites, and discussed the technical difficulties and improvements in the preparation of these composites. Finally, the research and applications of SiC particle-reinforced aluminum composites were summarized.
Science Press
Aluminum (Al) is a light and active metal material with a density of 2.702 g/c
Fig.1 Typical applications of SiCp/Al composite
The attractive physical and mechanical properties of metal matrix composites (MMCs), such as high specific modulus, strength, and thermal stability, have been documented extensively. MMCs combine metallic properties (ductility and toughness) with ceramic properties (high strength and modulus), which creates greater strength in shear and compression and higher service temperature capabilitie
Currently, the methods for preparing SiC/Al composites include the semi-solid stirring smelting casting metho
Although they are still in the development stage, SiC/Al composite
SiCp/Al composites are reinforced using SiC and Al2O3 ceramic particles, which are mixed with the aluminum matrix to form a new composite. The composite has high wear resistance, high hardness and strength, good thermal conductivity, low thermal expansion coefficient, and excellent corrosion resistance. These properties make it the best choice for light weight aluminum to replace cast iron when designing and manufacturing automobile brake disc material. SiCp/Al composites are usually prepared by stirring casting, melt infiltration, powder metallurgy, jet deposition, or pulse current sintering (
Fig.2 Five representative fabrication routes for SiC particle-reinforced aluminum matrix composites: (a) stirring casting, (b) pressure infiltration, (c) pressure-less infiltration, (d) powder metallurgy, and (e) jet depositio
Researchers have also developed additional processes for preparing SiCp/Al composites. For example, Alizade et a
The semi-solid stirring casting process combines SiC and aluminum through mechanical mixing to maximize the effect of the SiC particles by distributing them evenly in the aluminum substrate, forming a good interface, creating homogeneity, and refining the grain size of the composite materials. This allows the SiCp/Al composites to achieve the best performance possible. The semi-solid stirring temperature is generally controlled at 595~610 °C. The SiC particles are washed with clean water and then coarsened with 36% hydrochloric acid. Then, the particles are heated to 950 °C in a box-resistance furnace for 4 h. The purpose of this method is to remove the gas and water vapor adsorbed on the surface of the SiC particles, reduce the particle agglomeration as much as possible, and increase the fluidity of the SiC particles and the mutual wettability between the SiC particles and the matrix. This allows them to be distributed evenly throughout the matrix.
The stirring smelting casting method has the advantages of simple process and low cost. Furthermore, it can produce composite materials with more complex shapes, so it has broad application prospects. However, this method also has some weaknesses, such as poor mutual wettability between SiC particles and liquid aluminum, difficulty in particle addition, poor uniformity and dispersion, and easy chemical reaction at the interface. These weaknesses limit its potential applications.
In the stirring casting method, liquid stirring can lead to some problems, such as poor wettability between particles and liquid aluminum as well as difficulty for the particles to enter the liquid aluminum. Semi-solid stirring method can overcome the poor wettability of particles and liquid aluminum and achieve easy preparation of composite materials with uniform particle distribution. However, the fluidity of the composite materials prepared by semi-solid stirring is worse than that prepared by liquid stirring, as the agglomeration of particles reduces the fluidity of the melt. Therefore, the flow behavior of the melt becomes the key determinant for the uniform distribution of particles in the Al matrix.
Mao et a
Fig.3 3D modeling (a~c) and microstructures (d~f) and corresponding macromorphologies (g~i): (a, d, g) four-bladed paddle, (b, e, h) three-bladed propeller, and (c, f, i) double-stage three-bladed screw propeller
Bai et al
Fig.4 Effect of stirring temperature on the distribution of SiC particles in the composites: (a) 595 °C, (b) 610 °C, (c) 630 °C, and (d) 650 °
For semi-solid stirring, Bai et a
Fig.5 Effect of stirring speed on the distribution of SiC particles in composites prepared by semi-solid stirring: (a) 200 r/min, (b) 500 r/min, (c) 650 r/min and (d) 800 r/mi
To study the influence of stirring time on the distribution of SiC particles, the optimal stirring temperature was selected as 610 °C, and the stirring speed was set at 800 r/min. During the stirring process, the mixing of particles inside the melt consisted of two processes: “macro mixing” and “micro mixing
As shown in
Fig.6 Effect of stirring time on the distribution of SiC particles in composites by semi-solid stirring at 610 °C and 800 r/min: (a) 10 min, (b) 15 min, (c) 20 min, (d) 25 min, and (e) 30 mi
The melt infiltration method is generally divided into the pressure infiltration method and pressure-less infiltration method.
The pressure infiltration method is used to prepare SiC particles by first preparing the prefabricated blocks and then placing them into the extrusion die. The die is then preheated to a certain temperature, and the aluminum alloy liquid is poured into the die. The alloy liquid infiltrates the prefabricated block to obtain the required composite material (
Liao et a
In the pressure-less infiltration method, preformed SiC particles and aluminum alloy are placed in a heating furnace with flowing nitrogen, and the matrix alloy is melted. The melted alloy liquid is then spontaneously infiltrated into the preformed, networked reinforcement material to form the composite material (
Yang et a
Powder metallurgy is a common method used to prepare MMCs. Generally, it involves three steps: mixing, forming, and sintering (
The jet deposition method atomizes the alloy liquid with a high pressure inert gas jet, which is used to spray the reinforcing phase into the alloy liquid flow. After mixing, the alloy liquid is sprayed onto the substrate and solidified rapidly (
To determine the microstructure and mechanical properties of SiCp/Al composites, Gao et al
Pulsed current sintering devices include plasma activation sintering (PAS) devices and spark plasma sintering (SPS) devices, as shown in
Fig.7 Schematic of pulsed current sintering device: (a) plasma activation sintering structure (PAS) and
(b) spark plasma sintering structure (SPS)
Yang et a
To study the related mechanical properties of SiCp/Al composites, Tokaji et a
Ibrahi
increase, while the elongation decreases.
The mesoscopic finite element analysis (FEA) model for cutting particle-reinforced composites is shown in
Fig.8 Simulation model (a) and experiment setup (b) for the cutting of SiCp/Al composites
The effect of the milling tool nose must be considered when the axial depth of the cut is on the same size level as the tool nose radius, as the tool's effective cutting edge is mainly concentrated on the circle-shaped nose edge.
Fig.9 Schematic of surface generation during the end milling process: (a) macro picture and (b) micro pictur
In order to have a deeper understanding of its cutting process, simulations are performed for cutting round particle model and polygonal particle model, and chip formation of each model at four different cutting time are shown in
Fig.10 Cutting simulation of SiC particle composite without SiC fracture: (a) round SiC particle and (b) polygonal SiC particl
Von Mises stress distribution shows that the stress in SiC particles is much higher than that in Al matrix. The results show that the hard SiC particles mainly bear the load during milling, while the aluminum matrix mainly transmits the load. In the aspect of machining surface morphology, the simulated cutting surface is rough, including cavity defects of different sizes.
A single flute mono crystalline diamond square end mill was used as the cutting tool. Mono crystalline diamond is considered the ideal cutting tool material due to its extreme hardness and sharpness. As shown in
Fig.11 Single flute diamond square end mill: (a) overview of diamond flute, (b) cutting edge radius estimation, and (c) SEM image of the tool ti
A workpiece sample was stuck to an iron block, which was clamped by paraffin wax. The vise is fixed on a piezoelectric dynamometer with screws so that the grinding forces Fa in the axial direction and Fr in the feed direction can be properly measured, as shown in
Fig.12 Schematic (a) and experimental setup (b) of UAG using a diamond grinding wheel; (c) SEM image of surface morphology of SiCp/Al after UA
The SEM morphology in
The spatial distribution and configuration of the reinforce-ment phase are important factors for the mechanical properties that must be studied. An increasing number of scholars have studied enhanced particle non-uniform distribution in MMCs, and high-performance MMCs with the current configuration strength has become an important topic of research. To control different scales of spatial distribution and configuration of the reinforced phase in the matrix, a series of composites containing different reinforced phase configurations of the composite materials were prepared.
Huang et a
Fig.13 Schematic illustrations and representative SEM images (insets) of microstructural inhomogeneity of a reinforcement-rich phase with four different patterns: (a) isolated, (b) bar/laminated/ring-like, (c) 3D network with isolated particle-lean phase, and (d) 3D network with interconnected particle-lean phase forming the so-called bi-continuous microstructur
The introduction of reinforcing particles can cut the matrix grains to reduce their size and can also fix the matrix grain boundaries to restrict their growth. Since the grain boundaries have an inhibiting effect on dislocations, the matrix grain size directly affects the overall strength of the composite. Generally, the finer the matrix grains, the higher their contribution to the overall strength of the composite. The number of grain boundaries can be increased by refining grain size, which can also better hinder dislocation and improve material strength. The relationship between grain size and metal material strength is determined by the Hall-Petch equatio
| (1) |
where σHP is the yield strength, σ0 is a constant, D is the average grain size, and k is the strengthening factor related to the material.
Orowan strengthening is caused by the interaction between the second-phase particles and dislocations. Due to the effect of loads, dislocation after the second phase is blocked. When hard particles in the second phase is hard to deform, dislocation will continue to campaign around the second phase. Hard particles will form around the dislocation loop with the second phase of the dislocation line, so the more dislocation loop is left, the stronger the effect. The reinforcement caused by the Orowan reinforcement mechanism is expressed by the following formula
| (2) |
where σOR is the yield strength generated by Orowan strengthening, M is the Taylor factor, Gm is the shear modulus of the aluminum matrix, b is the Burgers vector of the dislocation, dp is the average diameter of the second-phase particles, and VP is the volume fraction of the second phase.
Huo et a
Fig.14 Schematic of Orowan strengthening mechanism showing dislocation propagation and multiplicatio
Different thermal expansion coefficients of the metal matrix and the reinforcing phase lead to different degrees of deformation. Therefore, during deformation and cooling, the interface between the matrix and the reinforcing material will produce strain gradient. The resulting dislocation is called thermal mismatch dislocation, through which the strength of the material can be improved. The formula for the effect of thermal mismatch strengthening proposed by Trojanova et a
| (3) |
where ΔσCTE is the thermal expansion coefficient difference between the reinforcing phase and the matrix, Gm is the shear modulus of the aluminum matrix, b is the Burgers vector of the dislocation, and α is the dislocation strengthening efficiency.
The heterogeneous deforming-induced (HDI) reinforcement theory was proposed by Zhu et al
Fig.15 Theoretical model schematics of hetero-deformation-induced strengthening and processing hardenin
In the elastoplastic deformation stage, the soft phase yields first. Since the hard phase is still in the elastic deformation state, the packing geometry on the soft phase side of the interface must be dislocated to form the strain gradient and maintain the strain continuity. When both phases enter the plastic deformation, a strain gradient must be located near the interface to adapt to the strain partition since the soft phase has endured a greater plastic deformation than the hard phase. The strain gradient should be adjusted by geometrically necessary dislocations to generate metamorphosis-induced hardening, which helps maintain its plasticity.
Unlike other reinforcement mechanisms, the physical origin of HDI strengthening is due to the ability of geometrically necessary dislocations to insert into the heterogeneous interface. This adds additional work-hardening capacity to the material while improving material strength and plasticity. Thus, using and exerting HDI to strengthen metallic materials has become a new, important means for strengthening and toughening non-uniform materials.
Among the above-mentioned strengthening and toughening mechanisms, HDI strengthening has attracted much attention. This mechanism utilizes the superiority of the composite material's soft and hard phases during deformation, which allows the aluminum substrate to undertake the main strain of the soft phase while the reinforcing particles assume the main stress. Because strain and stress are formed within the material due to its uneven distribution, a comprehensive performance with excellent strength and plasticity is obtained.
The interfacial tension and tension equation of solid-liquid-gas three-phase contact surfaces were first proposed by Youn
| (4) |
Wang et a
Fig.16 Schematic diagram showing the contact angle formed between the solid, liquid, and gas phase
Generally, the wettability of the SiC particles and Al alloy matrix is poor, and it is difficult to create a composite with conventional methods. Therefore, solving the wettability problem has become a key factor for preparing SiCp/Al composites with a uniform distribution of SiC particles, good interface bonding, and excellent comprehensive properties. According to Young's equation, good wettability can be obtained only when the wetting angle θ is reduced. Therefore, the basic methods to improve wettability are as follows: (1) increasing the particle surface energy γsg, (2) reducing the melt surface tension γlg, and (3) reducing the interface energy between the particles and the melt metal γsl.
The interface between the matrix and the reinforcement is a phase with a certain thickness (above 1 nm). Since the structures of the matrix and reinforcement are different, the interface acts as the link between them that transmits stress and other information. Various interfacial reactions may occur when composites are prepared at high temperatures
Researcher
The preparation process, technological parameters, and other factors have a great influence on the interface reaction. For example, Mg, Si, and other elements in the matrix inhibit the formation of the Al4C3 brittle phase
Therefore, the following effective measures can be taken into account to improve interface bonding: (1) Mg, Si, and other elements can be added to the alloy liquid, and the appropriate matrix strength can be selecte
At present, the preparation methods for SiCp/Al composites have not been perfected, and the powder metallurgy method is hard to meet the requirements of size and precision. Furthermore, the production cost of this method is still very high. Thus, industrial production must be studied to improve the yield rate and output, and to realize industrial mass production of SiCp/Al composites.
Research on the interface behavior between SiC particles and the matrix, as well as the strengthening mechanism for SiC/Al composites is not complete, rendering control of the interface reaction of SiCp/A1 composites is imprecise. Future research should focus on the preparation process, matrix alloy composition, interface behavior of SiCp/Al, and surface condition of SiC particles.
Additionally, the distribution uniformity of SiC particles in the matrix is not well controlled. When the volume fraction of micro- and nano-SiC particles reaches a certain value, serious agglomeration phenomena occur. Few reports on nano-SiC/Al composites exist relatively. Therefore, further research on nano-SiC/Al composites should be the focus in this field.
A large number of basic studies have examined in terms of the microstructure, mechanical properties, and fracture characteristics of SiC/pAl composites and have realized the organic combination of experimental research, physical models, and numerical simulation analysis. Moreover, the key factors restricting the development of these composites are gradually eliminated, so their application is extensive and diversified. Future research will be able to overcome the outstanding interface problems and realize controllability of the uniform distribution of SiC particles in the matrix.
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