Search results for: ceramic matrix composites

Authors: Kerim Emre Öksüz, Mehmet Çevik, A. Enbiya Bozdağ, Ali Özer, Mehmet Simsir

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Metal matrix composites (MMCs) have gained a considerable interest in the last three decades. Conventional powder metallurgy production route often involves the addition of reinforcing phases into the metal matrix directly, which leads to poor wetting behavior between ceramic phase and metal matrix and the segregation of reinforcements. The commonly used elements for ceramic phase formation in iron based MMCs are Ti, Nb, Mo, W, V and C, B. The aim of the present paper is to investigate the effect of sintering temperature and V-B addition on densification, phase development, microstructure, and hardness of Fe–V-B composites (Fe-(5-10) wt. %B – 25 wt. %V alloys) prepared by powder metallurgy process. Metal powder mixes were pressed uniaxial and sintered at different temperatures (ranging from 1300 to 1400ºC) for 1h. The microstructure of the (V, B) Fe composites was studied with the help of high magnification optical microscope and XRD. Experimental results show that (V, B) Fe composites can be produced by conventional powder metallurgy route.

Keywords: Hardness, Metal matrix composite (MMC), Microstructure, Powder Metallurgy.

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Authors: R. Santos Jiménez, A. San-Antonio-González, M. Del Río Merino, M. González Cortina, C. Viñas Arrebola

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In this study, the feasibility of incorporating ceramic waste from bricks (perforated brick and double hollow brick) and extruded polystyrene (XPS) waste, is analysed. Results show that it is possible to incorporate up to 25% of ceramic waste and 4% of XPS waste over the weight of gypsum in a gypsum matrix. Furthermore, with the addition of ceramic waste an 8% of surface hardness increase and a 25% of capillary water absorption reduction can be obtained. On the other hand, with the addition of XPS, a 26% reduction of density and a 37% improvement of thermal conductivity can be obtained. The obtained results are favorable to use these materials in order to produce prefabricated gypsum and also as material for interior cladding walls.

Keywords: CDW, waste materials, ceramic waste, XPS, construction materials, gypsum.

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Authors: S. I. Durowaye, O. P. Gbenebor, B. O. Bolasodun, I. O. Rufai, V. O. Durowaye

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Particles are the most common and cheapest reinforcement producing discontinuous reinforced composites with isotropic properties. Conventional fabrication methods can be used to produce a wide range of product forms, making them relatively inexpensive. Optimising composite development must include consideration of all the fundamental aspect of particles including their size, shape, volume fraction, distribution and mechanical properties. Research has shown that the challenges of low fracture toughness, poor crack growth resistance and low thermal stability can be overcome by reinforcement with particles. The unique properties exhibited by micro particles reinforced ceramic composites have made them to be highly attractive in a vast array of applications.

Keywords: Ceramic composites, Mechanical properties, Microparticles, Thermal stability.

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Authors: T. Kuchukhidze, N. Jalagonia, T. Korkia, V. Gabunia, N. Jalabadze, R. Chedia

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In this work, obtaining methods of ultrafine alumina powdery composites and high temperature pressing technology of matrix ceramic composites with different compositions have been discussed. Alumina was obtained by solution combustion synthesis and sol-gel methods. Metal carbides containing powdery composites were obtained by homogenization of finishing powders in nanomills, as well as by their single-step high temperature synthesis .Different types of matrix ceramics composites (α-Al2O3-ZrO2-Y2O3, α-Al2O3- Y2O3-MgO, α-Al2O3-SiC-Y2O3, α-Al2O3-WC-Co-Y2O3, α-Al2O3- B4C-Y2O3, α-Al2O3- B4C-TiB2 etc.) were obtained by using OXYGON furnace. Consolidation of powders were carried out at 1550- 1750°C (hold time - 1 h, pressure - 50 MPa). Corundum ceramics samples have been obtained and characterized by high hardness and fracture toughness, absence of open porosity, high corrosion resistance. Their density reaches 99.5-99.6% TD. During the work, the following devices have been used: High temperature vacuum furnace OXY-GON Industries Inc (USA), Electronic Scanning Microscopes Nikon Eclipse LV 150, Optical Microscope NMM- 800TRF, Planetary mill Pulverisette 7 premium line, Shimadzu Dynamic Ultra Micro Hardness Tester DUH-211S, Analysette 12 Dynasizer.

Keywords: α-Alumina, Consolidation, Matrix Ceramics, Powdery composites.

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Authors: L. Lancaster, M. H. Lung, D. Sujan

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The application of agro-industrial waste in Aluminum Metal Matrix Composites has been getting more attention as they can reinforce particles in metal matrix which enhance the strength properties of the composites. In addition, by applying these agroindustrial wastes in useful way not only save the manufacturing cost of products but also reduce the pollutions on environment. This paper represents a literature review on a range of industrial wastes and their utilization in metal matrix composites. The paper describes the synthesis methods of agro-industrial waste filled metal matrix composite materials and their mechanical, wear, corrosion, and physical properties. It also highlights the current application and future potential of agro-industrial waste reinforced composites in aerospace, automotive and other construction industries.

Keywords: Bond layer, Interfacial shear stress, Bi-layered assembly, Thermal mismatch, Flip Chip Ball Grid Array.

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Authors: Shenq Yih Luo, Chung Hsien Lu

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The aluminum bronze matrix alumina composites using hot press and resin infiltration were investigated to study their porosities, hardness, bending strengths, and microstructures. The experiment results show that the hardness of the sintered composites with the decrease of porosity increases. The composites without and with resin infiltration have about HRF 42-61 of about 34-40% of porosity and about HRF 62-83 of about 30-36% of porosity, respectively. Besides, the alumina composites contain a more amount of iron and nickel powders would cause a lower bending strength due to forming some weaker bonding among the iron, nickel, copper, aluminum under this hot pressing of shorter time.

Keywords: Aluminum bronze matrix composite, bending strength, hot pressing, porosity.

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Authors: R. N. Rao, S. L. Tulasi Devi

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Tribological behavior and wear regimes of ascast and heattreted Al-Cu-Mg matrix composites containing SiC particles were studied using a pin-on-disc wear testing apparatus against an EN32 steel counterface giving emphasis on wear rate as a function of applied pressures (0.2, 0.6, 1.0 and 1.4 MPa) at different sliding distances (1000, 2000, 3000, 4000 and 5000 meters) and at a fixed sliding speed of 3.35m/s. The results showed that the composite exhibited lower wear rate than that of the matrix alloy and the wear rate of the composites is noted to be invariant to the sliding distance and is reducing by heat treatment. Wear regimes such as low, mild and severe wear were observed as per the Archard-s wear calculations. It is very interesting to note that the mild wear is almost constant in all the wear regimes.

Keywords: Aluminum, matrix, regimes, wear.

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Authors: M. E. Turan, H. Zengin, E. Cevik, Y. Sun, Y. Turen, H. Ahlatci

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In this study, the effects of B₄C and SiC particle reinforcements on wear properties of magnesium matrix metal composites produced by pressure infiltration method were investigated. AZ91 (9%Al-1%Zn) magnesium alloy was used as a matrix. AZ91 magnesium alloy was melted under an argon atmosphere. The melt was infiltrated to the particles with an appropriate pressure. Wear tests, hardness tests were performed respectively. Microstructure characterizations were examined by light optical (LOM) and scanning electron microscope (SEM). The results showed that uniform particle distributions were achieved in both B₄C and SiC reinforced composites. Wear behaviors of magnesium matrix metal composites changed as a function of type of particles. SiC reinforced composite has better wear performance and higher hardness than B₄C reinforced composite.

Keywords: Magnesium matrix composite, pressure infiltration, SEM, wear.

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Authors: Nidal H. Abu-Zahra, Parisa Khoshnoud, Murtatha Jamel, Subhashini Gunashekar

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PVC foam-fly ash composites (PVC-FA) are characterized for their structural, morphological, mechanical and thermal properties. The tensile strength of the composites increased modestly with higher fly ash loading, while there was a significant increase in the elastic modulus for the same composites. On the other hand, a decrease in elongation at UTS was observed upon increasing fly ash content due to increased rigidity of the composites. Similarly, the flexural modulus increased as the fly ash loading increased, where the composites containing 25 phr fly ash showed the highest flexural strength. Thermal properties of PVC-fly ash composites were determined by Thermo Gravimetric Analysis (TGA). The microstructural properties were studied by Scanning Electron Microscopy (SEM). SEM results confirm that fly ash particles were mechanically interlocked in PVC matrix with good interfacial interaction with the matrix. Particle agglomeration and debonding was observed in samples containing higher amounts of fly ash.

Keywords: PVC Foam, Polyvinyl Chloride, Rigid PVC, Fly Ash Composites.

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Authors: Mohammad Tahaye Abadi

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The present paper concerns with the influence of fiber packing on the transverse plastic properties of metal matrix composites. A micromechanical modeling procedure is used to predict the effective mechanical properties of composite materials at large tensile and compressive deformations. Microstructure is represented by a repeating unit cell (RUC). Two fiber arrays are considered including ideal square fiber packing and random fiber packing defined by random sequential algorithm. The micromechanical modeling procedure is implemented for graphite/aluminum metal matrix composite in which the reinforcement behaves as elastic, isotropic solids and the matrix is modeled as an isotropic elastic-plastic solid following the von Mises criterion with isotropic hardening and the Ramberg-Osgood relationship between equivalent true stress and logarithmic strain. The deformation is increased to a considerable value to evaluate both elastic and plastic behaviors of metal matrix composites. The yields strength and true elastic-plastic stress are determined for graphite/aluminum composites.

Keywords: Fiber packing, metal matrix composites, micromechanics, plastic deformation, random

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Authors: Chong Wang, Kellem M. Soares, Luis E. Kosteski

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The problem of toughening in brittle materials reinforced by fibers is complex, involving all of the mechanical properties of fibers, matrix and the fiber/matrix interface, as well as the geometry of the fiber. Development of new numerical methods appropriate to toughening simulation and analysis is necessary. In this work, we have performed simulations and analysis of toughening in brittle matrix reinforced by randomly distributed fibers by means of the discrete elements method. At first, we put forward a mechanical model of toughening contributed by random fibers. Then with a numerical program, we investigated the stress, damage and bridging force in the composite material when a crack appeared in the brittle matrix. From the results obtained, we conclude that: (i) fibers of high strength and low elasticity modulus are beneficial to toughening; (ii) fibers of relatively high elastic modulus compared to the matrix may result in substantial matrix damage due to spalling effect; (iii) employment of high-strength synthetic fibers is a good option for toughening. We expect that the combination of the discrete element method (DEM) with the finite element method (FEM) can increase the versatility and efficiency of the software developed. The present work can guide the design of ceramic composites of high performance through the optimization of the parameters.

Keywords: Bridging stress, discrete element method, fiber reinforced composites, toughening.

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Authors: N. Winya, S. Chankapoe, C. Kiriratnikom

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In this study, an ablation, mechanical and thermal properties of a rocket motor insulation from phenolic/ fiber matrix composites forming a laminate with different fiber between fiberglass and locally available synthetic fibers. The phenolic/ fiber matrix composites was mechanics and thermal properties by means of tensile strength, ablation, TGA and DSC. The design of thermal insulation involves several factors.Determined the mechanical properties according to MIL-I-24768: Density >1.3 g/cm3, Tensile strength >103 MPa and Ablation <0.14 mm/s to optimization formulation of phenolic binder, fiber glass reinforcement and other ingredients were conducted after that the insulation prototype was formed and cured. It was found that the density of phenolic/fiberglass composites and phenolic/ synthetic fiber composite was 1.66 and 1.41 g/cm3 respectively. The ablative of phenolic/fiberglass composites and phenolic/ synthetic fiber composite was 0.13 and 0.06 mm/s respectively.

Keywords: Phenolic Resin, Ablation, Rocket Motor, Insulation

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Authors: Mohammed T. Hayajneh, Adel Mahmood Hassan, Moath AL-Qudah

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Burnishing is increasingly used as a finishing operation to improve surface roughness and surface hardness. This can be achieved by applying a hard ball or roller onto metallic surfaces under pressure, in order to achieve many advantages in the metallic surface. In the present work, the feed rate, speed and force have been considered as the basic burnishing parameters to study the surface roughness and surface hardness of metallic matrix composites. The considered metal matrix composites were made from Aluminum-Magnesium-Graphite with five different weight percentage of graphite. Both effects of burnishing parameters mentioned above and the graphite percentage on the surface hardness and surface roughness of the metallic matrix composites were studied. The results of this investigation showed that the surface hardness of the metallic composites increases with the increase of the burnishing force and decreases with the increase in the burnishing feed rate and burnishing speed. The surface roughness of the metallic composites decreases with the increasing of the burnishing force, feed rate, and speed to certain values, then it starts to increase. On the other hand, the increase in the weight percentage of the graphite in the considered composites causes a decrease in the surface hardness and an increase in the surface roughness.

Keywords: Burnishing process, Al-Mg-Graphite composites, Surface hardness, Surface roughness.

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Authors: Z. Salleh, M. N. Berhan, Koay Mei Hyie, D. H. Isaac

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Natural fibres have emerged as the potential reinforcement material for composites and thus gain attraction by many researchers. This is mainly due to their applicable benefits as they offer low density, low cost, renewable, biodegradability and environmentally harmless and also comparable mechanical properties with synthetic fibre composites. The properties of hybrid composites highly depends on several factors, including the interaction of fillers with the polymeric matrix, shape and size (aspect ratio), and orientation of fillers [1]. In this study, natural fibre kenaf composites and kenaf/fibreglass hybrid composites were fabricated by a combination of hand lay-up method and cold-press method. The effect of different fibre types (powder, short and long) on the tensile properties of composites is investigated. The kenaf composites with and without the addition of fibreglass were then characterized by tensile testing and scanning electron microscopy. A significant improvement in tensile strength and modulus were indicated by the introduction of long kenaf/woven fibreglass hybrid composite. However, the opposite trends are observed in kenaf powder composite. Fractographic observation shows that fibre/matrix debonding causes the fibres pull out. This phenomenon results in the fibre and matrix fracture.

Keywords: Kenaf, Fibreglass, Hybrid Composite, Tensile Strength, Tensile Modulus.

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Authors: A. Yönetken, A. Erol, A. Yakar, G. Peşmen

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The microstructure, mechanical properties and metalgraphic characteristics of Ni plated AlN-Astaloy Cr-M powders were investigated using specimens produced by tube furnace sintering at 1000-1400 °C temperature. A uniform nickel layer on AlN powders was deposited prior to sintering using electroless plating technique. A composite consisting of ternary additions, metallic phase, Ni and ceramic phase AlN within a matrix of Astaloy Cr-M had been prepared under Ar shroud and then tube furnace sintered. The experimental results carried out by using XRD (X-Ray Diffraction) and SEM (Scanning Electron Microscope) for composition (10% AlN-Astaloy Cr-M) 10% Ni at 1400 °C suggest that the best properties as 132.45HB and permittivity were obtained at 1400 °C.

Keywords: Composite, Electroless, Nickel plating, Powder metallurgy, Sintering.

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Authors: Bilge S. Oduncu, Sevil Yucel, Ismail Aydin, Isil D. Sener, Gokhan Yamaner

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The dental composites are preferably used as filling materials due to their esthetic appearances. Nevertheless one of the major problems, during the application of the dental composites, is shape change named as “polymerisation shrinkage" affecting clinical success of the dental restoration while photo-polymerisation. Polymerisation shrinkage of composites arises basically from the formation of a polymer due to the monomer transformation which composes of an organic matrix phase. It was sought, throughout this study, to detect and evaluate the structural polymerisation shrinkage of prepared dental composites in order to optimize the effects of various fillers included in hydroxyapatite (HA)-reinforced dental composites and hence to find a means to modify the properties of these dental composites prepared with defined parameters. As a result, the shrinkage values of the experimental dental composites were decreased by increasing the filler content of composites and the composition of different fillers used had effect on the shrinkage of the prepared composite systems.

Keywords: Dental composites, hydroxyapatite (HA), BisGMA, shrinkage.

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Authors: D. Sujan, Z. Oo, M. E. Rahman, M. A. Maleque, C. K. Tan

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Particulate reinforced metal matrix composites (MMCs) are potential materials for various applications due to their advantageous of physical and mechanical properties. This paper presents a study on the performance of stir cast Al2O3 SiC reinforced metal matrix composite materials. The results indicate that the composite materials exhibit improved physical and mechanical properties, such as, low coefficient of thermal expansion, high ultimate tensile strength, high impact strength, and hardness. It has been found that with the increase of weight percentage of reinforcement particles in the aluminium metal matrix, the new material exhibits lower wear rate against abrasive wearing. Being extremely lighter than the conventional gray cast iron material, the Al-Al2O3 and Al-SiC composites could be potential green materials for applications in the automobile industry, for instance, in making car disc brake rotors.

Keywords: Metal Matrix Composite, Strength to Weight Ratio, Wear Rate

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Authors: Sharifah Nabihah Syed Jaafar, Umar Adli Amran, Rasidi Roslan, Chia Chin Hua, Sarani Zakaria

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Bio-composites derived from plant fiber and/or bioderived polymer, are likely more ecofriendly and demonstrate competitive performance with petroleum based composites. In this research, the bio phenol-formaldehyde (bio-PF) was used as a matrix and oil palm empty fruit bunch fiber (EFB) as reinforcement. The matrix was synthesized via liquefaction and condensation to enhance the combination of phenol and formaldehyde, during the process. Then, the bio-PF was mixed with different percentage of EFB (5%, 10%, 15% and 20%) and molded at 180oC. The samples that viewed under scanning electron microscopy (SEM) showed an excellent wettability and interaction between EFB and matrix. Samples of 10% EFB gave the optimum properties of impact and hardness meanwhile sample 15% of EFB gave the highest reading of flexural modulus (MOE) and flexural strength (MOR). For thermal stability analysis, it was found that the weight loss and the activation energy (Ea) of the bio-composites samples were decreased as the filler content increased.

Keywords: EFB, liquefaction, phenol formaldehyde, lignin.

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Authors: B. Z. Manuel, H. D. Esmeralda, H. S. Felipe, D. R. Héctor, D. de la Torre Sebastián, R. L. Diego

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Aluminum Matrix Composites reinforced with nanocrystalline Ni3Al carbon-coated intermetallic particles, were synthesized by powder metallurgy. Powder mixture of aluminum with 0.5-volume fraction of reinforcement particles was compacted by spark plasma sintering (SPS) technique and the compared with conventional sintering process. The better results for SPS technique were obtained in 520ºC-5kN-3min.The hardness (70.5±8 HV) and the elastic modulus (95 GPa) were evaluated in function of sintering conditions for SPS technique; it was found that the incorporation of these kind of reinforcement particles in aluminum matrix improve its mechanical properties. The densities were about 94% and 97% of the theoretical density. The carbon coating avoided the interfacial reaction between matrix-particle at high temperature (520°C) without show composition change either intermetallic dissolution.

Keywords: Aluminum matrix composites, Intermetallics Spark plasma sintering.

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Authors: M.Puviyarasan, C.Praveen

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In this study, Friction Stir Processing (FSP) a recent grain refinement technique was employed to disperse micron-sized (2 *m) SiCp particles into aluminum alloy AA6063. The feasibility to fabricate bulk composites through FSP was analyzed and experiments were conducted at different traverse speeds and wider volumes of the specimens. Micro structural observation were carried out by employing optical microscopy test of the cross sections in both parallel and perpendicular to the tool traverse direction. Mechanical property including micro hardness was evaluated in detail at various regions on the specimen. The composites had an excellent bonding with aluminum alloy substrate and a significant increase of 30% in the micro hardness value of metal matrix composite (MMC) as to that of the base metal has observed. The observations clearly indicate that SiC particles were uniformly distributed within the aluminum matrix.

Keywords: Friction Stir Processing, Metal matrix composite, Bulk composite.

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Authors: S. Ghanaraja, Subrata Ray, S. K. Nath

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Particle reinforced Metal Matrix Composite (MMC) succeeds in synergizing the metallic matrix with ceramic particle reinforcements to result in improved strength, particularly at elevated temperatures, but adversely it affects the ductility of the matrix because of agglomeration and porosity. The present study investigates the outcome of tensile properties in a cast and hot forged composite reinforced simultaneously with coarse and fine particles. Nano-sized alumina particles have been generated by milling mixture of aluminum and manganese dioxide powders. Milled particles after drying are added to molten metal and the resulting slurry is cast. The microstructure of the composites shows good distribution of both the size categories of particles without significant clustering. The presence of nanoparticles along with coarser particles in a composite improves both strength and ductility considerably. Delay in debonding of coarser particles to higher stress is due to reduced mismatch in extension caused by increased strain hardening in presence of the nanoparticles. However, higher addition of powder mix beyond a limit results in deterioration of mechanical properties, possibly due to clustering of nanoparticles. The porosity in cast composite generally increases with the increasing addition of powder mix as observed during process and on forging it has got reduced. The base alloy and nanocomposites show improvement in flow stress which could be attributed to lowering of porosity and grain refinement as a consequence of forging.

Keywords: Aluminum, alumina, nanoparticle reinforced composites, porosity.

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Authors: S. P. Jordan, G. Christian, S. P. Jeffs

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Modern composite materials are increasingly being chosen in replacement of heavier metallic material systems within many engineering fields including aerospace and automotive industries. The increasing push towards satisfying environmental targets are fuelling new material technologies and manufacturing processes. This paper will introduce materials and manufacturing processes using metal matrix composites along with manufacturing processes optimized at Alvant Ltd., based in Basingstoke in the UK which offers modern, cost effective, selectively reinforced composites for light-weighting applications within engineering. An overview and introduction into modern optimized manufacturing methods capable of producing viable replacements for heavier metallic and lower temperature capable polymer composites are offered. A review of the capabilities and future applications of this viable material is discussed to highlight the potential involved in further optimization of old manufacturing techniques, to fully realize the potential to lightweight material using cost-effective methods.

Keywords: Aluminum matrix composites, light-weighting, hybrid squeeze casting, strategically placed reinforcements.

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Authors: Z. Pavlík, M. Čáchová, E. Vejmelková, T. Korecký, J. Fořt, M. Pavlíková, R. Černý

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The effect of waste ceramic powder on the thermal properties of lime-pozzolana composites is investigated. At first, the measurements of effective thermal conductivity of lime-pozzolan composites are performed in dependence on moisture content from the dry state to fully water saturated state using a pulse method. Then, the obtained data are analyzed using two different homogenization techniques, namely the Lichtenecker’s and Dobson’s formulas, taking into account Wiener’s and Hashin/Shtrikman bounds. 

Keywords: Waste ceramic powder, lime-pozzolan plasters, effective thermal conductivity, homogenization techniques.

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Authors: J. Wozniak, M. Kostecki, K. Broniszewski, W. Bochniak, A. Olszyna

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The influence of extrusion parameters on surface quality and properties of AA6061+x% vol. SiC (x = 0; 2,5; 5; 7,5;10) composites was discussed in this paper. The averages size of AA6061 and SiC particles were 10.6 μm and 0.42 μm, respectively. Two series of composites (I - compacts were preheated at extrusion temperature through 0.5 h and cooled by water directly after process; II - compacts were preheated through 3 hours and were not cooled) were consolidated via powder metallurgy processing and extruded by KoBo method. High values of density for both series of composites were achieved. Better surface quality was observed for II series of composites. Moreover, for these composites lower (compared to I series) but more uniform strength properties over the cross-section of the bar were noticed. Microstructure and Young-s modulus investigations were made.

Keywords: aluminum alloy, extrusion, metal matrix composites, microstructure

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Authors: Oluwagbenga B. Fatile, Felix U. Idu, Olajide T. Sanya

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This paper reports the viability of developing Zn-27Al alloy matrix hybrid composites reinforced with alumina, graphite and fly ash (solid waste bye product of coal in thermal power plants). This research work was aimed at developing low cost-high performance Zn-27Al matrix composite with low density. Alumina particulates (Al2O3), graphite added with 0, 2, 3, 4 and 5 wt% fly ash were utilized to prepare 10wt% reinforcing phase with Zn-27Al alloy as matrix using two-step stir casting method. Density measurement, estimated percentage porosity, tensile testing, micro hardness measurement and optical microscopy were used to assess the performance of the composites produced. The results show that the hardness, ultimate tensile strength, and percent elongation of the hybrid composites decrease with increase in fly ash content. The maximum decrease in hardness and ultimate tensile strength of 13.72% and 15.25% respectively were observed for composite grade containing 5wt% fly ash. The percentage elongation of composite sample without fly ash is 8.9% which is comparable with that of the sample containing 2wt% fly ash with percentage elongation of 8.8%. The fracture toughness of the fly ash containing composites was however superior to those of composites without fly ash with 5wt% fly ash containing composite exhibiting the highest fracture toughness. The results show that fly ash can be utilized as complementary reinforcement in ZA-27 alloy matrix composite to reduce cost.

Keywords: Fly ash, hybrid composite, mechanical behaviour, stir-cast.

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Authors: M. Chandrasekaran, D. Devarasiddappa

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Metal matrix composites have been increasingly used as materials for components in automotive and aerospace industries because of their improved properties compared with non-reinforced alloys. During machining the selection of appropriate machining parameters to produce job for desired surface roughness is of great concern considering the economy of manufacturing process. In this study, a surface roughness prediction model using fuzzy logic is developed for end milling of Al-SiCp metal matrix composite component using carbide end mill cutter. The surface roughness is modeled as a function of spindle speed (N), feed rate (f), depth of cut (d) and the SiCp percentage (S). The predicted values surface roughness is compared with experimental result. The model predicts average percentage error as 4.56% and mean square error as 0.0729. It is observed that surface roughness is most influenced by feed rate, spindle speed and SiC percentage. Depth of cut has least influence.

Keywords: End milling, fuzzy logic, metal matrix composites, surface roughness

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Authors: A. Udayakumar, M. Rizvan Basha, M. Stalin, V.V Bhanu Prasad

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Three dimensional non-Interlaced carbon fibre reinforced silicon carbide (3-D-Cf/SiC) composites with pyrocarbon interphase were fabricated using isothermal chemical vapor infiltration (ICVI) combined with polymer impregnation pyrolysis (PIP) process. Polysilazane (PSZ) is used as a preceramic polymer to obtain silicon carbide matrix. Thermo gravimetric analysis (TGA), Infrared spectroscopic analysis (IR) and X-ray diffraction (XRD) analysis were carried out on PSZ pyrolysed at different temperatures to understand the pyrolysis and obtaining the optimum pyrolysing condition to yield β-SiC phase. The density of the composites was 1.94 g cm-3 after the 3-D carbon preform was SiC infiltrated for 280 h with one intermediate polysilazane pre-ceramic PIP process. Mechanical properties of the composite materials were investigated under tensile, flexural, shear and impact loading. The values of tensile strength were 200 MPa at room temperature (RT) and 195 MPa at 500°C in air. The average RT flexural strength was 243 MPa. The lower flexural strength of these composites is because of the porosity. The fracture toughness obtained from single edge notched beam (SENB) technique was 39 MPa.m1/2. The work of fracture obtained from the load-displacement curve of SENB test was 22.8 kJ.m-2. The composites exhibited excellent impact resistance and the dynamic fracture toughness of 44.8 kJ.m-2 is achieved as determined from instrumented Charpy impact test. The shear strength of the composite was 93 MPa, which is significantly higher compared 2-D Cf/SiC composites. Microstructure evaluation of fracture surfaces revealed the signatures of fracture processes and showed good support for the higher toughness obtained.

Keywords: 3-D-Cf/SiC, charpy impact test, composites, dynamic fracture toughness, polysilazane, pyrocarbon, Interphase.

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Authors: Samra Isadounene, Amar Boukerrou, Dalila Hammiche

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In this work, the composites were prepared with poly(lactic acid) (PLA) and olive husk flour (OHF) with different percentages (10, 20 and 30%) using extrusion method followed by injection molding. The morphological, mechanical properties and thermal behavior of composites were investigated. Tensile strength and elongation at break of composites showed a decreasing trend with increasing fiber content. On the other hand, Young modulus and storage modulus were increased. The addition of OHF resulted in a decrease in thermal stability of composites. The presence of OHF led to an increase in percentage of crystallinity (Xc) of PLA matrix.

Keywords: Biopolymers, composites, mechanical properties, poly(lactic acid).

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Authors: K. Broniszewski, J. Woźniak, K. Czechowski, P. Orłowski, A. Olszyna

Abstract:

Alumina matrix composites with addition of hexagonal boron nitride (hBN), acting as solid lubricant, were produced. Main purpose of solid lubricants is to dispose the necessity of using cooling lubricants in machining process. Hot pressing was used as a consolidating process for Al2O3-x%wt.hBN (x=1/ 2,5/ 5 /7,5 /10) composites. Properties of sinters such as relative density, hardness, Young-s modulus and fracture toughness were examined. Obtained samples characterize by high relative density. Hardness and fracture toughness values allow the use of alumina – hBN composites for machining steels even in hardened condition. However it was observed that high weight content of hBN can negatively influence the mechanical properties of composites.

Keywords: Alumina. Composites, Hexagonal boron nitride, Machining

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Authors: M. Palizvan, M. T. Abadi, M. H. Sadr

Abstract:

Due to variations in damage mechanisms in the microscale, the behavior of fiber-reinforced composites is nonlinear and difficult to model. To make use of computational advantages, homogenization method is applied to the micro-scale model in order to minimize the cost at the expense of detail of local microscale phenomena. In this paper, the effective stiffness is calculated using the homogenization of nonlinear behavior of a composite representative volume element (RVE) containing fiber-matrix debonding. The damage modes for the RVE are considered by using cohesive elements and contacts for the cohesive behavior of the interface between fiber and matrix. To predict more realistic responses of composite materials, different random distributions of fibers are proposed besides square and hexagonal arrays. It was shown that in some cases, there is quite different damage behavior in different fiber distributions. A comprehensive comparison has been made between different graphs.

Keywords: Homogenization, cohesive zone model, fiber-matrix debonding, RVE.

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