Effect of Synthesis Procedure on Particle Dispersion and Hardness of Al- Sic Functionally Graded Metal Matrix Composite

2021 ◽  
pp. 1-26
Author(s):  
Noha M. Hassan ◽  
May Antar ◽  
Natalie Saleem ◽  
Sara Aboukhelil ◽  
Lina Ghonim
Keyword(s):  
Process Parameters ◽  
Metal Matrix ◽  
Volume Fraction ◽  
Desirability Function ◽  
Minimum Cost ◽  
Processing Technique ◽  
Poor Quality ◽  
Particle Dispersion ◽  
Functionally Graded ◽  
Cost Of Poor Quality

Abstract Fabrication of Functionally Graded Metal Matrix Composites (FGMMC) especially with high ceramic reinforcement's volume fraction is highly challenging. Depending on the processing technique and process parameters various defects may arise. This research aims to find the best procedure to make FGMMCs with the highest quality and minimum cost. A new method is proposed that incorporates lost-foam and melt infiltration with semicentrifugal casting to produce FGMMC. Experiments were performed to in-situ fabricate 6061-Aluminum alloy reinforced with gradient distributed Silicon carbide particles (Al/SiC FGMMC). Effect of SiC %, Al pouring temperature and rotational speed on the fabricated specimens hardness and reinforcement gradient were investigated using design of experiments and regression analysis. Results reveal the optimum procedure and process settings based on desired properties/gradient required. Mathematical model formulated captures the effect of these process parameters on process cost, and cost of poor quality. Improper selection of those parameters may lead to extensive losses due cost of poor quality which is 12 times higher than the material cost. The proposed manufacturing process proved satisfactory in ensuring proper dispersion. A desirability function can by used to determine the process parameters and volume fraction that minimizes the defects and gives superior properties for a specific application.

scholarly journals Microstructure Characterization of Aluminium Syntactic Functionally Graded Composites Containing Hollow Ceramic Microspheres Manufactured by Radial Centrifugal Casting

2008 ◽  
Vol 587-588 ◽  
pp. 207-211 ◽  
Author(s):  
S.C. Ferreira ◽  
Alexandre Velhinho ◽  
L.A. Rocha ◽  
Francisco Manuel Braz Fernandes
Keyword(s):  
Metal Matrix ◽  
Radial Direction ◽  
Volume Fraction ◽  
Centrifugal Casting ◽  
Particle Volume Fraction ◽  
Particle Diameter ◽  
Functionally Graded ◽  
Particle Volume ◽  
Centrifugally Cast ◽  
Functionally Graded Composites

Syntactic functionally graded metal matrix composites (SFGMMC) are a class of metallic foams in which closed porosity results from the presence of hollow ceramic microspheres (microballoons), whose spatial distribution varies continuously between the inner and the outer section of the part, thus resulting in a continuous variation in properties. In this work, aluminiumbased SFGMMC rings were fabricated by radial centrifugal casting. The graded composition along the radial direction is controlled mainly by the difference in the centrifugal forces which act on the molten metal matrix and the ceramic particles, due to their dissimilar densities. In this case where the density of the SiO2-Al2O3 microballoons is lower than that of molten aluminium, the particles show a tendency to remain closer to the inner periphery of the ring. Thus the microballoon volume fraction increases along the radial direction of the ring from the outer to the inner periphery; in other words, the particle-rich zone is limited to an inner layer of the ring. Precursor conventional MMCs were prepared by stir-casting from the constituent materials, by homogeneously dispersing commercial SiO2-Al2O3 microballoons (particle size: 50 µm; particle volume fraction: 5 and 10 %) within a molten commercial Al-7Si-0.3Mg (A356) alloy. The resulting MMCs were then re-melt and centrifugally cast in order to produce the functionally graded composites. Particle gradients in the centrifugally cast composites were investigated by quantitative image analysis of optical micrographs (for the estimation of the particle volume fraction, mean particle diameter and porosity volume fraction).

Fabrication of Cu-Based Functionally Graded Materials Dispersing Fine Sic Particles by a Centrifugal Mixed-Powder Method

2010 ◽  
Vol 638-642 ◽  
pp. 2160-2165 ◽  
Author(s):  
Hisashi Sato ◽  
Yoshifumi Inaguma ◽  
Yoshimi Watanabe
Keyword(s):  
Solid Particle ◽  
Powder Mixture ◽  
Volume Fraction ◽  
Processing Technique ◽  
Functionally Graded ◽  
Solid Particles ◽  
Mixed Powder ◽  
Powder Method ◽  
Sic Particles ◽  
Graded Material

Recently, a centrifugal mixed-powder method has been proposed as the processing technique of functionally graded material (FGM) containing fine solid-particles. In this study, Cu-based FGM containing SiC particles was fabricated using this technique. Although the density of SiC is smaller than that of Cu, these SiC particles are successfully distributed on surface of the cylindrical FGM. From this result, it is clear the movement of solid particle in powder mixture during casting is small. Therefore, the gradual distribution of the solid particle can be formed by the control of the volume fraction of solid-particles in powder mixture. Also, it is found that smaller SiC particle can improve the hardness on the surface of the FGMs effectively rather than larger one. In this study, the assignment of the centrifugal mixed-powder method was suggested from the obtained results.

Effect of Improved ThO2 Particle Dispersion in Nickel on High-Temperature Strength

1970 ◽  
Vol 28 ◽  
pp. 444-445
Author(s):  
E. R. Kimmel ◽  
H. L. Anthony ◽  
W. Scheithauer
Keyword(s):  
High Temperature ◽  
Metal Matrix ◽  
Oxide Particle ◽  
Oxide Phase ◽  
Dislocation Motion ◽  
Particle Dispersion ◽  
High Temperature Strength ◽  
Strengthening Effect ◽  
Oxide Particles ◽  
The Stability

The strengthening effect at high temperature produced by a dispersed oxide phase in a metal matrix is seemingly dependent on at least two major contributors: oxide particle size and spatial distribution, and stability of the worked microstructure. These two are strongly interrelated. The stability of the microstructure is produced by polygonization of the worked structure forming low angle cell boundaries which become anchored by the dispersed oxide particles. The effect of the particles on strength is therefore twofold, in that they stabilize the worked microstructure and also hinder dislocation motion during loading.

scholarly journals Predictive Computational Model for Damage Behavior of Metal-Matrix Composites Emphasizing the Effect of Particle Size and Volume Fraction

Materials ◽  
2021 ◽  
Vol 14 (9) ◽  
pp. 2143
Author(s):  
Shaimaa I. Gad ◽  
Mohamed A. Attia ◽  
Mohamed A. Hassan ◽  
Ahmed G. El-Shafei
Keyword(s):  
Finite Element ◽  
Metal Matrix Composites ◽  
Metal Matrix ◽  
Volume Fraction ◽  
Particulate Composites ◽  
Aluminum Matrix Composites ◽  
Matrix Composites ◽  
Zone Method ◽  
Stress Strain ◽  
The Matrix

In this paper, an integrated numerical model is proposed to investigate the effects of particulate size and volume fraction on the deformation, damage, and failure behaviors of particulate-reinforced metal matrix composites (PRMMCs). In the framework of a random microstructure-based finite element modelling, the plastic deformation and ductile cracking of the matrix are, respectively, modelled using Johnson–Cook constitutive relation and Johnson–Cook ductile fracture model. The matrix-particle interface decohesion is simulated by employing the surface-based-cohesive zone method, while the particulate fracture is manipulated by the elastic–brittle cracking model, in which the damage evolution criterion depends on the fracture energy cracking criterion. A 2D nonlinear finite element model was developed using ABAQUS/Explicit commercial program for modelling and analyzing damage mechanisms of silicon carbide reinforced aluminum matrix composites. The predicted results have shown a good agreement with the experimental data in the forms of true stress–strain curves and failure shape. Unlike the existing models, the influence of the volume fraction and size of SiC particles on the deformation, damage mechanism, failure consequences, and stress–strain curve of A359/SiC particulate composites is investigated accounting for the different possible modes of failure simultaneously.

scholarly journals An Intrinsic Material Tailoring Approach for Functionally Graded Axisymmetric Hollow Bodies Under Plane Elasticity

2021 ◽  
Author(s):  
Hassan Mohamed Abdelalim Abdalla ◽  
Daniele Casagrande
Keyword(s):  
Optimization Problem ◽  
Volume Fraction ◽  
Minimum Principle ◽  
Equivalent Stress ◽  
Micromechanical Model ◽  
Plane Elasticity ◽  
Functionally Graded ◽  
Pontryagin Minimum Principle ◽  
Volume Fractions ◽  
Material Tailoring

AbstractOne of the main requirements in the design of structures made of functionally graded materials is their best response when used in an actual environment. This optimum behaviour may be achieved by searching for the optimal variation of the mechanical and physical properties along which the material compositionally grades. In the works available in the literature, the solution of such an optimization problem usually is obtained by searching for the values of the so called heterogeneity factors (characterizing the expression of the property variations) such that an objective function is minimized. Results, however, do not necessarily guarantee realistic structures and may give rise to unfeasible volume fractions if mapped into a micromechanical model. This paper is motivated by the confidence that a more intrinsic optimization problem should a priori consist in the search for the constituents’ volume fractions rather than tuning parameters for prefixed classes of property variations. Obtaining a solution for such a class of problem requires tools borrowed from dynamic optimization theory. More precisely, herein the so-called Pontryagin Minimum Principle is used, which leads to unexpected results in terms of the derivative of constituents’ volume fractions, regardless of the involved micromechanical model. In particular, along this line of investigation, the optimization problem for axisymmetric bodies subject to internal pressure and for which plane elasticity holds is formulated and analytically solved. The material is assumed to be functionally graded in the radial direction and the goal is to find the gradation that minimizes the maximum equivalent stress. A numerical example on internally pressurized functionally graded cylinders is also performed. The corresponding solution is found to perform better than volume fraction profiles commonly employed in the literature.

Flexural behavior of functionally graded polymeric composite beams

2021 ◽  
pp. 152808372110003
Author(s):  
M Atta ◽  
A Abu-Sinna ◽  
S Mousa ◽  
HEM Sallam ◽  
AA Abd-Elhady
Keyword(s):  
Flexural Strength ◽  
Volume Fraction ◽  
Stress Gradient ◽  
Polymeric Composite ◽  
Composite Beams ◽  
Functionally Graded ◽  
Flexural Behavior ◽  
Bending Test ◽  
Polymeric Composite Material ◽  
Fiber Volume

The bending test is one of the most important tests that demonstrates the advantages of functional gradient (FGM) materials, thanks to the stress gradient across the specimen depth. In this research, the flexural response of functionally graded polymeric composite material (FGM) is investigated both experimentally and numerically. Fabricated by a hand lay-up manufacturing technique, the unidirectional glass fiber reinforced epoxy composite composed of ten layers is used in the present investigation. A 3-D finite element simulation is used to predict the flexural strength based on Hashin’s failure criterion. To produce ten layers of FGM beams with different patterns, the fiber volume fraction ( Vf%) ranges from 10% to 50%. A comparison between FGM beams and conventional composite beams having the same average Vf% is made. The experimental results show that the failure of the FGM beams under three points bending loading (3PB) test is initiated from the tensioned layers, and spread to the upper layer. The spreading is followed by delamination accompanied by shear failures. Finally, the FGM beams fail due to crushing in the compression zone. Furthermore, the delamination failure between the layers has a major effect on the rapidity of the final failure of the FGM beams. The present numerical results show that the gradient pattern of FGM beams is a critical parameter for improving their flexural behavior. Otherwise, Vf% of the outer layers of the FGM beams, i.e. Vf% = 30, 40, or 50%, is responsible for improving their flexural strength.

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