Professional Documents
Culture Documents
105~112
doi: 10.1007/s12540-013-1017-2
1,*
1. INTRODUCTION
Metals and alloys are generally produced and shaped in
bulk form but can also be intimately combined with another
material that serves to improve their performance: The
resulting material is a metal matrix composite (MMC). This
class of composites encompasses many different materials
that can be distinguished according to their base metal (e.g.,
aluminum, copper, titanium); according to other factors such
as, reinforcement or phase (e.g., fibers, particles, whiskers); or
according to their manufacturing process (e.g., powder
metallurgy, diffusion bonding, infiltration, stir casting) [1].
The choice of traditional materials used in high precision
technology processes are strongly influenced by the materials own performances and processing procedures.
The major advantage of multi-layered composite materials, as compared to classical materials is the possibility to
change the materials thermal and mechanical properties,
which may vary considerably [2]. The possibility to combine
*Corresponding author: dnedelcu@tcm.tuiasi.ro
KIM and Springer, Published 10 January 2013
106
Fig. 1. Types of stratified composites with regular structure: (a) planeparallel layers A, B; dt is the distance of transition from one layer to
another in the direction perpendicular to the layers, (b) parallel corrugated layers, dt and lt are regular distances in the two directions (X and
Y), (c) coaxial layers with constant thickness in a cylinder, and (d)
ball, separate layers of spherical thickness.
2. EXPERIMENTAL PROCEDURES
From the very moment they are incorporated in the liquid
metallic matrix, the reinforcement fibers are in permanent
contact with the alloy. The manner in which the interaction,
mass transfer and static equilibrium stages succeed each
other depends on the temperature, and pressure, and on
possible changes in the chemical composition. During the
manufacturing process, when the liquid alloy is characterized by continuous movement, the diffusion and the mass
transfer at and from the interface liquid alloy - fiber take place
under a stationary regime. After the fiber pre-forms are
infiltrated, as well as after solidification there may appear
conditions for stationary regime diffusion at the interface.
When solidification occurs, the kinetics of the biphasic system processes is conditioned by the non-stationary regime
diffusion of the elements at and from the interphase limit.
Depending on the nature and state of the components, the
factor limiting the complex processes taking place during
the manufacture and solidification of composite materials
may be either the diffusion and mass transfer in heterogeneous systems or the chemical interaction at the interface
level.
The processes taking place on the surface of reinforcement fibers that are completely incorporated in the metallic
melt may be limited either by the resistance to the mass
transfer of a thin static film that covers the fiber or by the
rate of the heterogeneous chemical reactions.
For a radius R fiber whose surface interacts with the liquid alloy in which it is immersed the following possibilities
arise: the chemical reaction rate can be much higher than
the diffusion rate; the diffusion rate can be higher than that
of the chemical reactions and the diffusion rate and the
chemical reaction rate can both be reduced and can act as
Technology for Obtaining Samples of Layered Composite Materials with Metallic Matrix
107
(1)
(3)
XA = XA1 for r = R1
XA = XA2 for r = R2
we obtain:
(5)
(8)
(4)
(1/R1-1/R2)ln((1-mXA)/(1-mXA1))
= (1/R1-1/r)ln((1-mXA2)/(1-mXA1))
(2)
(7)
(9)
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(9) and a spacer ring under the compression mould (7), used to
lift the composite material sample; d) a sampling ring (3)
and e) a temperature sensor (4).
The layered composite manufacturing process requires the
observance of the following stages: manufacture of alloy with
the required chemical composition; pouring mould preheating
at 200 to 300 C; lubrication of the active mould surface
using colloidal graphite; transfer of the semi-fluid suspension in the metallic matrix cavity; fastening of the matrix
onto the hydraulic press table; application of pressure until
full part solidification occurs; composite material removal
from the matrix; matrix cleaning.
All the parts touching the liquid metal are covered with a
graphite film, in order to diminish the friction between the
parts and to limit corrosion.
In addition to its improving the mechanical properties by
decreasing the inner flaws (pores), liquid forging allows
improving of size tolerances and part surfaces, making them
ready to use.
Liquid forging is currently very frequently used in industry for the manufacture of many ferrous or non-ferrous alloys.
The method has been successfully used both on semi-solid
alloys with high melting points and on low melting point
alloys. It has also been increasingly used in CMM.
When conducted under pressure, liquid forging changes
the alloy solidification conditions.
Fig. 4. Taguchi graphs: (a) for model: Pa represents the hydraulic pressure, Mat represents the reinforced material, A is the type of alloy
used, D is the fiber diameter, Rm is the mass ratio between the reinforcement and composite masses, Tp is the metallic matrix preheating
temperature, and (b) standard.
Pa [MPa]
75
100
Mat
Stainless steel mesh with 1.4 mm eye
Fiberglass mesh with 1.4 mm eye
A
AlSi5Cu3Mg
AlSi7Cu2Mg
D [mm]
0,5
0,3
Rm
10
20
Tp [C]
25
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Technology for Obtaining Samples of Layered Composite Materials with Metallic Matrix
Table 2. Assigned columns of independent factors
Factors
Tests number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Pa
Mat
Rm
Tp
1
1
2
2
1
1
2
2
2
2
1
1
2
2
1
1
1
1
2
2
1
1
2
2
1
1
2
2
1
1
2
2
1
2
1
2
2
1
2
1
1
2
1
2
2
1
2
1
1
2
1
2
2
1
2
1
2
1
2
1
1
2
1
2
1
2
2
1
1
2
2
1
1
2
2
1
1
2
1
1
1
2
1
2
1
2
1
2
1
2
1
2
1
1
2
2
109
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temperature has a moderate effect on the mechanical characteristics as a result of the effect the former has on the adherence between the matrix and the reinforcement material.
The fracture strength of a composite material with a metallic
matrix is strongly influenced by the following factors: matrix
fracture strength, reinforcement fracture strength, reinforcement volume (its shape and distribution) and the amount of
intermetallic interface compound. A perfect interface of a
composite material involves the presence of a matrix-reinforcement reaction product, one that does not diminish the
stress bearing section of the reinforcement material.
The tensile test was performed according to the EN
10002-1 European standard, on an INSTRON 3382 (USA)
universal testing machine running Bluehill Series IXTM
software. Here are the sizes of the cylindrical specimen used:
4 mm calibrated diameter, 20 mm inter-mark length, 70 mm
total length and 1 mm/min cross-piece speed. Here are the
equipment characteristics: 100 kN load rating; 0.005 mm/min.
minimum speed; 500 mm/min. maximum speed; 0.0598 m
Fig. 6. Characteristic curves: (a) base alloy, and (b) composite material obtained.
displacement measurement resolution; 0.5% load cell precision; 0.5% displacement transducer precision.
Here are the testing parameters: cross-piece progression
speed vd = 1,0 mm/min; strain temperature = 23 0.5 C (air
conditioned laboratory).
Figure 6(a) shows results for the tensile test conducted on
Fig. 7. The SEM and EDX images in the case of fiberglass reinforcement: (a) image of fibers embedded in aluminum metal matrix (SEM), (b)
elements of the matrix and fiber distribution (EDX), (c), and (d) varying content and fiber matrix elements along the line of the first image.
Technology for Obtaining Samples of Layered Composite Materials with Metallic Matrix
111
Fig. 8. The distribution of elements in the matrix of Al: (a) distribution of elements in Al matrix alloy and stainless steel fibers (EDX), (b) distribution of aluminum inside the matrix, and (c) distribution of silicon inside the matrix.
the base alloy, whereas Fig. 6(b) shows results of the number 9 tensile test.
The image in Fig. 7(a) (SEM-Scanning electron microscope) shows a break area where the glass fibers appear
distributed in different planes from the pressing direction.
Figure 7(b) (EDX-Energy-dispersive X-ray spectroscopy)
shows the distribution of chemical elements on both the
rupture area and the outer surface of the workpiece. The images
in Figs. 7(c) and (d) shows the distribution of elements
along a reference line (Fig. 7(c)) that passes both inside the
rupture area and inside workpiece surface. It can be observed
that on the exterior the workpiece is covered with a layer of
Al alloy and inside the rupture area the O2 content variation
is similar to that of Si. From the image shown in Fig. 7(d) it
can be seen that the Al distribution is not uniform due to
the uncontrolled nature of the fiber direction in the perpendicular plane due to the means of pressing. Another result
is the focus on the distribution of elements in the Al matrix
alloy and the stainless steel fibers (EDX) (Fig. 8(a), this
includes) the distribution of aluminum inside the matrix
(Fig. 8(b)) and the distribution of silicon inside the matrix
(Fig. 8(c)).
4. CONCLUSIONS
Layered composite materials may be used in numerous
fields and industries, depending on their mechanical properties. The layered composite material we created enjoys
virtually double the fracture strength of the basic material
that was used, which means a significant improvement of
the mechanical work of fracturing. Estimation of some properties of multilayer composites can be done by applying
mathematical models of mass transfer at the interface of the
matrix-fiber reinforcement. Distribution of elements in the
fiber-matrix interface, highlighted by EDX analysis, confirms the mathematical model of molar flux established.
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REFERENCES
1. A. Mortensen and Llorca, J. Metal Matrix Composites 40,
15.1 (2010).
2. V. V. Skorokhod, Powder Metallurgy and Metal Ceramics
42, 35 (2003).
3. G. Neagu and Fl. S tefnescu, Metalurgia Int. 15, 24 (2007).
4. T. Altinbalik, Int. J. Modern Manufacturing Technologies
3, 1 (2011).
5. I. Carcea, Materiale Compozite, p. 38, Politehnium, Romania (2008).