Fabrication of controlled expansion Al-Si composites by pressureless and spark plasma sintering

Haque, Md. Asraful; Shekhar, Shashank; Murty, S. V. S. Narayana; Ramkumar, J.; Kar, Kamal K.; Mondal, K.

doi:10.1016/j.apt.2018.09.024

Cited by 26 publications

(4 citation statements)

References 26 publications

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“…The DSC chart showed three phase transitions of the coated steel sheet within the measured temperature range from 700 K and 1150 K (Figure 4a). The first endothermic peak at 845 K upon heating was attributed to the melting of eutectic Al-Si phase, and the second peak at 882 K indicated the melting of α(Al) phase according to the Al-Si binary phase diagram [41]. The third peak at 1014 K corresponded to the austenitization of boron steel [42], which was consistent with the dilatometric data ( Figure 4b).…”

Section: Al-si Coatingsupporting

confidence: 86%

Enhancement of Fatigue Endurance by Al-Si Coating in Hot-Stamping Boron Steel Sheet

Tan

et al. 2019

Metals

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Most structural components undertake cyclic loads in engineering and failures always cause catastrophic economic losses and casualties. In the present work, the phase evolution of Al-Si coating of high-strength boron steel during hot stamping was investigated. Two types of 1500 MPa grade boron steel sheets, one with Al-Si coating and the other without, were studied to reveal the effect on the high-cycle fatigue behavior. The as-received continuously hot-dip Al-Si coating was composed of α(Al), eutectic Al-Si and τ5. After hot stamping at 1193 K, three phases formed in this coating: β2, Fe(Al,Si)2 and α(Fe). The experimental results showed that the endurance limit of the coated steel sheet was 370 MPa under 107 fully reversed tension-compression loading cycles as opposed to 305 MPa in the uncoated sheet. Both the coated and the uncoated specimens showed surface-induced transgranular fatigue fractures. In the uncoated sheet, the fatigue cracks were generated from the decarburization surface, but the Al-Si coating effectively prevented the occurrence of near-surface decarburization during high-temperature hot stamping, and the only cracks in the coated steel sheet were initiated at wire-cutting surfaces.

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Section: Al-si Coatingsupporting

confidence: 86%

Enhancement of Fatigue Endurance by Al-Si Coating in Hot-Stamping Boron Steel Sheet

Tan

et al. 2019

Metals

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“…In Taguchi's multifactor orthogonal experimental design, the orthogonal array serves as the foundation [18][19][20]. It is easy to pick sample points that are equally dispersed across the whole factor test for optimum results in multifactor research.…”

Section: Introductionmentioning

confidence: 99%

Optimization of the Spark Plasma Sintering Process for High-Volume Fraction Tungsten Carbide/Al 2025 Composites

Mahesha

Suprabha

Polayya³

et al. 2022

Advances in Materials Science and Engineering

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With an orthogonal experimental design, Spark plasma sintering method was used to create tungsten carbide with Al 2025 composites. Pressure, temperature, and hold time all had an influence on the mechanical characteristics of the composites. Pressure had the greatest effect on density and bending strength, followed by temperature and holding duration. After five minutes of sintering at 556°C under 40 MPa, a 50% tungsten carbide/Al 2025 composite material was produced, resulting in a density of 997.7 percent and a spectacular bending strength of 766.65 MPa. This study revealed the ability of high-volume fraction mixes to support huge loads.

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“…Recently, it was demonstrated that electric current activated sintering (ECAS), commonly known as spark plasma sintering (SPS), has the ability to produce a characteristic eutectic free microstructure in hypereutectic Al− Si alloys for electronic packaging applications. 11,12 However, in electronic device packages, these high thermal conductive hypereutectic Al−Si will be joined to an electrically insulating substrate such as alumina ceramics or a lightweight chassis such as aluminum alloys depending upon the functionality.…”

Section: ■ Introductionmentioning

confidence: 99%

“…To improve the mechanical behavior of hypereutectic Al–Si, the equilibrium acicular eutectic Si structure needs to be modified to be finer in size and possibly globular in shape. , Al–Si alloys potentially cannot replace the existing electronic packaging materials without refinement in characteristic acicular eutectic structure. Recently, it was demonstrated that electric current activated sintering (ECAS), commonly known as spark plasma sintering (SPS), has the ability to produce a characteristic eutectic free microstructure in hypereutectic Al–Si alloys for electronic packaging applications. , However, in electronic device packages, these high thermal conductive hypereutectic Al–Si will be joined to an electrically insulating substrate such as alumina ceramics or a lightweight chassis such as aluminum alloys depending upon the functionality. The conventional joining processes adopted in the electronic industry such as brazing and soldering results in contamination of devices due to the fluxes used .…”

Section: Introductionmentioning

confidence: 99%

On Simultaneous Sintering and Joining by Electric Current Activated Interfacial Eutectic Melting of Al–Si for Electronic Packaging Applications

Thiagarajan

Kamaraj

Jayapalan

et al. 2022

ACS Appl. Eng. Mater.

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Worldwide, exponential growth in energy consumption demands energy efficient and innovative material synthesis techniques. Conventional material joining processes for electronic applications such as brazing and soldering have limitations due to chemically distinct interface materials and multiple step processing. In this work, we have demonstrated a single step metal−ceramic joining and a single step metal−metal joining, without any interface material, using electric current activated eutectic melting during spark plasma sintering. Particulates of hypereutectic Al−Si, a potential candidate for electronic packaging of high-power density electronic components, were sintered and simultaneously joined with a solid alumina substrate. Similarly, hypereutectic Al−Si particulates were sintered and joined with solid aluminum alloy AA6061 as well. The selective interfacial eutectic melting between Al and Si, due to the resistance offered to electric current, aids in simultaneous joining with solid substrates apart from aiding in densification of particulate aggregates. The Al−Si regions at joint interfaces are characterized by finer eutectic silicon formation. The interlaminar shear strengths (ILSS) of Al−Si/AA6061 joints were nearly 3-fold (≈110 MPa) higher than that of Al−Si/Al 2 O 3 joints due to the nature bonding. The absence of a chemically distinct interfacial layer and existence of finer microstructure at the joint interface resulted in excellent structural integrity. Our work paves the way for employing electric current assisted eutectic melting to create metal−ceramic and metal−metal joints.

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Fabrication of controlled expansion Al-Si composites by pressureless and spark plasma sintering

Cited by 26 publications

References 26 publications

Enhancement of Fatigue Endurance by Al-Si Coating in Hot-Stamping Boron Steel Sheet

Enhancement of Fatigue Endurance by Al-Si Coating in Hot-Stamping Boron Steel Sheet

Optimization of the Spark Plasma Sintering Process for High-Volume Fraction Tungsten Carbide/Al 2025 Composites

On Simultaneous Sintering and Joining by Electric Current Activated Interfacial Eutectic Melting of Al–Si for Electronic Packaging Applications

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