Friction Stir Processing of Copper-Coated SiC Particulate-Reinforced Aluminum Matrix Composite

Abstract

In the present work, we proposed a novel friction stir processing (FSP) to produce a locally reinforced aluminum matrix composite (AMC) by stirring copper-coated SiC particulate reinforcement into Al6061 alloy matrix. Electroless-plating process was applied to deposit the copper surface coating on the SiC particulate reinforcement for the purpose of improving the interfacial adhesion between SiC particles and Al matrix. The core-shell SiC structure provides a layer for the atomic diffusion between aluminum and copper to enhance the cohesion between reinforcing particles and matrix on one hand, the dispersion of fine copper in the Al matrix during FSP provides further dispersive strengthening and solid solution strengthening, on the other hand. Hardness distribution and tensile results across the stir zone validated the novel concept in improving the mechanical properties of AMC that was realized via FSP. Optical microscope (OM) and Transmission Electron Microscopy (TEM) investigations were conducted to investigate the microstructure. Energy dispersive spectrometer (EDS), electron probe micro-analyzer (EPMA), and X-ray diffraction (XRD) were explored to analyze the atomic inter-diffusion and the formation of intermetallic at interface. The possible strengthening mechanisms of the AMC containing Cu-coated SiC particulate reinforcement were interpreted. The concept of strengthening developed in this work may open a new way of fabricating of particulate reinforced metal matrix composites.

Sintering and Mechanical Properties of (SiC + TiCx)p/Fe Composites Synthesized from Ti3AlC2, SiC, and Fe Powders

“…According to the EDS results in Figure 4 and Figure 5 , it can be known that SiC was found, which agreed well with the OM observations and XRD results in Figure 2 and Figure 3 . There was no reaction between the iron matrix and SiC, and similar results were also found in other kinds of metal-based materials reinforced by SiC [ 12 , 13 , 14 , 15 , 16 ], which means SiC is a stable reinforcer. As to Figure 5 b,d, it shows that Ti was detected in the reinforcing particle area; however, Al was found in the whole observation area.…”

“…The grinding ball material was GCr15 and the mass ratio of the ball to the material was 5:1 with a speed of 300 r/min during the dry grinding process. The fast resistance-sintering technology, based on the equipment adapted from the traditional hot-pressing furnace [ 6 , 9 , 10 , 11 , 12 ], was adopted for the sintering of the cold-pressed samples. The main parameters of the sintering process were pressure, voltage, heating, and holding time.…”

“…This sintering process, which is normally done in a few minutes, makes manufacturing feasible with low costs and produces excellent material properties due to the short processing time [ 5 , 8 ]. With a good load-bearing effect in composites, SiC is a very common reinforcing agent in many metal base materials, such as iron [ 5 , 9 ], aluminum [ 10 , 11 , 12 , 13 ], magnesium [ 14 , 15 ], nickel [ 16 , 17 ], and zinc [ 18 ]. Our previous research results showed that SiC has the best enhancement effect compared with the common candidate reinforcements, such as TiC, TiN, and Cr 3 C 2 in IMCs [ 8 ].…”

Microstructure of In-Situ Friction Stir Processed Al-Cu Transition Zone

“…Metallomatrix composite surface materials modified using friction stir processing (FSP) are state-of-the-art materials, which are intended to combine high strength, wear resistance with high ductility and fatigue resistance of a core metal such as an aluminum alloy [1]. The FSP was originally a process used for surface structural modification, i.e., grain refining, which then was adapted to prepare the metallic matrix composites (MMC) surface coatings by means of introducing various reinforcement particles and admixing them to the matrix metal [1][2][3][4][5][6][7][8][9][10]. The FSP utilizes the friction-generated heat for plasticizing the matrix metal, which then is transferred to the rear zone by means of tool rotation and translational motion.…”

Pd-Free Activation Pretreatment for Electroless Ni-P Plating on NiFe2O4 Particles

“…However, the metallic phase hardly distributes uniformly and easily agglomerates, where the properties are debased dramatically [16,17,18]. A network structure of metallic phase is formed by metal coating on the surface of ceramic particles, where the properties especially conductivity are improved significantly [19,20,21]. …”