New Processing Route for the Production of Functionally Graded 7075 Al/SiCp Composites through the Combination of Semi-Solid Stirring and Sequential Squeeze Casting

Abstract

Due to the difficult metallurgical conditions during production, advanced processing techniques are required to produce functionally graded metal matrix composites. In this study, we explored a novel approach by using a combination of two different methods to produce Functionally Graded 7075 Al / SiCp composites. First process was direct semi-solid stirring that was used to prevent particle agglomeration, brittle reaction products, floating or settling of the reinforcements and poor wettability for the production of SiCp (wt. 5-20%) reinforced aluminum matrix composites. In the direct semi-solid mixing process, the matrix material remains in a semi-solid state until the reinforcement addition process is completed. The second novel process was sequential squeeze casting to provide liquid diffusion between two composite layers that were used to produce functionally graded aluminum matrix composite. The microstructure and interlayer zones were characterized by using optical microscopy and scanning electron microscopy. The resulting functionally graded material was subjected to spectrometer analyses, density measurements, and metallographic examinations in order to determine the characteristics of its layers and interfacial zones, as well as to assess the formation of the graded structure. The results obtained from this research provide the potential to use this new combined manufacturing method, which is relatively inexpensive, efficient and easily applicable, in order to produce functionally graded SiCp reinforced aluminum composites.