Metal-Matrix Composites: Advances in Processing, Characterization, Performance and Analysis: Self-Healing Composite Materials and Other Composites
Sponsored by: TMS Structural Materials Division, TMS: Composite Materials Committee
Program Organizers: Srivatsan Tirumalai; Pradeep Rohatgi, University of Wisconsin; Simona Hunyadi Murph, Savannah River National Laboratory
Tuesday 2:30 PM
March 1, 2022
Room: 256B
Location: Anaheim Convention Center
Session Chair: Tirumalai S Srivatsan, The University of Akron
2:30 PM Keynote
Design and Fabrication of a Novel Al-based Self-healing Metal-matrix Composite: David Svetlizky1; Baolong Zheng2; Sen Jiang2; Yizhang Zhou2; Lorenzo Valdevit2; Enrique Lavernia3; Julie Schoenung2; Noam Eliaz1; 1Tel-Aviv University; 2University of California, Irvine; 3National Academy of Engineering
The concept of metallic-based self-healing materials has attracted a rapid increase of interest in recent years, yet it is in its infancy. In this Keynote talk we present a novel design of an advanced aluminum-based metal matrix composite (MMC) with self-healing characteristics. The study combines both numerical simulations with experimental work. The design concept consists of a low-melting agent, Zn-8Al (wt.%) alloy microparticles, encapsulated in a metal-based shell and embedded in an Al 5083 matrix. A two-step encapsulation process that yields a uniform, compact, and conformal Co/CoP shell on the Zn-8Al powder is demonstrated. Potential fabrication methodologies and the associated challenges are presented. The liquid-based healing process of the Al-based MMC is implemented via an external thermal treatment of the cracked specimen, which results in full melting of the encapsulated particulates to seal the crack. The first proof-of-concept of this MMC self-healing capability at the macro-scale is presented.
3:00 PM Invited
Particle Injection and Phase Formation in Directed Energy Deposited Nickel-based Superalloy Composites: Sen Jiang1; Baolong Zheng1; Xin Wang1; Benjamin MacDonald1; Yizhang Zhou1; Julie Schoenung1; 1University of California Irvine
Directed energy deposition (DED) has been demonstrated to be an effective alternative in fabricating particle reinforced metal matrix composites (MMCs). The volume fraction of reinforcement particles injected and the interactions between the reinforcement particles and the molten pool can significantly affect the phase formation upon solidification in deposited parts. In this work, two types of nickel-based superalloy composites, Inconel 718/TiC and Haynes 282/TiC, were deposited using laser engineered net shaping (LENSŪ) with premixed powder feedstock. High-speed photography was used to record and analyze the powder flow as well as the powder-molten pool interactions during deposition. The resultant microstructures in the as-deposited parts were characterized with electron microscopy (SEM and TEM). Scheil solidification calculations were performed with Thermocalc software to study the effects of TiC content and elemental segregation on phase formation. The mechanical behavior of the deposited composites was also evaluated, and the related deformation mechanisms are discussed.
3:20 PM Invited
NOW ON-DEMAND ONLY - Solidification Processing of Functionally Graded Metal Matrix Composites: TPD Rajan1; 1CSIR-National Institute for Interdisciplinary Science and Technology
Functionally Graded Materials (FGM) are in their early stages of evolution and expected to have a strong impact on the design and development of new components and structures with better performance. FGM exhibit gradual transitions in the microstructure and/or the composition in a specific direction, the presence of which lead to variation in the functional performance with in a part. Functionally graded metal matrix composites (FGMMC) are potential materials for various applications. Among the various fabrication routes available for FGMMC the ones based on solidification route are preferred because of their economics and capability to make large size products. The present paper describes the solidification processing techniques such as centrifugal casting, sequential casting, selective infiltration and laser melting for FGMMC. The paper describes in details the processing methodologies adopted for tailoring the microstructures and properties in metallic composites by above techniques, the products developed and the prospective areas of applications.
3:45 PM
Recent Advances in Self-healing Metal Matrix Composites: Masum Bellah1; Michael Nosonovsky1; Pradeep Rohatgi1; 1University of Wisconsin Milwaukee
Recent progress in research and development of self-healing metal matrix composites (MMCs) by (a) embedding micro-balloons /capsules /tubes encapsulating a low-melting alloy as a healing agent into the matrix of a higher melting alloy, and by (b) reinforcing metal matrices with long, short, or nanosized NiTi and other shape memory alloy fibers is reviewed. Self-healing mechanisms, advantages and disadvantages of different self-healing concepts in MMCs are discussed. Future challenges, knowledge gaps, and future research directions, including the need for autonomous and multicycle healing capability in MMCs are outlined.
4:05 PM Break
4:20 PM Invited
Tribological Response of Magnesium/Glass Microballoon Syntactic Foams: Vyasaraj Manakari1; Gururaj Parande1; Mrityunjay Doddamani2; Srivatsan Tirumalai3; Manoj Gupta1; 1National University of Singapore; 2National Institute of Technology Karnataka; 3The University of Akron
Magnesium (Mg) based materials have great potential to replace the existing aluminum alloys and steels used in defense, aerospace, and automotive applications due to their excellent specific strength, damping characteristics and impact resistance. Here, we design an ultralow density magnesium/glass microballoon (GMB) syntactic foams with a density of 1.47-1.67 g/cc through Disintegrated Melt Deposition (DMD) technique having extraordinary properties outperforming the existing aluminium and iron syntactic foams in terms of specific strength improvements. Further, the wear resistance of magnesium under dry sliding conditions showed a significant enhancement (~2.5 times) post GMB addition. Abrasion and oxidation were identified as dominant wear mechanisms post worn-surface analysis. Morphology of the worn specimen also indicate that delamination wear which has traditionally limited the competitive advantages of magnesium in safety-critical components for transportation vehicles can be effectively overcome by the development of these proposed syntactic foams which provide unique cushioning effect against the applied load.
4:45 PM
NOW ON-DEMAND ONLY – Wettability of High Pressure Die Cast Aluminium Alloy on SiC and Al2O3 with the Influence of Surfactants: Mahfuz Karim1; Guangyu Liu1; Brian McKay1; Dmitry Eskin1; 1BCAST Brunel University
Replacing components with a substitute lightweight metal matrix composite (MMC) material is a rising trend in the automotive and aerospace industry. The key issue affecting the repeatability and upscaling of the manufacturing process is the poor wettability of reinforcement material with the metal matrix, which subsequently affects the particle distribution and porosity. The wettability of ceramic reinforcement material (SiC and Al2O3) by a high pressure die cast (HPDC) aluminium alloy is investigated at typical casting temperature (680-700oC) by a sessile drop method. Molten drops of alloys are deposited on to reinforcement substrate surface and the contact angle is measured to determine the wettability. Modification to alloy composition is made to produce the best wetting behaviour with the reinforcement material whilst maintaining HPDC alloys criteria. The surfactant addition of Mg, Cu, Bi, Zr and Zn, which lower the surface tension, are assessed to improve the wettability of alloy with the reinforcement.