Metal-Matrix Composites: Advances in Analysis, Measurement and Observations: Metal Matrix Composites
Sponsored by: TMS Structural Materials Division, TMS: Composite Materials Committee
Program Organizers: Srivatsan Tirumalai; William Harrigan, Gamma Alloys; Simona Hunyadi Murph, Savannah River National Laboratory
Monday 8:30 AM
March 15, 2021
Room: RM 32
Location: TMS2021 Virtual
Session Chair: Goswami Ramasis, Naval Research Laboratory
8:30 AM Invited
The Mechanical Performance of an In Situ Processed Nickel-Titanium-Graphite Metal Matrix Composites: Influence of Processing: Amit Patil1; Tushar Borkar1; 1Cleveland State University
Nickel-Titanium-Graphite based metal matrix composites (MMC) with in situ formed titanium carbide (TiC), as well as graphite (C) reinforcement in the nickel (Ni) metal matrix, were processed using Mechanical Alloying (MA) and Spark Plasma Sintering (SPS). The objective of this study is to synthesize the Ni-Ti-C composites by altering the C/Ti ratio and characterize to study its effects on mechanical and tribological behavior as compared with SPS processed pure nickel. Results indicated that these composites exhibit refined microstructure and the homogeneously distributed TiC reinforcement in the nickel matrix. Moreover, by tailoring the C/Ti ratio in these composites, an additional graphitic phase is engineered into the microstructure. The steady-state coefficient of friction is obtained for pure nickel and Ni-Ti-C composites. The Ni-Ti-C composites exhibited increment in microhardness, as well as a significant improvement in the tribological behavior as compared to pure nickel.
9:00 AM
Development of Ultra-high Conductivity Metal Composites: Keerti Kappagantula1; Xiao Li1; Woongjo Choi1; Glenn Grant1; 1Pacific Northwest National Laboratory
Ultra-high conductivity metal composites (UCM) developed in the last decade are a highly sought-after technology owing to their application as energy-efficient conductors. Next-generation conductors made with such composites can be used in automobiles, airplanes, and UAVs for light-weighting; in motors and electronics for volumetric savings; and in power grid for energy efficient generation and transmission. In this talk, recent advances in the development of UCMs with nano-carbon additives such as graphene and carbon nanotubes will be presented. Advantages of using melt-free solid phase processing approaches for synthesizing such composites over traditional approaches will be discussed. Material features resulting in ultra-high conductivity will be elaborated. Microstructure, material interfaces, and electron transport pathways conducive for improved electrical performance will be discussed. Effects of carbon additive structure, concentration, and defect density on composite properties will be examined. Finally, current barriers to commercial applications of UCMs and their mitigation strategies will be presented.
9:20 AM Invited
Role of Microstructure on the Potential of MAX and MAB Phases and Their Derivative-based Composites – A Review: Surojit Gupta1; 1University of North Dakota
MAX and MAB phases are novel layered solids. These solids have an instrinsic nanolaminate structure which bestow them with promising properties like machinability, triboactive behavior, low hardness as compared to carbides among others. We have shown that the addition of these solids in metal matrix can also impart enhanced mechanical and triboactive behavior to these metal matrices. In this presentation, I will present a review on the current development in this field. I will also outline some of the applications of MAX or MAB phase reinforced metal composites.
9:50 AM
Microstructure Evolution of Al/Ca Metal-Matrix Composite Conductor Wires by Thermal Aging: Dustin Hickman1; Trevor Riedemann2; Iver Anderson2; 1Iowa State University; 2Ames Laboratory
Existing varieties of overhead high-voltage transmission cable lack versatility for increased specific strength and electrical conductivity, for both AC and DC transmission. Al/Ca deformation formed metal-matrix composite (DMMC) conductors have the potential to reach higher specific strengths and electrical conductivity than widely used aluminum conductor steel reinforced cable and are superior for DC power transmission. A PM route for Al/Ca DMMCs will be described that employs powder blending, die pressing, canning of compacts, warm extrusion, and drawn wire at different levels of deformation strain for testing. The simplistic synthesis, abundance of elemental components, and superior bulk material properties indicate Al/Ca DMMCs will be cost-competitive with industry-leading cable with an increased operational life. Mechanical and microstructural analysis of thermal aging results up to 1000h at 160-200°C informed the selection of an upper operating temperature limit promoted by improved Ca-filament intermetallic reinforcement. Work funded by USDOE-OE through Ames Lab contract DE-AC02-07CH11358.
10:10 AM
Understanding the Mechanical Response of Friction Stir Welded In-situ Processed Aluminum Alloy Metal Matrix Composite: Experimental and Statistical Modelling Approaches: Jimmy Karloopia1; Shaik Mozammil1; Pradeep Jha1; Srivatsan Tirumalai2; 1Indian Institute of Technology; 2University of Akron
The present study discusses the effectiveness of stir casting technique using the mixed salt route method and the joining of obtained in-situ TiB2/Al-Si composites using friction stir butt welding technique. The bimetallic flame-hardened friction stir welding tool with a threaded titanium probe having different shoulder geometries was used for the study. The variation in process parameters; tool shoulder geometry, tool rotational speed, and welding speed significantly affects the properties like ultimate tensile strength, elongation, and micro-hardness of the welds. The change in the grain morphology along with refinement and uniform redistribution of the reinforcement phase was observed with the Titanium weld probe through all the experiments. Microstructural studies were conducted using scanning electron microscopy, high-resolution electron microscopy, and X-Ray diffraction. A statistical model and optimization techniques were used to evaluate the output responses of the joints. A substantial improvement in the joint properties was observed in comparison with base composite.
10:40 AM
The Effect of Titanium Carbide and Spark Plasma Sintering Processing on Nickel-titanium Carbide Composites: Ganesh Walunj1; Tushar Borkar1; 1Cleveland State University
Titanium carbide (TiC) reinforced nickel (Ni) matrix composites were processed via mechanical alloying (MA) followed by spark plasma sintering (SPS) process. Mechanical alloying has gained special attention as a powerful non-equilibrium process for fabricating amorphous and nanocrystalline materials, whereas SPS is a unique technique for processing dense and near net shape bulk alloys with homogenous microstructure. TiC reinforcement varied from 5 to 50 wt.% into nickel matrix to investigate its effect on the microstructure and mechanical behavior of Ni-TiC composites. All Ni-TiC composites powder was MA using planetary high energy ball mill with 400 rpm for 24 hours and then sintered via SPS process at 65 MPa pressure and 900-1200C temperature. All Ni-TiC composites exhibited higher microhardness and compressive strength, as compared to pure nickel due to the presence of homogeneously distributed TiC particles within the nickel matrix, matrix grain refinement, and excellent interfacial bonding between nickel and TiC reinforcement.
11:00 AM
The Tribological Behavior of an In-situ Processed Magnesium Alloy Based Metal Matrix Composite: Arabinda Meher1; Manas Mohan Mahapatra1; 1Indian Institute of Technology Bhubaneswar
Magnesium RZ5/10 wt.% TiB2 in-situ composite was synthesized using self-propagating high temperature synthesis route and its tribological behaviour was investigated for the application in the aerospace industries. The wear behaviour of both RZ5 alloy and RZ5/10 wt.% TiB2 composites were studied using pin-on-disc wear testing apparatus. The wear characteristic was analysed under different loading conditions of 10, 20 and 30 N, and sliding distance of 1000, 2000 and 3000 m. Significant improvement in the wear resistance was observed by the addition of TiB2 reinforcement in the magnesium RZ5 alloy matrix. It was concluded that increasing the applied load wear loss increases with a corresponding decrease in the coefficient of friction. Moreover, with an increase in the sliding distance, both wear loss and coefficient of friction increases. The mechanism of wear and debris formation for both RZ5 alloy and composites at different loading conditions were examined using FESEM.