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Abstract

In this study, the effect of adding SiC nanoparticles and heat treatment on the mechanical properties and wear behavior of A380 aluminum alloy was investigated. Al A380 aluminum powder and SiC nanoparticles with values (0, 0.5, 1, and 2% wt%) were milled in a planetary ball mill with balls of different diameters (4–10 mm) in an argon atmosphere for 10 hours. After the milling process, a hot press (510°C) was used to produce the samples. The microstructure, mechanical properties, and wear behavior of the samples were examined using an optical and scanning electron microscope (SEM), micro Vickers hardness test, and pin-on-disk test, respectively. To investigate the effect of heat treatment, the samples were placed in a furnace at 530°C for 3 hours, then the sample was quenched with boiling water, then placed in a furnace at 175°C for 16 hours, and then by micro Vickers hardness device, the hardness of the samples were measured. The best hardness of the samples was related to aluminum alloy with 0.5 wt% of SiC nanoparticles. Also, after heat treatment, the hardness of the samples increased significantly. Al A380 2wt% SiC nanocomposite sample represents the greatest wear properties when compared with the other experiment samples.

Keywords

Aluminum matrix nanocomposite SiC nanoparticles microstructure hardness wear behavior

Introduction

There is an increasing tendency toward employing metal matrix composites (MMCs) to improve the efficiency of engineering materials. As a result, MMC manufacturing and utilization have increased in recent years. Aluminum-based discontinuously reinforced MMCs have drawn interest due to their higher strength, modulus, and wear resistance compared to standard aluminum alloys.^1–3 Even though discontinuously reinforced MMCs may not have the comparable particular strength as continuously reinforced composites, their isotropic characteristics have the potential to be efficient wear-resistant materials due to their reasonable cost^4,5 The complicated issue in fabricating particulate-reinforced MMCs is distributing the particles uniformly throughout the matrix without agglomeration and minimal interfacial reactions. Numerous processing techniques, including powder metallurgy, traditional casting, spark plasma sintering, and conventional hot extrusion, were evolved to fabricate MMCs.^2,6 Powder metallurgy seems to be a good technology for fabricating MMCs. The fundamental advantage of this technology over melting procedures is its moderate processing temperature. As a result, there is no response between the matrix and the reinforcement phases.^1,3

On the other hand, excellent reinforcing particle dispersion is feasible. Another benefit of powder metallurgy is its capability to produce products with near-net shapes at a reasonable cost. Hot pressing (HP), one of the powder metallurgy manufacturing processes, produces dense materials. Generally, powder metallurgy composites have intrinsic porosity, and compaction pressure and the volume percentage of reinforcements influence porosity.^7,8 Heat treatment may remove or decrease the sintered porosity. Al₂O₃ and SiC could be considered the two most used ceramic particle reinforcing materials.^6,9 Because of their lower density, great toughness, and high corrosion resistance, aluminum MMCs (AMMCs) have made multiple uses in aerospace, automotive, military, and electronic industries, among others. Aluminum's low wear resistance is a significant disadvantage in various applications. Hard SiC particles have been added as reinforcement to fix it.^4,7

Furthermore, the addition of SiC ceramic nanoparticles to aluminum improves its strength, durability, and corrosion resistance.¹⁰ According to several kinds of research, the wear resistance of MMCs made by powder metallurgy improved with the growing volume fraction of reinforcements. The primary advantage of nano reinforcements is that improved characteristics may be achieved at fewer volume fractions (2%) while micron-scale particle-reinforced MMC requires more significant volume fractions (10%).^8,11 Rahman et al.¹² fabricated Al matrix composites reinforced with 0, 5, 10, and 20 wt% SiC by casting and evaluating the mechanical properties and wear behavior of the composites. Their results showed that the composite reinforced with 20 wt% SiC possessed the highest hardness, tensile strength, and pin-on-disc wear resistance In another study, Kazaz et al.¹³ prepared Al matrix composites with 10 and 50 vol.% SiC by HP under 25 MPa at 525 and 550 MPa. The hardness of the samples increased from 54 Brinell hardness number (BHN) for the matrix alloy to 148 BHN for the sample reinforced with 50 vol.% SiC. In addition, both the tensile strength and elastic modulus are increased by increasing the SiC content of the composite.

SiC nanoparticles were employed in this research to strengthen Al A380 matrix nanocomposites by HP. The influence of pressing type and reinforcing particle weight percent on the wear characteristics, microstructure, relative density, and hardness of specimens were investigated. The research could be employed to determine the optimal processing settings and the critical strengthening methods.

Materials and methods

Materials

Commercially, aluminum alloy (Al A380) powder of the size range∼30–50 μm and 99.95% purity was used for the matrix. The chemical composition of the Al A380 powder as cited by the manufacturer is shown in Table 1 and Figure 1. SiC nanoparticles with a size of 40–100 nm and 99% purity were used as the reinforcement (Figure 1). Figure 2 shows energy-dispersive X-ray spectroscopy (EDS) and map analysis of Al A380 powder via scanning electron microscope (SEM).

Figure 1.

Scanning electron microscope (SEM) micrograph of raw materials used in this research: (a) Al A380 alloy and (b) SiC nanoparticles.

Figure 2.

Energy-dispersive X-ray spectroscopy and map analysis of Al A380 powder.

Table 1.

Al A380 chemical compositions.

Al	Si	Cu	Mn	Mg	Zn	Fe	Ni	Sn
Balance	8.5	3.5	0.5	0.5	3	1.3	0.5	0.35

Fabrication and heat treatment of Al A380-SiC nanocomposites

Al A380 powder and SiC nanoparticles with values (0, 0.5, 1, and 2 wt%) were milled in a planetary ball mill with balls of different diameters (4–10 mm) in an argon atmosphere for 10 hours. To protect the powder from agglomeration and cold welding, 2wt% of stearic acid was added to the mixtures as a process control agent. The ball-to-powder weight ratio was 10:1 at the rotation speed of 250 rpm. After milling, a hot press was used for the preparation of samples. The products were placed in a hot press machine using a graphite mold with a 15 mm diameter; the rate of temperature increase was 10°/min up to the final curing temperature of 510°C for 30 minutes at vacuum and under 50 Mpa pressure. The final samples were prepared with the dimensions of 15 mm diameter and 10 mm height. For heat treatment, the prepared samples were placed in a furnace at 530°C for 3 h. Then, they were quenched in hot water at 95°C. Finally, the prepared samples were placed in a furnace at 175°C for 16 hours to complete precipitation hardening. An optical microscope and SEM were used for the study of the samples’ surface. X-ray diffraction (XRD) analysis was utilized to observe the developed phases.

Hardness and wear tests

The hardness of samples was determined via a micro Vickers hardness testing machine, model MHV-1000Z with 25 gram force for 15 seconds. Hardness measurement was carried out on five points. The wear properties of the prepared samples were investigated using the pin-on-disk method with a chrome steel pin and according to ASTM G99 standards at room temperature and atmosphere. The abrasive pin was made of AISI 52100 steel with a hardness of about 55–60 HRC and a diameter of 6 mm. The end of the pin was spherical with a radius of 3 mm. The applied force, slip distance, and rotation speed were 2 N, 500 m, and 191 rpm.

Result and discussion

Morphology of powder

Before ball milling, the morphology of aluminum alloy powder was spherical and the particle size was almost ∼15 μm. Figure 3 illustrates the SEM micrographs of morphology for the Al A380-SiC nanocomposite powders after 10 hours of milling. It can be observed that in the case of 0.5 wt% SiC, the nanocomposite powders after the milling process changed to flat morphology. However, in the case of 2 wt% SiC, the morphology of powders was more equiaxed. As the amount of SiC nanoparticles increases, the Al alloy powders become finer since hard SiC particles act like milling balls to transfer energy to the metal matrix. Moreover, the addition of hard particles leads to a decrease in the fracture toughness of the Al alloy powders. Therefore, the fracture mechanism is activated sooner during the milling process of the composite powders containing 2 wt% SiC and as a result, the powders become finer.¹⁴

Figure 3.

Morphology of powder after 10 hours of milling. (a) Al A380 alloy, (b) 0.5 wt% silicon carbide nanoparticles, (c) 1 wt% silicon carbide nanoparticles, and (d) 2 wt% silicon carbide nanoparticles.

XRD analysis

Figure 4 shows the phase analysis of the composite fabricated with various weight percentages of SiC. The peaks of aluminum and silicon can be seen. Moreover, owing to the low content of SiC reinforcement, they cannot be observed in any of the samples. Also, the sintering temperature was not high enough to cause either the decomposition of SiC or the formation of intermetallic compounds of Al-C and/or Al-Si. In addition, no unwanted oxide compound can be observed owing to controlling both the milling and sintering atmospheres.¹⁵

Figure 4.

XRD analysis of Al A380 powder with various weight percentages of SiC nanoparticles.

Microstructure characterization

To study the microstructure, sanding and polishing were performed on the surface of the samples. Afterward, the samples were etched according to ASTM E 407-2015 standard using a mixture of 190 ml water, 1 ml HF, 3 ml HCl, and 5 ml HNO₃ for 10 to 20 seconds. The etched samples were studied using an optical microscope.¹⁶

Figure 5 shows the microstructure of the samples with various SiC contents. As can be seen, by increasing the SiC nanoparticles content, the porosity of the samples increases.

Figure 5.

Optical microstructure of metallographic preparation of (a) Al A380 alloy, (b) 0.5 wt% silicon carbide nanoparticles, (c) 1 wt% silicon carbide nanoparticles, and (d) 2 wt% silicon carbide nanoparticles.

Figure 6 represents the metallography of the samples after going through heat treatment. It is clear that the porosity of the samples decreased after heat treatment and the amount of alpha phase in aluminum has increased and adopted a spherical shape to reduce the surface energy.

Figure 6.

Optical microstructure of metallographic preparation of (a) Al A380 alloy, (b) 0.5 wt% silicon carbide nanoparticles, (c) Al 1 wt% silicon carbide nanoparticles, and (d) 2 wt% silicon carbide nanoparticles.

In the Al-Cu system, the solid solubility of copper in the aluminum matrix is restricted and decreases from a maximum value of 5.65 wt% at 548°C to a value of around 0.1 wt% at ambient temperature when temperature follows a declining trend (Figure 7). Therefore, A380 aluminum alloy is the appropriate one to be employed for age hardening (precipitation hardening) because of the lower percentage of copper than 5.65 wt%. In the solubilization treatment, all hard $θ$ precipitates are solved in the soft matrix $α$ in such a way that a solid solution $α$ is created and kept at 530°C. The mechanical properties of the alloy will adversely be affected if melting is undertaken during the solubilization treatment.

After the solubilization treatment, only one phase, that is, $α$ , was detected in the structure of the alloy. As a consequence, the phase $θ$ will not be able to form and precipitate in the matrix because atoms will not have sufficient time to diffuse into favorable places for nucleation. In this case, the structure and chemical composition will be in the form of a supersaturated solid solution, that is, $α_{s s}$ , at the temperature after cooling.¹⁹

In aging, the supersaturated solid solution is heated to a temperature lower than the solution temperature and is allowed time so that the additional solution elements to diffuse and form several precipitates. The precipitates grow over time, and the GP semi-stable phases turn into stable equilibrium precipitates $θ$ which are uniformly dispersed on the surface.¹⁷

Figure 7.

Precipitation hardening treatment.^17,18

Figure 8 represents the metallography of the aluminum before and after heat treatment which shows the formation of a secondary phase as a consequence of heat treatment.

Figure 8.

(a) Al A380 alloy before heat treatment and (b) Al A380 alloy after heat treatment.

To get a better image of the secondary phase sediment, images were taken at higher magnifications using the optical microscope. As can be seen, after the heat treatment, the secondary phase sediment is homogenously formed inside the alpha phase of aluminum (Figure 9).

Figure 9.

Al A380 alloy after heat treatment.

Density

The density of the nanocomposite samples is shown in Supplementary Figure 10. The density of the samples was increased by increasing the loading of SiC nanoparticles to 0.5 wt% but at higher loadings of 1 and 2 wt%, the density of the samples declined. Initially, reinforcing nanoparticles that have a smaller size compared to the substrate particles are placed between substrate particles and fill the available pores. This leads to increasing the density but at high percentage of SiC nanoparticles, agglomeration occurs which will result in a non homogeneous dispersion inside powders. One of the restrictions of EDX and map analyses is their low precision to detect low-weight elements. Therefore, since carbon is lighter than silicon, the map analysis of Si is used to show the distribution of SiC nanoparticles (Supplementary Figure 11). As can be seen, the accumulation of silicon increases with an increase in the content of SiC nanoparticles, which proves the agglomeration of SiC nanoparticles.²⁰ In addition, due to the soft nature of aluminum particles, they can change their shape under pressure but this is not the case for the hard SiC nanoparticles, as a result of that, the density of the composite samples decreases by increasing the SiC nanoparticle amounts that are higher than the optimum loading percentage.²¹

Hardness

The hardness of the nanocomposite samples is shown in Supplementary Figure 12. By increasing the loading of the reinforcement to 0.5 wt%, the hardness of the samples was increased which can be attributed to the fact that SiC nanoparticles act like barriers against displacement motions in the substrate, but the hardness of the samples declined by increasing the SiC content to 1 and 2 wt%. Adding more SiC leads to the formation of three different mechanisms. The first mechanism consists of even more restriction of displacement motions which increases the hardness by increasing the loading of SiC nanoparticles. The second mechanism is related to the difference in thermal expansion coefficient, this coefficient is equal to 21.8 × 10⁻⁶ C⁻¹ for aluminum (A380) and 4 × 10⁻⁶ C⁻¹ for SiC which shows the thermal expansion coefficient of aluminum is 5.5 times higher than SiC.²² The difference in thermal expansion coefficient will show its effect when the samples are cooled down. Due to the difference in length reduction, cracks will appear between reinforcing nanoparticles and the substrate particles. Upon the formation of cracks, stress concentrates at the tip of the crack and leads to the development of the crack which in turn results in decreasing the hardness of the nanocomposites.²³ The third mechanism is related to the density that can be increased by increasing the SiC loading to 0.5 wt% and above this threshold, density and hardness will decrease.

Heat treatment

Heat treatment will result in filling the pores utilizing of the liquid phase. The liquid phase will flow inside the pores and fills them which lead to better bonding between particles and as a consequence, the density and hardness of the samples will increase. In addition to that, performing aging heat treatment results in the formation of secondary phase sediments scattered inside the structure. These sediments restrict the displacement motions across the network leading to the improvement of the hardness (Supplementary Figures 10 and 12).^17,19

Wear test

Supplementary Figure 13 represents the weight loss of the samples during the wear test. It can be observed that by increasing the percentage of SiC nanoparticles, the weight loss decrease. SEM micrographs of the worn surfaces of the samples are shown in Supplementary Figure 14. The unreinforced blend had a high weight loss due to its low hardness. In addition, due to severe plastic deformation, adhesive and scratch abrasion takes place at the same time and the protecting layer cannot stay on the surface which is the reason for the higher weight loss. Although the hardness of the sample containing 0.5 wt% of SiC nanoparticles was more than the other samples, the blend sample with 2 wt% of SiC nanoparticles had a lower weight loss when compared with other samples. The reason for this observation is that at lower reinforcement loadings, they cannot sufficiently restrict the wear of the pin and form a protective layer.²⁴ As a result, adhesive abrasion takes place in those samples but at high reinforcement loadings, the reinforcement nanoparticles protect the contact surface and prevent abrasion. Reinforcing materials form a protecting layer between the surface of the sample and the pin which leads to protection of the sample against abrasion, reduction of deformation, and an increase in scratch abrasion.²⁵

Supplementary Figure 15 shows the map analysis of oxygen with various amounts of SiC. With an increase in the content of SiC nanoparticles, the concentration, and accumulation of oxygen increase on the surface, which indicates the formation of an oxide layer on the surface. The composites containing no SiC or containing low percentages of SiC nanoparticles cannot maintain the oxide layer because of the severe plastic deformation.²⁶

Friction coefficient

In the friction coefficient diagram (Supplementary Figure 16), samples with 1 and 2 wt% of SiC nanoparticles show an increase in friction coefficient at the beginning but over time the friction coefficient decreases and reaches a constant amount. This observation is due to the formation of a protection layer at the surface which decreases the friction coefficient.

The sample without SiC nanoparticles showed a large number of ups and down in the friction coefficient diagram, Bonache et al.²⁷ related these ups and downs to several factors that are effective on friction coefficients such as adhesive abrasion, surface roughness, and abrasive particles. It seems like this sample is deformable, as a result, adhesive abrasion and crushing of the coating to the surrounding of the groove and ball are possible. Repetitive sticking and separation of the ball to the surface of the sample leads to increasing the friction coefficient and its fluctuation. However, Srinivasan et al.²⁸ believe that due to the heat generated from the friction coefficient, the temperature at the contact spot between the ball and the surface of the sample will rise. This, in turn, will result in softening of the contact spot and increasing the formability of the coating but the availability of the SiC nanoparticles prevents this from happening by increasing the thermal stability of the samples.

In the friction coefficient diagram for samples with 1 and 2 wt% of SiC nanoparticles, the coefficient is nearly constant but it has some fluctuations too. Wang et al.²⁹ attributed this to the separation of the reinforcing particles from the substrate. The addition of SiC nanoparticles results in a change from the adhesive abrasion mechanism in samples without nanoparticles to scratch coating in samples with 1 and 2 wt% of nanoparticles. According to the evidence, it can be predicted that the sample with 0.5 wt% of SiC nanoparticles is the threshold of transition from adhesive abrasion to scratch abrasion which means that these two will occur simultaneously.

Conclusion

In this study, the effect of the addition of SiC nanoparticles and heat treatment on the mechanical properties of the aluminum blend A380 was investigated. The main results of this study are as follows:

The optimum hardness before heat treatment belongs to the sample with 0.5 wt% of SiC nanoparticles and after heat treatment belongs to the sample with 2 wt% of the nanoparticles. This effect is due to the negative effect of the reinforcement phase which leads to a reduction in density, and the highest hardness after heat treatment.

Heat treatment results in filling the pores, increasing the density, and hardness of the samples. In addition, performing aging heat treatment leads to the formation of secondary phase sediments that prevent dislocation movements across the entire network and increase the hardness.

Samples with 2 wt% of the SiC nanoparticles have the lowest weight loss in the abrasion test due to the formation of a protective layer.

The sample with 0.5 wt% of the SiC nanoparticles is the threshold between adhesive and scratch abrasion which means that both of them occur simultaneously and no protective layer is formed. As a result of that, due to high hardness compared to other samples, this sample has a higher weight loss.

Supplemental Material

sj-docx-1-pie-10.1177_09544089221145482 - Supplemental material for Investigation of microstructure, mechanical properties, and wear behavior of A380 aluminum nanocomposite reinforced with SiC nanoparticles produced by powder metallurgy

Supplemental material, sj-docx-1-pie-10.1177_09544089221145482 for Investigation of microstructure, mechanical properties, and wear behavior of A380 aluminum nanocomposite reinforced with SiC nanoparticles produced by powder metallurgy by Ali Mohammadi and Mohammad Alipour in Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering

Footnotes

Author’s Contribution

Material preparation, data collection, and analysis were performed by Mohammad Alipour and Ali Mohammadi. The first draft of the manuscript was written by Ali Mohammadi and all authors commented on previous versions of the manuscript. All authors read and approved the final manuscript. All authors contributed to the study conception and design.

Declaration of conflicting interests

The authors declared no potential conflicts of interest with respect to the research, authorship, and/or publication of this article.

Funding

The authors received no financial support for the research, authorship, and/or publication of this article.

ORCID iD

Mohammad Alipour

Supplemental material

Supplemental material for this article is available online.

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Supplementary Material

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Investigation of microstructure,mechanical properties,and wear behavior of A380 aluminum nanocomposite reinforced with SiC nanoparticles produced by powder metallurgy

Abstract

Keywords

Introduction

Materials and methods

Materials

Fabrication and heat treatment of Al A380-SiC nanocomposites

Hardness and wear tests

Result and discussion

Morphology of powder

XRD analysis

Microstructure characterization

Density

Hardness

Heat treatment

Wear test

Friction coefficient

Conclusion

Supplemental Material

sj-docx-1-pie-10.1177_09544089221145482 - Supplemental material for Investigation of microstructure, mechanical properties, and wear behavior of A380 aluminum nanocomposite reinforced with SiC nanoparticles produced by powder metallurgy

Footnotes

Author’s Contribution

Declaration of conflicting interests

Funding

ORCID iD

Supplemental material

References

Supplementary Material