Abstract: Overview of the development history of aluminum matrix composites and the status of research at home and abroad, focusing on the silicon carbide particles reinforced aluminum matrix composites preparation process
development status. Meanwhile, the problems still exist in the research of silicon carbide particles reinforced aluminum matrix composites are explained, on the basis of which the development prospect of this composite material is envisioned.
Keywords: SiCp /Al composites; preparation method
Chinese Figure Classification Number: TB333 Literature Identification Number: A Article Number: 1001-3814(2011)12-0092-05
Research Status and Development Trend of SiCP/ Al Composite
ZHENG Xijun, MI Guofa
(College of Material Science and Engineer, Henan Polytechnic University, Jiaozuo 454000, China)
Abstract: The development history, domestic and foreign research present situation of SiCP /Al composite wasintroduced, the research progress of preparation process for SiCP /Al composite was
introduced, the research progress of preparation process for SiCP /Al composite were elaborated, the research on SiCP /Al
composite was analyzed and the development The research on SiCP /Al
composite was analyzed and the development prospect of the composite was put forward.
Key words: SiCp /Al composite; preparation methods
Received:2010-11-20
Author's introduction:Zheng Xijun(1982-),Male ), male, Xiping, Henan Province, master's degree, research direction for material
Material Processing Engineering; Tel: 0391-3987472; E-mail:zxjdaili@126.com
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Application of a wide range of attention and research, from the preparation process,
organizational structure, mechanical behavior and fracture toughness of the material and other aspects of the basic
foundational work, has made significant achievements. In the United States and Japan and other
countries, the preparation process and performance of such materials has become increasingly mature, in the
electronics, military field began to get practical applications. SiC from industrial
abrasives, can be hundreds of tons of production, cheap, SiC particles reinforced aluminum
composites by the United States is regarded as breakthrough progress in the material, and its performance
can be compared with the SiC
composites.
Carbonized
SiC particle-reinforced aluminum composites are the fastest growing and most widely used class of discontinuous reinforced metal composites in the world over the last 20 years, and are considered an ideal lightweight structural material,
especially in the production of pistons and cylinder heads for motor vehicle engines.
Key products such as motor vehicle engine pistons, cylinder heads (cylinder heads), cylinder blocks, etc. and the aerospace industry have broad application prospects [5-7].
In 1986, the U.S. DuralAluminumComposites
Department of the invention of silicon carbide particles reinforced aluminum-silicon alloy of the new technology, the realization of
the casting of aluminum-based composite materials for large-scale production in the form of ingots
supplied to a number of foundries to manufacture a variety of parts [8-9]. In Canada, Duralcan (USA)
has built a specialized plant with an annual production capacity of 11,340 t of SiC/Al composites
profiles, rods, ingots, and composite parts. At present, the yield strength of 20% SiCp/A356Al composite materials produced by Duralcan
is 75% higher than that of the base aluminum alloy, the modulus of elasticity is 30% higher, the coefficient of thermal expansion is 29% lower, and the abrasion resistance is improved by 3 to 4
times. American DWA company produces silicon carbide reinforced composites with
SiCp content increases, only the elongation decreases, other properties are
greatly improved. So far, SiCp/Al composites have been
successfully used in aerospace, electronics industry, advanced weapon systems, optical
precision instruments, automotive industry and sporting goods, and have achieved great
economic benefits. Table 1 lists some of the force
academic properties of SiCp/Al composites.
Currently, domestic research institutes and universities engaged in the research and development of SiC particles reinforced aluminum composite
composite materials are mainly the Beijing Institute of Aeronautical Materials
Research Institute, Shanghai Jiao Tong University, Harbin Institute of Technology, Northwestern Polytechnical
University, University of Science and Technology for National Defense and so on. Harbin Institute of Technology developed
SiCw/Al for a satellite antenna wire rod, Beijing Institute of Aeronautical Materials
developed SiCp/Al for a satellite remote sensor calibration device [10-11].
Domestic so far there is no high-quality and high-performance carbon
SiCp particles reinforced aluminum composite materials, although some of the performance has reached
Foreign products, but in the dimensional accuracy of the product there is still a small gap, in addition to the manufacturing cost is too high, away from the industrialization of the production of there is still a
a distance to go.
2 Aluminum matrix composites performance characteristics
(1) high specific strength, specific modulus due to the addition of
in the metal matrix
the appropriate amount of high strength, high modulus, low density of the reinforcement, obviously
higher composite material specific strength and specific modulus, especially high-performance connecting
continuous fibers, such as boron fiber, carbon (graphite) fiber, silicon carbide fibers and other reinforcements
strength, they have high strength and modulus [1].
(2) Good high-temperature performance, a wide range of use temperature reinforced fibers
Weaves, whiskers, particles are mainly inorganic, at high temperatures with good
high-temperature strength and modulus, so the metal matrix composites than the matrix metal
have a higher high-temperature performance. In particular, continuous fiber-reinforced metal matrix composites
have high-temperature properties that can be maintained close to the melting point of the metal and are much higher than those of the
metal matrix.
(3) good thermal and electrical conductivity of metal matrix composites
Metal matrix occupies a high volume percentage, generally in 60%
on, so still maintain the good thermal and electrical conductivity of the metal.
(4) good wear resistance metal matrix composites, especially ceramic
Ceramic fibers, whiskers, particles reinforced metal matrix composites have good
wear resistance. This is due to the addition of a large number of fine ceramic
particle reinforcement in the matrix, ceramic particles of high hardness, wear resistance, chemical stability,
with them to enhance the metal not only to improve the strength and stiffness of the material,
but also to improve the hardness and wear resistance of the composite material.
(5) small coefficient of thermal expansion, good dimensional stability of metal-based composite
materials used in the reinforcing phase of carbon fibers, silicon carbide fibers, whiskers, particles
granules, boron fibers, etc. have a very small coefficient of thermal expansion, in particular, ultra-high
modulus graphite fibers have a negative coefficient of thermal expansion, adding a considerable amount of
such reinforcing material can reduce the coefficient of expansion of the material, so as to reduce the expansion coefficient of the material, and thus improve the hardness and wear resistance. The addition of a considerable amount of such
reinforcement can reduce the coefficient of expansion of the material, thus obtaining the thermal expansion
expansion coefficient is less than that of the base metal, dimensional stability of the metal matrix composite
materials.
(6) good fatigue resistance and fracture toughness of metal-based composite
composite material fatigue resistance and fracture toughness of the main factors are the reinforcing material and
composite system preparation process
reinforcement content
(vol,%)
tensile strength
/MPa
Modulus of Elasticity
/GPa
Elongation
(%)
SiCP /2009Al Powder Metallurgy20 572 109 5.3
SiCP/2124Al Powder Metallurgy20 552 103 7.0
SiCP/6061Al Powder Metallurgy20 496 103 5.5
SiCP/7090Al Powder Metallurgy20 724 103 2.5
SiCP/6061Al Powder Metallurgy40 441 125 0.7
SiCP/7091Al Powder Metallurgy15 689 97 5.0
SiCP/A356Al Stir Cast 20 350 98 0.5
SiCP/A359Al unpressurized immersion 30 382 125 0.4
Table 1 Mechanical properties of aluminum matrix composites reinforced by SiC particles[1]
Tab. 1 Mechanical properties of aluminum matrix
composite reinforced by SiC particle
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The interfacial bonding state of the metal matrix, the properties of the metal matrix and the reinforcement itself
and the distribution of the reinforcement in the matrix. In particular, the interfacial
binding strength is moderate, which can effectively transfer the load, but also prevent crack propagation
and thus improve the fracture toughness of the material.
(7) does not absorb moisture, does not age, good airtightness and polymer compared to the nature of the gold
generic stability, dense organization, there is no aging, decomposition, moisture absorption and other problems
problems, and will not occur the natural degradation of performance, the use of space will not decompose
out of low molecular substances and contamination of the instrumentation and the environment, there are obvious advantages.
(8) better secondary processing performance can be utilized in the traditional hot extrusion,
forging and other processing techniques and equipment to achieve secondary
processing of metal matrix composites. As aluminum matrix composites not only have the plasticity and toughness of metal
, but also has a high specific strength, specific modulus, fatigue and creep
resistant, heat-resistant and other excellent comprehensive performance. Especially in the last
20 years, aluminum matrix composites have gained an amazing development rate,
Table 2 lists some mechanical properties of aluminum matrix composites.
3 Main application areas
3.1 Application in aerospace and military fields
ACMC and the Optical Research Center of the University of Arizona
Collaboration has resulted in the development of an ultra-lightweight space telescope and reflector, which has a main mirror diameter of 0.3 m and weighs only 4.54 kg. ACMC
used a powdered aluminum composite material to produce the mirror, which has a diameter of 0.3 m and weighs only 4.54 kg.
Silicon carbide particles made by powder metallurgy to strengthen aluminum matrix composites
also used in laser mirrors, satellite solar mirrors, space remote sensors
scanning with high-speed pendulum mirrors, etc.; the U.S. with a high volume fraction of SiCp/Al
replacement of beryllium material, used in the inertial ring laser gyroscope guidance system, Trident
missile inertial guide ball and tube type Inertial guide ball of Trident
missile and inspection port cover of tubular measurement unit, the cost
is 2/3 lower than beryllium material; in 1980s, the U.S. Lockheed. The United States will be SiCp/6092Al used in the ventral fin of the F-16 fighter aircraft
, instead of the original 2214 aluminum alloy skin, the stiffness is increased
, and the cost is reduced by 2/3 compared with beryllium. Stiffness increased
50%, life from a few hundred hours to about 8000 hours, life
increase 17 times, can greatly reduce the number of maintenance, improve the aircraft's
mobility, but also can be used for the F-16's missile track; British aerospace metal
Metal and composite materials company (AMC) using high-energy ball milling powder metallurgy method
developed a high-energy powder metallurgy method
high-performance ball milling powder metallurgy method
high-performance ball milling powder metallurgy method
The high stiffness and fatigue-resistant SiCp/2009Al developed by AMC has been successfully used in the N4 and EC-120 helicopters produced by Eurocopter[12]; the high volume fraction SiCp/Al prepared by pressureless infiltration method has been used in the F-22 Raptor[13] as a core board for printed circuit boards. "The use of high volume fraction SiCp/Al as printed circuit board core boards for the F-22 Raptor's remote-control
autopilot, power generation, pilot's over-head display, and electronic
counting and measuring arrays has resulted in a 70% reduction in mass and a reduction in the operating temperature of the
electronic templates; SiCp/Al was prepared by pressure-impregnation as a core board for printed circuit boards for use in the F-22 Fighter aircraft. SiCp/Al printed circuit board cores have been used
in earth-orbiting global mobile satellite communication systems; as electronic packaging materials
, they can also be used in the Mars Pathfinder and Cassini rovers
. Saturn probe
spacecraft. The U.S. has adopted high volume fraction SiCp /Al instead of
Cu-W encapsulated alloy as a power module heat sink, which has been used in EV1-type
electric cars and S10 light trucks; and the U.S. has used SiC-Al2O3/Al prepared by oxidation-reaction infiltration method
as additional armor for Desert Storm
. "
Armored vehicles for ground attack; GardenGrove Optical Devices, USA
used SiCp/Al to prepare the Leopardl tank fire-control system sight.
3.2 Applications in the Automotive Industry
SiCp/Al pistons jointly developed by Shandong University and Qufu Jinhuang Piston Co. have been used in motorcycle and small car engines;
Since the 1990s, Ford and Toyota have started to use 20% of Alcan's SiC/Al-Si to make their engines. SiC/Al-Si from Alcan to make brake discs; SiCp/Al automotive brake pads from Lanxide in the United States were put into mass production in 1996[13]; and discs made from this material have been successfully used in high-speed trains at speeds of up to 160km/h in Germany. Integral forged SiCp/Al pistons have been successfully used in Ferrari's Formula 1 cars.
3.3 Applications in sports equipment
The 20% SiCp/2124Al bicycle frame developed by BP has been used
in Raleigh racing cars; SiCp /Al composites can be used in
advanced sporting goods such as bicycle sprockets, golf club heads and tennis rackets; and
in medicine
for the manufacture of prostheses. for the manufacture of prostheses.
4 Preparation and Molding Methods
Generally speaking, depending on the state of the aluminum matrix, the preparation methods of SiCp/Al can be roughly divided into two categories: solid and liquid methods. At present, the main
methods are powder metallurgy, spray deposition, stir casting and extrusion casting
method.
4.1 Powder Metallurgy Method
Powder metallurgy method is also known as solid-state metal diffusion method, which is due to the gram
Reinforcement Phase/ Matrix Reinforcement Phase Content
Tensile Strength
/Mpa
Modulus of Elasticity
/GPa
Elongation (%)
SiC/ Al-4Cu 15 476 92 2.3
SiCp /ZL101 20 375 101 1.64
SiCp /ZL101A 20 330 100 0.5
SiCp /6061 25 517 114 4.5
SiCp /2124 25 565 114 5.6
Al2O3 /Al-1.5Mg 20 226 95 5.9
Cf /Al 26 387 112 -
Tab.2 Mechanical properties of metal matrix composite[1]
Tab.2 Mechanical properties of metal matrix composite[1 ]
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Subscribes the disadvantage of the difficulty of the silicon carbide particles in wettability with the molten aluminum alloy, and thus
is the first to be developed and used for the preparation of SiCp/Al. SiCp/Al is one of the first methods to be developed and used for the preparation of SiCp/Al.
Powder metallurgy process routes for the preparation of SiCp/Al are various, and the most
popular and typical process flow is: silicon carbide powder mixed with aluminum alloy powder
end of a cold molding (or cold isostatic pressing), a vacuum degassing, a hot pressing and sintering
knotting (or hot isostatic pressing), a thermomechanical processing (hot extrusion, rolling, forging).
The advantage of the powder metallurgy method is that silicon carbide powder and aluminum alloy powder
The powder can be mixed in any proportion, and the ratio control is accurate and convenient.
Powder metallurgy is a mature process, low molding temperature, basically no
interfacial reaction, stable quality, volume fraction of reinforcement can be higher, can be selected
with fine reinforcement particles. The disadvantage is that the equipment cost is high, the particles are not easy to
uniform mixing, prone to more pores, to carry out secondary processing, in order to
improve the mechanical properties, but often not easy to eliminate the follow-up process;
the structure, shape and size of the parts made by a certain degree of restriction, the complexity of the powder
end of the metallurgical technology process, the sintering shall be in the sealing
Powder metallurgy technology is a complex process, sintering must be carried out in a sealed, vacuum or
protected atmosphere, the preparation cycle is long, the possibility of cost reduction
small, therefore restricting the large-scale application of powder metallurgy method.
4.2 Jet deposition method
Jet deposition was first proposed by Prof. Singer
at Swansea University in 1969[14] and developed into an
industrial scale manufacturing technique by Ospray Metals Ltd. The basic principle of the method is to atomize an
aluminum alloy matrix while adding SiC reinforcement particles,
so that they are deposited together on a water-cooled liner and solidify to obtain an aluminum-based composite
material. The advantages of this process is that the reinforcing body and matrix melt contact time
short, easy to control the reaction between the two; interface wettability requirements are not high,
can eliminate particle segregation and other undesirable organizations, the organization of the fast solidification
signature; short process, simple procedures, high efficiency, is conducive to the realization of the industrial
production. The disadvantage is that the equipment is expensive, the preparation of the material due to porosity
high and poor quality must be secondary processing, generally only made of ingots
or flat plate; a large number of reinforcing particles in the spray process failed to atomize
alloy droplet composite, resulting in a large loss of raw materials, the process control is more complex
mixed, the utilization of reinforcing particles, slower deposition, and higher costs. slower deposition speed and higher cost.
4.3 Stir casting method
The basic principle of stir casting method[15-17]: rely on the strong stirring in the alloy liquid
vortex vortex formed in the negative pressure suction, enhancement particles will be sucked
into the matrix alloy liquid. Specific process route: the particles of reinforcement into the matrix metal melt, through a certain way of stirring and a certain
stirring speed so that the particles of reinforcement uniformly dispersed in the metal melt
in order to achieve the purpose of mixing each other with the infiltration of the particles
reinforcement of the metal matrix composites melt. Then can be cast into ingot billets, castings
and other uses. The advantages of this method are: simple process, less investment in equipment, high production
efficiency, low manufacturing costs, and can be produced on a large scale. Disadvantages are: add
the enhancement of the body particle size can not be too small, otherwise with the base metal liquid
infiltration is poor, not easy to enter the metal liquid or in the metal liquid is easy to agglomerate
and aggregation; the prevalence of interfacial reactions, strong stirring easily caused by the oxidation of the metal
metal liquid, a large number of suction and inclusions into the mix, the particles added to the amount of
to a certain limit, can only be made of casting, and can only be used to make the casting, the production efficiency, manufacturing costs, and can be produced in large scale. >To a certain limit, can only be made into ingots, the need for secondary processing.
4.4 Squeeze casting method
Squeeze casting method is the first SiC particles with the appropriate binder adhesion
junction, made of prefabricated blocks into the casting model, preheated to a certain temperature,
then pour the base metal liquid, immediately pressurized, so that the molten metal melt immersed in
infiltration into the prefabricated blocks, and finally de-pressurized, cooled and solidified. The advantages of this method
are: simpler equipment and less investment, simple and stable process
better, shorter production cycle, easy to industrialize production, can achieve nearly residual
volume molding, higher volume fraction of reinforcement, basically no interfacial reaction. Disadvantages
is prone to gas or inclusions, defects are more, need to enhance the particles
need to be made in advance of the pre-molded body, the pre-molded body of the product quality has a great impact,
mold cost is high, and the production of complex parts is more difficult.
5 SiCp / Al composite materials development proposals and countermeasures
SiCp / Al composite materials as a new structural material has
broad prospects for development, but to realize the industrialization of the need to do a lot of research
research work. In addition to further research on the preparation process, boundary
facial bonding state, and reinforcement mechanism of SiCp/Al composites,
research and development in related fields should also be emphasized.
5.1 Further Improvement of the Existing Preparation Processes and Development of New Processes
The existing process preparation methods have been successfully manufactured composite materials
materials, but it is difficult to be used for industrial production and is still in the laboratory stage of research
stage [18]. SiC particles in the aluminum liquid, so that the liquid viscosity of the liquid metal, flow
reduced, poor filling during casting When the content of SiC particles is increased to 20% or at lower temperatures (<730°C), the fluidity decreases sharply to the extent that normal casting is not possible. In addition, SiC particles have a large surface area, surface energy is
large, easy to adsorb gas and bring into the liquid metal, and the viscosity of the liquid metal is also easy to
involved in the gas and difficult to discharge, resulting in porosity defects. Therefore, the further improvement of the existing
technology and the development of new processes has become the main task of the next research work
.
5.2 Research on follow-up processing
The research on the follow-up
processing of metal matrix composites, such as cutting, welding, heat treatment, etc., is relatively small, which has become a bottleneck limiting its application. The addition of high
strength and high hardness reinforcement makes metal matrix composites
difficult to process [18-19], and the increase in dislocation density due to the large difference in thermal expansion
coefficients between the reinforcement and the matrix alloy also makes metal matrix composites
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The aging behavior of materials is different from that of matrix alloys [20]. In addition, the reinforcement affects the viscosity and fluidity of the weld pool and reacts chemically with the matrix metal, limiting the welding speed and making the welding of metal matrix composites
extremely difficult. Therefore, to solve the problem of poor weldability
has become the main direction of further research.
5.4 Improvement of environmental performance
Metal matrix composites environmental performance research, that is, such as
How to solve the adaptability of metal matrix composites and the environment, to achieve its waste
Recycling has also attracted some scholars to pay attention to the problem of
Relevance of the effective use of resources, the realization of the social and sustainable development, because
Social and economic development of the metal matrix composites, the development of the metal matrix composites, the development of the metal matrix composites and the environment. This
issue is related to the effective utilization of resources and the realization of social sustainable development, so
this research on the environmental performance will be the hot spot of this field in the future research
. As aluminum matrix composites are formed by combining two or more materials with different weaving structures, physical and chemical properties, the technical difficulty of recycling is much greater than that of traditional single materials. With the batch
volume application of aluminum matrix composites, will inevitably face the problem of waste recycling, through the composite material
recycling, not only to reduce the waste pollution of the environment can
reduce the cost of preparation of aluminum matrix composites, reduce the price, and increase the competitiveness of its
other materials, and is conducive to promote their own development. Literature [21]
formulated a mixed salt solvent, the use of molten salt method to successfully separate the reinforcing materials in the particle
granule reinforced aluminum matrix composites, the results show that
use the technology to deal with the particle reinforced aluminum matrix composites, and its recycling
use rate of up to 85%.
6 Conclusion
Compared with aluminum alloy matrix, aluminum matrix composites have higher
use temperature, modulus, and strength, increased thermal stability, and better wear-resistant
damage properties, which will be more and more widely used. However, there are still many questions and problems to be solved in the current
research, such as
How to overcome the outstanding interfacial problems of aluminum matrix composites, and strive
to improve the results of the research will help to improve the production of the application problems; before and after the preparation process
How to improve the finished product of all aspects of the performance
through the heat treatment; how to take advantage of the thermal mismatch due to the thermal mismatch, and how to use the thermal stability and strength increase, and better wear resistance
It will be more and more widely used. How to utilize internal and external stresses due to thermal mismatch to make the material work
in various environments. In addition, the presence of other side-reaction
inclusions in the in-situ reaction and the difficulty of controlling the volume fraction of the reinforcement precisely
are problems that need to be solved.
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