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Microstructual Characteristics of Magnesium Metal Matrix Composites
Title
Microstructual Characteristics of Magnesium Metal Matrix Composites.
Creator
Shin, Dongho, Sohn, Yongho, Coffey, Kevin, Suryanarayana, Challapalli, University of Central Florida
Abstract / Description
Magnesium (Mg) Metal matrix composites (MMCs) reinforced by ceramic reinforcements are being developed for a variety of applications in automotive and aerospace because of their strength-to-weight ratio. Reinforcement being considered includes SiC, Al2O3, Carbon fiber and B4C in order to improve the mechanical properties of MMCs. Microstructural and interfacial characteristics of MMCs can play a critical role in controlling the MMCs' mechanical properties. This study was carried out to...
Show moreMagnesium (Mg) Metal matrix composites (MMCs) reinforced by ceramic reinforcements are being developed for a variety of applications in automotive and aerospace because of their strength-to-weight ratio. Reinforcement being considered includes SiC, Al2O3, Carbon fiber and B4C in order to improve the mechanical properties of MMCs. Microstructural and interfacial characteristics of MMCs can play a critical role in controlling the MMCs' mechanical properties. This study was carried out to understand the microstructural and interfacial development between Mg-9wt.Al-1wt.Zn (AZ91) alloy matrix and several reinforcements including SiC, Al2O3, Carbon fibers and B4C. X-ray diffraction, scanning electron microscopy and transmission electron microscopy was employed to investigate the microstructure and interfaces. Al increase in hardness due to the presence of reinforcements was also documented via Vicker's hardness measurements. Thermodynamic consideration based on Gibbs free energy was employed along with experimental results to describe the interfacial characteristics of MMCs. Reaction products from AZ91-SiC and AZ91-Al2O3 interfaces were identified as MgO, since the surface of SiC particles is typically covered with SiO2 and the MgO is the most thermodynamically stable phase in these systems. The AZ91-Carbon fiber interface consist of Al4C3 and this carbide phase is considered detrimental to the mechanical toughness of MMCs. The AZ91-B4C interface was observed to contain MgB2 and MgB2C2. In general, Vicker's hardness increased by 3X due to the presence of these reinforcements.
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Date Issued
2012
Identifier
CFE0004441, ucf:49324
Format
Document (PDF)
PURL
http://purl.flvc.org/ucf/fd/CFE0004441
MECHANICAL CHARACTERIZATION AND NUMERICAL SIMULATION OF A LIGHT-WEIGHT ALUMINUM A359 METAL-MATRIX COMPOSITE
Title
MECHANICAL CHARACTERIZATION AND NUMERICAL SIMULATION OF A LIGHT-WEIGHT ALUMINUM A359 METAL-MATRIX COMPOSITE.
Creator
DeMarco, James, Gordon, Ali, University of Central Florida
Abstract / Description
Aluminum metal-matrix composites (MMCs) are well positioned to replace steel in numerous manufactured structural components, due to their high strength-to-weight and stiffness ratios. For example, research is currently being conducted in the use of such materials in the construction of tank entry doors, which are currently made of steel and are dangerously heavy for military personnel to lift and close. However, the manufacture of aluminum MMCs is inefficient in many cases due to the loss of...
Show moreAluminum metal-matrix composites (MMCs) are well positioned to replace steel in numerous manufactured structural components, due to their high strength-to-weight and stiffness ratios. For example, research is currently being conducted in the use of such materials in the construction of tank entry doors, which are currently made of steel and are dangerously heavy for military personnel to lift and close. However, the manufacture of aluminum MMCs is inefficient in many cases due to the loss of material through edge cracking during the hot rolling process which is applied to reduce thick billets of as-cast material to usable sheets. In the current work, mechanical characterization and numerical modeling of as-cast aluminum A359-SiCp-30% is employed to determine the properties of the composite and identify their dependence on strain rate and temperature conditions. Tensile and torsion tests were performed at a variety of strain rates and temperatures. Data obtained from tensile tests were used to calibrate the parameters of a material model for the composite. The material model was implemented in the ANSYS finite element software suite, and simulations were performed to test the ability of the model to capture the mechanical response of the composite under simulated tension and torsion tests. A temperature- and strain rate-dependent damage model extended the constitutive model to capture the dependence of material failure on testing or service conditions. Trends in the mechanical response were identified through analysis of the dependence of experimentally-obtained material properties on temperature and strain rate. The numerical model was found to adequately capture strain rate and temperature dependence of the stress-strain curves in most cases. Ductility modeling allowed prediction of stress and strain conditions which would lead to rupture, as well as identification of areas of a solid model which are most likely to fail under a given set of environmental and load conditions.
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Date Issued
2011
Identifier
CFE0004007, ucf:49177
Format
Document (PDF)
PURL
http://purl.flvc.org/ucf/fd/CFE0004007
Graphene Oxide Reinforcement in Plasma Sprayed Nickel-5%Aluminum Coatings
Title
Graphene Oxide Reinforcement in Plasma Sprayed Nickel-5%Aluminum Coatings.
Creator
Ward, David, Seal, Sudipta, Vaidyanathan, Raj, Heinrich, Helge, Zhai, Lei, University of Central Florida
Abstract / Description
Metallic plasma sprayed coatings are widely used in the aerospace industry for repair on worn engine components. However, the inherent defects in these coatings limit the variety of repairs and reduce the service life of the repaired parts. A potential solution to overcome this problem is to mix small amounts of inexpensive graphene oxide in the powder feedstock. The incredible strength to weight ratio of graphene oxide makes it a viable additive to improve mechanical properties of metallic...
Show moreMetallic plasma sprayed coatings are widely used in the aerospace industry for repair on worn engine components. However, the inherent defects in these coatings limit the variety of repairs and reduce the service life of the repaired parts. A potential solution to overcome this problem is to mix small amounts of inexpensive graphene oxide in the powder feedstock. The incredible strength to weight ratio of graphene oxide makes it a viable additive to improve mechanical properties of metallic plasma sprayed coatings. The powder system chosen for this research is Nickel-5Aluminum since it is a common coating for such repairs. The greatest challenge was retaining graphene oxide, which combusts at 400(&)deg;C, while melting the Nickel above 1450(&)deg;C using a high temperature plasma plume. Graphene oxide was successfully retained in the coatings using either of two configurations: (1) Injecting the graphene oxide powder via solution suspension separately from the metal powder, or (2) Installing a shroud on the front of the plasma gun and backfilling with Argon to inhibit combustion. The uniquely designed solution suspension configuration resulted in a higher deposition efficiency of graphene oxide while the inert shroud configuration had a more homogeneous distribution and retention of graphene oxide in the coatings. The best overall coating was achieved using the inert shroud configuration using a powder mixture containing 2% weight Edge Functionalized Graphene Oxide. Vickers microhardness increased 46% and tensile adhesion strength increased 26% over control samples. This is possible due to the mechanisms of dislocation strengthening and stress transfer previously reported in graphene oxide reinforced Aluminum composites formed by flake powder metallurgy. It was also observed that the energy released by the combustion of graphene oxide helps to uniformly melt the Nickel particles and improve the coating microstructure, allowing for more forgiving spray parameters. The methods developed and results attained in this research open opportunities for graphene oxide to be added as inexpensive reinforcements to other metallic compositions for widespread use in metal matrix composite manufacturing.
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Date Issued
2014
Identifier
CFE0005901, ucf:50857
Format
Document (PDF)
PURL
http://purl.flvc.org/ucf/fd/CFE0005901
Development of Nitrogen Concentration During Cryomilling of Aluminum Composites
Title
Development of Nitrogen Concentration During Cryomilling of Aluminum Composites.
Creator
Hofmeister, Clara, Sohn, Yongho, Suryanarayana, Challapalli, Coffey, Kevin, University of Central Florida
Abstract / Description
The ideal properties of a structural material are light weight with extensive strength and ductility. A composite with high strength and tailorable ductility was developed consisting of nanocrystalline AA5083, boron carbide and coarser grained AA5083. The microstructure was determined through optical microscopy and transmission electron microscopy. A technique was developed to determine the nitrogen concentration of an AA5083 composite from secondary ion mass spectrometry utilizing a nitrogen...
Show moreThe ideal properties of a structural material are light weight with extensive strength and ductility. A composite with high strength and tailorable ductility was developed consisting of nanocrystalline AA5083, boron carbide and coarser grained AA5083. The microstructure was determined through optical microscopy and transmission electron microscopy. A technique was developed to determine the nitrogen concentration of an AA5083 composite from secondary ion mass spectrometry utilizing a nitrogen ion-implanted standard. Aluminum nitride and amorphous nitrogen-rich dispersoids were found in the nanocrystalline aluminum grain boundaries. Nitrogen concentration increased as a function of cryomilling time up to 72hours. A greater nitrogen concentration resulted in an enhanced thermal stability of the nanocrystalline aluminum phase and a resultant increase in hardness. The distribution of the nitrogen-rich dispersoids may be estimated considering their size and the concentration of nitrogen in the composite. Contributions to strength and ductility from the Orowan relation can be more accurately modeled with the quantified nitrogen concentration.
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Date Issued
2013
Identifier
CFE0004864, ucf:49702
Format
Document (PDF)
PURL
http://purl.flvc.org/ucf/fd/CFE0004864
A modeling framework of brittle and ductile fractures coexistence in composites
Title
A modeling framework of brittle and ductile fractures coexistence in composites.
Creator
Qiao, Yangyang, Bai, Yuanli, Gou, Jihua, Kassab, Alain, Gordon, Ali, An, Linan, University of Central Florida
Abstract / Description
In order to reduce the weight of automobiles and aircrafts, lightweight materials, such as aluminum alloy, advanced high strength steel, composite materials, are widely used to replace the traditional materials like mild steel. Composite materials are complicated in material mechanical properties and less investigated compared to metallic materials. Engineering composites can be categorized into polymer matrix composites (PMCs), metal matrix composites (MMCs) and ceramic matrix composites ...
Show moreIn order to reduce the weight of automobiles and aircrafts, lightweight materials, such as aluminum alloy, advanced high strength steel, composite materials, are widely used to replace the traditional materials like mild steel. Composite materials are complicated in material mechanical properties and less investigated compared to metallic materials. Engineering composites can be categorized into polymer matrix composites (PMCs), metal matrix composites (MMCs) and ceramic matrix composites (CMCs) according to their matrix materials.A set of mechanical experiments ranging from micro scale (single fiber composite and thin film composite) to macro scale (PMCs and MMCs) were conducted to fully understand the material behavior of composite materials. Loading conditions investigated includes uniaxial tension, three-point bending, uniaxial compression, simple shear, tension combined with shear, and compression combined with shear.For single fiber composite and thin-film composite, details of each composition are modelled. For the PMCs and MMCs which have plenty of reinforcements like fibers and particles, the details of the composition of structures cannot be modelled due to the current limitations of computing power. A mechanics framework of composite materials including elasticity, plasticity, failure initiation and post failure softening is proposed and applied to two types of composite materials.Uniaxial tension loading is applied to several single fiber composites and thin film composites. A surprising phenomenon, controllable and sequential fragmentation of the brittle fiber to produce uniformly sized rods along meters of polymer cladding, rather than the expected random or chaotic fragmentation, is observed with a necking propagation process. A combination of necking propagation model, fiber cracking model and interfacial model are proposed and applied to the finite element simulations. Good predictions of necking propagation and uniform fragmentation phenomenon are achieved. This modeling method of the micro-scale phenomenon reveals the physics inside composites in micro scale and helps the understanding of the process of nano fragmentation.Unidirectional carbon fiber composites were tested under multi-axial loading conditions including tensile/compression/shear loadings along and perpendicular to the fiber direction. Compression dominated tests showed a brittle fracture mode like local kicking/buckling, while tension dominated tests showed a fracture mode like delamination and fiber breakage. Simple shear tests with displacement control showed matrix material hardening and softening before total failure. The proposed modeling framework is successfully applied to the PMCs. A new parameter ? was introduced to represent different loading conditions of PMCs. Numerical simulations using finite element method well duplicated the anisotropic elasticity and plasticity of this material. Failure features like delamination was simulated using cohesive surface feature. It is also applied to carbon fiber composite laminates to further validate the proposed model.A round of experimental study on high volume fraction of metallic matrix nano composites was conducted, including uniaxial tension, uniaxial compression, and three-point bending. The example materials were two magnesium matrix composites reinforced with 10 and 15% vol. SiC particles (50nm size). Brittle fracture mode was exhibited under uniaxial tension and three-point bending, while shear dominated ductile fracture mode (up to 12% fracture strain) was observed under uniaxial compression. Transferring the Modified Mohr Coulomb (MMC) ductile fracture model to the stress based MMC model (sMMC), the proposed modeling framework is applied to this material. This model has been demonstrated to be capable of predicting the coexistence of brittle and ductile fracture modes under different loading conditions for MMCs. Numerical simulations using finite element method well duplicated the material strength, fracture initiation sites and crack propagation modes of the Mg/SiC nano composites with a good accuracy.
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Date Issued
2018
Identifier
CFE0007078, ucf:51977
Format
Document (PDF)
PURL
http://purl.flvc.org/ucf/fd/CFE0007078
Experimental study and modeling of mechanical micro-machining of particle reinforced heterogeneous materials
Title
Experimental study and modeling of mechanical micro-machining of particle reinforced heterogeneous materials.
Creator
Liu, Jian, Xu, Chengying, An, Linan, Gordon, Ali, Bai, Yuanli, Gong, Xun, University of Central Florida
Abstract / Description
This study focuses on developing explicit analytical and numerical process models for mechanical micro-machining of heterogeneous materials. These models are used to select suitable process parameters for preparing and micro-machining of these advanced materials. The material system studied in this research is Magnesium Metal Matrix Composites (Mg-MMCs) reinforced with nano-sized and micro-sized silicon carbide (SiC) particles.This research is motivated by increasing demands of miniaturized...
Show moreThis study focuses on developing explicit analytical and numerical process models for mechanical micro-machining of heterogeneous materials. These models are used to select suitable process parameters for preparing and micro-machining of these advanced materials. The material system studied in this research is Magnesium Metal Matrix Composites (Mg-MMCs) reinforced with nano-sized and micro-sized silicon carbide (SiC) particles.This research is motivated by increasing demands of miniaturized components with high mechanical performance in various industries. Mg-MMCs become one of the best candidates due to its light weight, high strength, and high creep/wear resistance. However, the improved strength and abrasive nature of the reinforcements bring great challenges for the subsequent micro-machining process.Systematic experimental investigations on the machinability of Mg-MMCs reinforced with SiC nano-particles have been conducted. The nanocomposites containing 5 Vol.%, 10 Vol.% and 15 Vol.% reinforcements, as well as pure magnesium, are studied by using the Design of Experiment (DOE) method. Cutting forces, surface morphology and surface roughness are characterized to understand the machinability of the four materials. Based on response surface methodology (RSM) design, experimental models and related contour plots have been developed to build a connection between different materials properties and cutting parameters. Those models can be used to predict the cutting force, the surface roughness, and then optimize the machining process.An analytical cutting force model has been developed to predict cutting forces of Mg-MMCs reinforced with nano-sized SiC particles in the micro-milling process. This model is different from previous ones by encompassing the behaviors of reinforcement nanoparticles in three cutting scenarios, i.e., shearing, ploughing and elastic recovery. By using the enhanced yield strength in the cutting force model, three major strengthening factors are incorporated, including load-bearing effect, enhanced dislocation density strengthening effect and Orowan strengthening effect. In this way, the particle size and volume fraction, as significant factors affecting the cutting forces, are explicitly considered. In order to validate the model, various cutting conditions using different size end mills (100 (&)#181;m and 1 mm dia.) have been conducted on Mg-MMCs with volume fraction from 0 (pure magnesium) to 15 Vol.%. The simulated cutting forces show a good agreement with the experimental data. The proposed model can predict the major force amplitude variations and force profile changes as functions of the nanoparticles' volume fraction. Next, a systematic evaluation of six ductile fracture models has been conducted to identify the most suitable fracture criterion for micro-scale cutting simulations. The evaluated fracture models include constant fracture strain, Johnson-Cook, Johnson-Cook coupling criterion, Wilkins, modified Cockcroft-Latham, and Bao-Wierzbicki fracture criterion. By means of a user material subroutine (VUMAT), these fracture models are implemented into a Finite Element (FE) orthogonal cutting model in ABAQUS/Explicit platform. The local parameters (stress, strain, fracture factor, velocity fields) and global variables (chip morphology, cutting forces, temperature, shear angle, and machined surface integrity) are evaluated. Results indicate that by coupling with the damage evolution, the capability of Johnson-Cook and Bao-Wierzbicki can be further extended to predict accurate chip morphology. Bao-Wierzbiki-based coupling model provides the best simulation results in this study. The micro-cutting performance of MMCs materials has also been studied by using FE modeling method. A 2-D FE micro-cutting model has been constructed. Firstly, homogenized material properties are employed to evaluate the effect of particles' volume fraction. Secondly, micro-structures of the two-phase material are modeled in FE cutting models. The effects of the existing micro-sized and nano-sized ceramic particles on micro-cutting performance are carefully evaluated in two case studies. Results show that by using the homogenized material properties based on Johnson-Cook plasticity and fracture model with damage evolution, the micro-cutting performance of nano-reinforced Mg-MMCs can be predicted. Crack generation for SiC particle reinforced MMCs is different from their homogeneous counterparts; the effect of micro-sized particles is different from the one of nano-sized particles.In summary, through this research, a better understanding of the unique cutting mechanism for particle reinforced heterogeneous materials has been obtained. The effect of reinforcements on micro-cutting performance is obtained, which will help material engineers tailor suitable material properties for special mechanical design, associated manufacturing method and application needs. Moreover, the proposed analytical and numerical models provide a guideline to optimize process parameters for preparing and micro-machining of heterogeneous MMCs materials. This will eventually facilitate the automation of MMCs' machining process and realize high-efficiency, high-quality, and low-cost manufacturing of composite materials.
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Date Issued
2012
Identifier
CFE0004570, ucf:49196
Format
Document (PDF)
PURL
http://purl.flvc.org/ucf/fd/CFE0004570