Effect of Carbon in Fabrication Al-SiC Nanocomposites for Tribological Application

Glassy Carbon Open-Celled Foams as a Reinforcement in Polymer Matrix Composites Dedicated for Tribological Applications

This work presents the results of a tribological examination of polymer matrix composites reinforced with carbon foams with different porosity. The application of open-celled carbon foams allows an easy infiltration process by liquid epoxy resin. At the same time, carbon reinforcement remains its initial structure, which prevents its segregation in polymer matrix. Dry friction tests, conducted under 0.7, 2.1, 3.5 and 5.0 MPa loads, show that higher friction load results in higher mass loss, but it strongly lowers the coefficient of friction (COF). The change in coefficient of friction is related to the size of the pores of the carbon foam. Open-celled foams with pores size below 0.6 mm (40 and 60 ppi), used as a reinforcement in epoxy matrix, allow to obtain COF twice lower than composite reinforced with 20 ppi open-celled foam. This phenomenon occurs due to a change of friction mechanisms. In composites reinforced with open-celled foams, general wear mechanism is related to destruction of carbon components, which results in solid tribofilm formation. The application of novel reinforcement, in the form of open-celled foams with stable distance between carbon components, allows the decrease of COF and the improvement of stability, even under a very high friction load.

Characteristics of the Surface Topography and Tribological Properties of Reinforced Aluminum Matrix Composite

Due to their excellent synergistic properties, Aluminum Matrix Composites (AMC) have achieved a high degree of prominence in different industries. In addition to strength, the wear resistance of materials is also an important criterion for numerous applications. The wear resistance depends on the surface topography as well as the working conditions of the interacting parts. Therefore, extensive experiments are being conducted to improve the suitability of engineering materials (including AMC) for different applications. This paper presents research on manufactured aluminum metal matrix composites reinforced with 10 wt.% of Al2SiO5 (aluminum sillimanite). The manufactured and prepared samples were subjected to surface topography measurements and to tribological studies both with and without lubricant using a block-on-ring tester. Based on the results, analyses of the surface topography (i.e., surface roughness parameters, Abbott-Firestone curve, and surface defects) as well as of the tribological characteristics (i.a. friction coefficient, linear wear, and wear intensity) were performed. Differences in the surface topography of the manufactured elements were shown. The surface topography had a significant impact on tribological characteristics of the sliding joints in the tests where lubrication was and was not used. Better tribological characteristics were obtained for the surfaces characterized by greater roughness (determined on the basis of both the profile and surface texture parameters). In the case of tribological tests with lubrication, the friction coefficient as well as the wear intensity was significantly lower compared to tribological tests without lubrication. However, lower values of the friction coefficient and wear intensity were still recorded for the surfaces that were characterized by greater roughness. The obtained results showed that it is important to analyze the surface topography because surface characteristics influence tribological properties.

Regeneration of Aluminum Matrix Composite Reinforced by SiCp and GCsf Using Gas Tungsten Arc Welding Technology

The main motivation behind the presented research was the regeneration of the damaged surface of composite materials. The testing of melting and pad welding of the composite surface by Gas Tungsten Arc Welding (GTAW) with alternating current (AC) were carried out. The material of investigation was an AlSi12/SiCp + GCsf hybrid composite made by a centrifugal casting process. The composite was reinforced with 5 wt.% of silicon carbide particles and 5 wt.% of glassy carbon spheres. The composites were investigated in tribological tests. It was found that there was a possibility for modification or regeneration of the surface with pad welding technology. Recommended for the repairs was the pad welding method with filler metal with a chemical composition similar to the aluminum matrix composite (ISO 18273 S Al4047A (AlSi12 [A])). The surface of the pad welding was characterized by the correct structure with visible SiCp. No gases or pores were observed in the pad welding; this was due to a better homogeneity of the silicon carbide (SiCp) distribution in the composite and better filling spaces between liquid metal particles in comparison to the base material. Based on the tribological tests, it was found that the lowest wear was observed for the composite surface after pad welding. This was related to the small number of reinforcing particles and their agreeable bonding with the matrix. The plastic deformation of the Al matrix and scratching by worn particles were a dominant wear mechanism of the surface.

Al Matrix Composites Reinforced by Ti and C Dedicated to Work at Elevated Temperature

In this paper, the applicability of aluminium matrix composites to high-temperature working conditions (not exceeding the Al melting point) was evaluated. The behaviour of Al-Ti-C composites at elevated temperatures was described based on microstructural and phase composition observations for composites heated at temperatures of 540 and 600 °C over differing time intervals from 2 to 72 h. The materials investigated were aluminium matrix composites (AMC) reinforced with a spatial carbon (C) structure covered by a titanium (Ti) layer. This layer protected the carbon surface against contact with the aluminium during processing, protection which was maintained for the material’s lifetime and ensured the required phase compositions of Al₄C₃ phase limitation and AlTi₃ phase creation. It was also proved that heat treatment influenced not only phase compositions but also the microstructure of the material, and, as a consequence, the properties of the composite.

Impact of the Morphology of Micro- and Nanosized Powder Mixtures on the Microstructure of Mg-Mg2Si-CNT Composite Sinters

The problem of preparing a ternary powder mixture, which was meant to fabricate sintered heterophase composite, and consisted of micro- and two nanosized powders, was analyzed. The microsized powder was a pure magnesium, and as nanocomponents, a silicon powder (nSi) and carbon nanotubes (CNTs) with 2% and 1% volume fractions, respectively, were applied. The powder mixtures were prepared using ultrasonic and mechanical mixing in technological fluid, and four mixing variants were applied. The morphology of the powder mixtures was characterized with scanning electron microscopy (SEM), and then, composite sinters were fabricated in a vacuum with hot temperature pressing at 580 °C under 15 MPa pressure, using a Degussa press. The reaction between the nSi and the Mg matrix, which caused the creation of the Mg₂Si phase in the fabricated Mg-Mg₂Si-CNT composite, was confirmed with X-ray diffraction (XRD). The porosity and hardness of the composite sinters were examined, and optical microscopy (OM) and quantitative image analyses were carried out to characterize the microstructure of the composites. In the manufacturing process of the Mg-nSi-CNT mixtures, the best results were the following: first separate de-agglomeration of nanocomponents, then their common mixing, and finally, the deposition of nanocomponents at the surface of the microsized magnesium powder. The applied procedure ensured the uniform layer formation of de-agglomerated nanocomponents on the Mg powder, without re-agglomerated nSi and CNTs. Moreover, this type of powder mixture morphology allows to obtain sinters with lower porosity and higher hardness, which is accompanied by precipitation of a finer Mg₂Si phase. In the Mg-Mg₂Si-CNT composite, the carbon phase was present, and it was located in the magnesium matrix and in silicide.

Tribological Properties of Single (AlSi7/SiCp, AlSi7/GCsf) and Hybrid (AlSi7/SiCp + GCsf) Composite Layers Formed in Sleeves via Centrifugal Casting

When designing the composition and structure of a composite material intended for tribological cooperation, many external and structural factors must be considered. The aim of this research was to compare the tribological properties (wear resistance and friction coefficient) of AlSi7Mg1Sr0.03/SiC_p and AlSi7Mg1Sr0.03/GC_sf single-reinforced composite layers with AlSi7Mg1Sr0.03/SiC_p + GC_sf hybrid composite layer formed in sleeves via vertical centrifugal casting. Profilometry enabled quantitative and qualitative analyses to be performed on the wear traces formed on investigated surfaces. The results show that a hybrid composite layer containing spherical glassy carbon particles had a significantly lower and more stable coefficient of friction (μ) and a higher wear resistance compared with single composite layers. The obtained effect was related to the mechanism of vitreous carbon consumption, which was crushed during operation, and then introduced between the cooperating friction surfaces. In this way, it acted as a solid lubricant, which stabilized the coefficient of friction and reduced the wear process.

Effects of Carbon Source on TiC Particles' Distribution, Tensile, and Abrasive Wear Properties of In Situ TiC/Al-Cu Nanocomposites Prepared in the Al-Ti-C System

The in situ TiC/Al-Cu nanocomposites were fabricated in the Al-Ti-C reaction systems with various carbon sources by the combined method of combustion synthesis, hot pressing, and hot extrusion. The carbon sources used in this paper were the pure C black, hybrid carbon source (50 wt.% C black + 50 wt.% CNTs) and pure CNTs. The average sizes of nano-TiC particles range from 67 nm to 239 nm. The TiC/Al-Cu nanocomposites fabricated by the hybrid carbon source showed more homogenously distributed nano-TiC particles, higher tensile strength and hardness, and better abrasive wear resistance than those of the nanocomposites fabricated by pure C black and pure CNTs. As the nano-TiC particles content increased, the tensile strength, hardness, and the abrasive wear resistance of the nanocomposites increased. The 30 vol.% TiC/Al-Cu nanocomposite fabricated by the hybrid carbon source showed the highest yield strength (531 MPa), tensile strength (656 MPa), hardness (331.2 HV), and the best abrasive wear resistance.

Microstructures and Compressive Properties of Al Matrix Composites Reinforced with Bimodal Hybrid In-Situ Nano-/Micro-Sized TiC Particles

Bimodal hybrid in-situ nano-/micro-size TiC/Al composites were prepared with combustion synthesis of Al-Ti-C system and hot press consolidation. Attempt was made to obtain in-situ bimodal-size TiC particle reinforced dense Al matrix composites by using different carbon sources in the reaction process of hot pressing forming. Microstructure showed that the obtained composites exhibited reasonable bimodal-sized TiC distribution in the matrix and low porosity. With the increasing of the carbon nano tube (CNT) content from 0 to 100 wt. %, the average size of the TiC particles decreases and the compressive strength of the composite increase; while the fracture strain increases first and then decreases. The compressive properties of the bimodal-sized TiC/Al composites, especially the bimodal-sized composite synthesized by Al-Ti-C with 50 wt. % CNTs as carbon source, were improved compared with the composites reinforced with single sized TiC. The strengthening mechanism of the in-situ bimodal-sized particle reinforced aluminum matrix composites was revealed.

Tribological Properties of AlSi12-Al₂O₃ Interpenetrating Composite Layers in Comparison with Unreinforced Matrix Alloy

Alumina–Aluminum composites with interpenetrating network structures are a new class of advanced materials with potentially better properties than composites reinforced by particles or fibers. Local casting reinforcement was proposed to take into account problems with the machinability of this type of materials and the shaping of the finished products. The centrifugal infiltration process fabricated composite castings in the form of locally reinforced shafts. The main objective of the research presented in this work was to compare the tribological properties (friction coefficient, wear resistance) of AlSi12/Al₂O₃ interpenetrating composite layers with unreinforced AlSi12 matrix areas. Profilometric tests enabled both quantitative and qualitative analyses of the wear trace that formed on investigated surfaces. It has been shown that interpenetrating composite layers are characterized by lower and more stable coefficients of friction (μ), as well as higher wear resistance than unreinforced matrix areas. At the present stage, the study confirmed that the tribological properties of the composite layers depend on the spatial structure of the ceramic reinforcement, and primarily the volume and size of alumina foam cells.

The Dry Sliding Wear Properties of Nano-Sized TiCp/Al-Cu Composites at Elevated Temperatures

Nano-sized ceramic particle reinforced aluminum composites exhibit excellent room-temperature mechanical properties. However, there is limited research on the dry sliding wear behavior of those composites at elevated temperatures, which should be one of the major concerns on elevated temperature applications. Here the Al-Cu composites reinforced with nano-sized TiC_p were fabricated. The dry sliding wear behaviors of the nano-sized TiC_p/Al-Cu composites at various temperatures (140–220 °C) and loads (10–40 N) with different TiC_p contents were studied, and the results showed that the nanocomposites exhibited superior wear resistance. For instance, the relative wear resistance of the 0.5 wt.% nano-sized TiC_p/Al-Cu composite was 83.5% higher than that of the Al-Cu matrix alloy at 180 °C under 20 N, and was also 16.5% higher than that of the 5 wt.% micro-sized TiC_p/Al-Cu composite, attributed to the pronounced Orowan strengthening effect of nanoparticles. The wear rates of the nanocomposites were always lower than those of the Al-Cu matrix alloy under the same test condition, which increased with the increase in temperature and load and with the decrease in TiC_p content.