Optimization of cold-sprayed AA2024/Al2O3 metal matrix composites via friction stir processing: Effect of rotation speeds

doi:10.1016/j.jmst.2018.03.016

Abstract

Abstract:

In this study, friction stir processing (FSP) was employed to modify cold-sprayed (CSed) AA2024/Al₂O₃ metal matrix composites (MMCs). Three different rotation speeds with a constant traverse speed were used for FSP. Microstructural analysis of the FSPed specimens reveals significant Al₂O₃ particle refinement and improved particle distribution over the as-sprayed deposits. After FSP, a microstructural and mechanical gradient MMC through the thickness direction was obtained. Therefore, a hybrid technique combining these two solid-state processes, i.e. CS and FSP, was proposed to produce functionally gradient deposits. The Guinier-Preston-Bagaryatskii zone was dissolved during FSP, while the amounts at different rotation speeds were approximately the same, which is possibly due to the excellent thermal conductivity of the used Cu substrate. Mechanical property tests confirm that FSP can effectively improve the tensile performance and Vickers hardness of CSed AA2024/Al₂O₃ MMCs. The properties can be further enhanced with a larger rotation speed with a maximum increase of 25.9% in ultimate tensile strength and 27.4% in elongation at 1500 rpm. Friction tests show that FSP decreases the wear resistance of CSed MMCs deposits due to the breakup of Al₂O₃ particles. The average values and fluctuations of friction coefficients at different rotation speeds vary significantly.

Key words: Cold spray, Friction stir processing, Metal matrix composite, Functionally gradient deposit, Mechanical property, Tribology

Kang Yang, Wenya Li, Chunjie Huang, Xiawei Yang, Yaxin Xu. Optimization of cold-sprayed AA2024/Al₂O₃ metal matrix composites via friction stir processing: Effect of rotation speeds[J]. J. Mater. Sci. Technol., 2018, 34(11): 2167-2177.

Figures/Tables 14

Fig. 1. Morphologies of (a) AA2024 and (b) Al2O3 powders.

Fig. 2. (a) Details of micro-tensile specimen (unit: mm), (b) schematic diagram of FSP and (c) specially designed fixture for tensile tests.

Fig. 3. (a) Typical macroscopic cross-section of FSPed AA2024/Al2O3 MMCs and magnifying views of rectangular area marked in (a) at rotation speeds of (b) 900 rpm, (c) 1200 rpm and (d) 1500 rpm.

Fig. 4. OM micrographs of (a) CSed and FSPed AA2024/Al2O3 MMCs at rotation speeds of (b) 900 rpm, (c) 1200 rpm and (d) 1500 rpm.

Fig. 5. SEM micrographs of (a) CSed and FSPed AA2024/Al2O3 MMCs at rotation speeds of (b) 900 rpm, (c) 1200 rpm and (d) 1500 rpm.

Fig. 6. XRD spectra of CSed and FSPed AA2024/Al2O3 MMCs.

Fig. 7. DSC thermograms of CSed and FSPed AA2024/Al2O3 MMCs.

Fig. 8. Load vs. depth curves obtained from nanoindentation of AA2024 particles of (a) CSed and FSPed state at rotation speeds of (b) 900 rpm, (c) 1200 rpm and (d) 1500 rpm.

Fig. 9. Vickers hardness of AA2024/Al2O3 MMCs.

Fig. 10. Vickers hardness of AA2024/Al2O3 MMCs through thickness marked by arrows in Fig. 3.

Fig. 11. (a) Representative stress-strain curves and (b) UTS and elongation of CSed and FSPed AA2024/Al2O3 MMCs.

Fig. 12. SEM micrographs of fracture surfaces of tensile specimens for (a, b) CSed and FSPed states at rotation speeds of (c, d) 900 rpm, (e, f) 1200 rpm and (g, h) 1500 rpm. (b, d, f, h) are higher magnification images of (a, c, e, g), respectively.

Fig. 13. Variation of friction coefficient with sliding time for CSed and FSPed AA2024/Al2O3 MMCs.

Fig. 14. SEM micrographs of worn-out surfaces after wear tests for (a, b) CSed and FSPed states at rotation speeds of (c, d) 900 rpm, (e, f) 1200 rpm and (g, h) 1500 rpm. (b, d, f, h) are higher magnification images of (a, c, e, g), respectively.

References

[1]	M. Barmouz, M.K.B. Givi, Compos. Part A 42 (2011) 1445-1453.
[2]	M. Lekka, D. Koumoulis, N. Kouloumbi, P.L. Bonora, Electrochim. Acta 54(2009) 2540-2546.
[3]	S. Yin, Y.C. Xie, J. Cizek, E.J. Ekoi, T. Hussain, D.P. Dowling, R. Lupoi, Compos.Part B 113 (2017) 44-54.
[4]	C.J. Huang, W.Y. Li, Y.C. Xie, M.P. Planche, H.L. Liao, G. Montavon, J. Mater. Sci.Technol. 33(2017) 338-346.
[5]	M. Barmouz, M.K.B.Givi, J. Seyfi, Mater. Charact. 62(2011) 108-117.
[6]	N. Gangil, A.N. Siddiquee, S. Maheshwari, J. Alloys Compd. 715(2017) 91-104.
[7]	Q.C. Wang, M.H. Chen, Z.M. Shan, C.G. Sui, L. Zhang, S.L. Zhu, F.H. Wang, J.Mater. Sci.Technol. 33(2017) 1416-1423.
[8]	H. Xing, X. Cao, W. Hu, L. Zhao, J. Zhang, Mater. Lett. 59(2005) 1563-1566.
[9]	W. Li, Y. Yang, J. Liu, Y. Zhou, M. Li, S.F. Wen, Q.S. Wei, C.Z. Yan, Y.S. Shi, ActaMater. 136(2017) 90-104.
[10]	H.J. Zhao, L. Liu, Y.T. Wu, W.B. Hu, Compos. Sci. Technol. 67(2007) 1210-1217.
[11]	L. Zhu, J.N. He, D.R. Yan, Y.C. Dong, J.X. Zhang, X.Z. Li, H.L. Liao, Appl. Surf. Sci.257(2011) 10282-10288.
[12]	S. Yin, E.J. Ekoi, T.L. Lupton, D.P. Dowling, R. Lupoi, Mater. Des. 126(2017)305-313.
[13]	H. Assadi, H. Kreye, F. Gartner, T. Klassen, Acta Mater. 116(2016) 382-407.
[14]	S. Grigoriev, A. Okunkova, A. Sova, P. Bertrand, I. Smurov, Surf. Coat. Technol.268(2015) 77-84.
[15]	K. Yang, W.Y. Li, X.P. Guo, X.W. Yang, Y.X. Xu, J. Mater. Sci.Technol. 34(2018)1570-1579.
[16]	W.Y. Li, K. Yang, S. Yin, X.W. Yang, Y.X. Xu, R. Lupoi, J. Mater. Sci.Technol. 34(2018) 440-457.
[17]	M. Yu, X. Suo, W. Li, Y. Wang, H. Liao, Appl. Surf. Sci. 289(2014) 188-196.
[18]	E. Pialago, O. Kwon, C.W. Park, Ceram. Int. 41(2015) 6764-6775.
[19]	T. Peat, A. Galloway, A. Toumpis, P. McNutt, N. Iqbal, Appl. Surf. Sci. 396(2017) 1635-1648.
[20]	K. Yang, W.Y. Li, P.L. Niu, X.W. Yang, Y.X. Xu, J. Alloys Compd. 736(2018)115-123.
[21]	Z. Zhang, D.L. Chen, Mater. Sci. Eng.A 483-484(2008) 148-152.
[22]	A.M. Redsten, E.M. Klier, A.M. Brown, D.C. Dunand, Mater. Sci. Eng. A 201(1995) 88-102.
[23]	M.R. Rokni, C.A. Widener, V.K. Champagne, G.A. Crawford, S.R. Nutt, Surf. Coat.Technol. 310(2017) 278-285.
[24]	P. Coddet, C. Verdy, C. Coddet, F. Debray, Mater. Sci. Eng. A 637 (2015) 40-47.
[25]	Z.Y. Ma, Metall. Mater. Trans. A 39 (2008) 642-658.
[26]	R.S. Mishra, Z.Y. Ma, I. Charit, Mater. Sci. Eng. A 341 (2003) 307-310.
[27]	J. Gandra, R. Miranda, P. Vilaca, A. Velhinho, J.P. Teixeira, J. Mater. Process.Technol. 211(2011) 1659-1668.
[28]	K.J. Hodder, H. Izadi, A.G. McDonald, A.P. Gerlich, Mater. Sci. Eng. A 556 (2012)114-121.
[29]	C.J. Huang, W.Y. Li, M. Yu, M. Planche, H. Liao, G. Montavon, Surf. Coat.Technol. 296(2016) 69-75.
[30]	T. Peat, A. Galloway, A. Toumpis, R. Steel, W.Z. Zhu, N. Iqbal, Mater. Des. 120(2017) 22-35.
[31]	C.J. Huang, W.Y. Li, Y. Feng, Y.C. Xie, M.P. Planche, H.L. Liao, G. Montavon,Mater. Charact. 125(2017) 76-82.
[32]	W. Wang, Q.Y. Shi, P. Liu, H.K. Li, T. Li, J. Mater. Process.Technol. 209(2009)2099-2103.
[33]	S.W. Xu, X.M. Deng, Acta Mater. 56(2008) 1326-1341.
[34]	E.R.I.Mahmoud, K. Ikeuchi, M.Takahashi, Sci. Technol. Weld. Join. 13(2008)607-618.
[35]	H.J. Liu, Y.Y. Hu, C. Dou, D.P. Sekulic, Mater. Charact. 123(2017) 9-19.
[36]	Y. Watanabe, N. Yamanaka, Y. Fukui, Compos. Part A 29 (1998)595-601.
[37]	R. Ghelichi, D. MacDonald, S. Bagherifard, H. Jahed, M. Guagliano, B. Jodoin,Acta Mater. 60(2012) 6555-6561.
[38]	V. Luzin, K. Spencer, M.X. Zhang, Acta Mater. 59(2011) 1259-1270.
[39]	D. Ghanbari, M.K. Asgarani, K. Amini, F. Gharavi, Measurement 104 (2017)151-158.
[40]	A. Shafei-Zarghani, S.F.Kashani-Bozorg, A.Zarei-Hanzaki, Mater. Sci. Eng. A500(2009) 84-91.
[41]	Z.H. Zhang, W.Y. Li, Y. Feng, J.L. Li, Y.J. Chao, Acta Mater. 92(2015) 117-125.
[42]	M. Dumont, A. Steuwer, A. Deschamps, M. Peel, P.J. Withers, Acta Mater. 54(2006) 4793-4801.
[43]	Y.S. Sato, H. Kokawa, M. Enomoto, Metall. Mater. Trans. A 30 (1999)2429-2437.
[44]	Z.H. Zhang, W.Y. Li, Y. Feng, J.L. Li, Y.J. Chao, Mater. Sci. Eng. A 598 (2014)312-318.
[45]	X.L. Feng, H.J. Liu, S.S. Babu, Scr. Mater. 65(2011) 1057-1060.
[46]	M.X. Huang, E.J.Pedro Rivera-Díaz-del-Castillo, B.Olivier, Mech. Mater. 41(2009) 982-988.
[47]	M.A.Munoz-Morris, O.C. Garcia, D.G. Morris, Acta Mater. 50(2002)2825-2836.
[48]	M. Gupta, M.O. Lai, C.Y. Soo, Mater. Sci. Eng. A 210 (1996) 114-122.
[49]	E.R.I. Maahmoud, M. Takahashi, T. Shibayanagi, K. Ikeuchi, Wear 268 (2010)1111-1121.
[50]	A. Ghasemi-kahrizsangi, S.F. Kashani-Bozorg, M. Moshref-Javadi, Surf. Coat.Technol. 276(2015) 507-515.

Optimization of cold-sprayed AA2024/Al₂O₃ metal matrix composites via friction stir processing: Effect of rotation speeds

RichHTML

Knowledge

Abstract

Cite this article

share this article

Figures/Tables 14

References

Related Articles 15

Recommended Articles

Metrics

Comments

[1]	H. Niu, H.C. Jiang, M.J. Zhao, L.J. Rong. Effect of interlayer addition on microstructure and mechanical properties of NiTi/stainless steel joint by electron beam welding [J]. J. Mater. Sci. Technol., 2021, 61(0): 16-24.
[2]	Xiawei Yang, Wenya Li, Siqi Yu, Yaxin Xu, Kaiwei Hu, Yaobang Zhao. Electrochemical characterization and microstructure of cold sprayed AA5083/Al₂O₃ composite coatings [J]. J. Mater. Sci. Technol., 2020, 59(0): 117-128.
[3]	Lin Chen, Mingyu Hu, Jun Guo, Xiaoyu Chong, Jing Feng. Mechanical and thermal properties of RETaO₄ (RE = Yb, Lu, Sc) ceramics with monoclinic-prime phase [J]. J. Mater. Sci. Technol., 2020, 52(0): 20-28.
[4]	Ji Zou, Guo-Jun Zhang, Zheng-Yi Fu. In-situ ZrB₂- hBN ceramics with high strength and low elasticity [J]. J. Mater. Sci. Technol., 2020, 48(0): 186-193.
[5]	Przemysł Kot; aw, BaczmańAndrzej ski, GadalińElż ska; bieta, WrońSebastian ski, WrońMarcin ski, WróMirosł bel; aw, Gizo Bokuchava, ScheffzüChristian k, Krzysztof Wierzbanowski. Evolution of phase stresses in Al/SiC_p composite during thermal cycling and compression test studied using diffraction and self-consistent models [J]. J. Mater. Sci. Technol., 2020, 36(0): 176-189.
[6]	Pablo D. Enrique, Ehsan Marzbanrad, Yahya Mahmoodkhani, Ali Keshavarzkermani, Hashem Al Momani, Ehsan Toyserkani, Norman Y. Zhou. Design of binder jet additive manufactured co-continuous ceramic-reinforced metal matrix composites [J]. J. Mater. Sci. Technol., 2020, 49(0): 81-90.
[7]	Jinxiong Hou, Wenwen Song, Liwei Lan, Junwei Qiao. Surface modification of plasma nitriding on Al_xCoCrFeNi high-entropy alloys [J]. J. Mater. Sci. Technol., 2020, 48(0): 140-145.
[8]	Xiang Qiu, Naeem ul Haq Tariq, Lu Qi, Jun-Rong Tang, Xin-Yu Cui, Hao Du, Ji-Qiang Wang, Tian-Ying Xiong. Influence of particulate morphology on microstructure and tribological properties of cold sprayed A380/Al₂O₃ composite coatings [J]. J. Mater. Sci. Technol., 2020, 44(0): 9-18.
[9]	Zhiqiang Zhang, Changshu He, Ying Li, Lei Yu, Su Zhao, Xiang Zhao. Effects of ultrasonic assisted friction stir welding on flow behavior, microstructure and mechanical properties of 7N01-T4 aluminum alloy joints [J]. J. Mater. Sci. Technol., 2020, 43(0): 1-13.
[10]	Jialin Wu, Li Jin, Jie Dong, Fenghua Wang, Shuai Dong. The texture and its optimization in magnesium alloy [J]. J. Mater. Sci. Technol., 2020, 42(0): 175-189.
[11]	Kaustubh Bawane, Kathy Lu. Microstructure evolution of nanostructured ferritic alloy with and without Cr₃C₂ coated SiC at high temperatures [J]. J. Mater. Sci. Technol., 2020, 43(0): 126-134.
[12]	S.M. Liang, H.M. Ji, X.W. Li. Thickness-dependent mechanical properties of nacre in Cristaria plicata shell: Critical role of interfaces [J]. J. Mater. Sci. Technol., 2020, 44(0): 1-8.
[13]	P.A. Morton, H.C. Taylor, L.E. Murr, O.G. Delgado, C.A. Terrazas, R.B. Wicker. In situ selective laser gas nitriding for composite TiN/Ti-6Al-4V fabrication via laser powder bed fusion [J]. J. Mater. Sci. Technol., 2020, 45(0): 98-107.
[14]	Langlang Zhao, Shitong Wei, Dong Wu, Dianbao Gao, Shanping Lu. δ-ferrite transformation mechanism and its effect on mechanical properties of 316H weld metal [J]. J. Mater. Sci. Technol., 2020, 57(0): 33-42.
[15]	B.W. Dong, S.H. Wang, Z.Z. Dong, J.C. Jie, T.M. Wang, T.J. Li. Novel insight into dry sliding behavior of Cu-Pb-Sn in-situ composite with secondary phase in different morphology [J]. J. Mater. Sci. Technol., 2020, 40(0): 158-167.