Controlling Particle/Metal Interactions in Metal Matrix Composites During Solidification: The Role of Melt Viscosity and Cooling Rate

Renhai Shi, Janet M. Meier, Alan A. Luo

Research output: Contribution to journalArticlepeer-review

23 Scopus citations

Abstract

Abstract: The homogenous dispersion of particles in a metal matrix is of critical importance to the design and manufacturing of particle-reinforced metal matrix composites (MMCs). This work studied the effects of increasing melt viscosity via microalloying and increasing cooling rate on the dispersion of particles in an aluminum-based MMC. A CALculation of PHAse Diagrams (CALPHAD)-based viscosity model was developed for the Al-Ni binary system. This viscosity model was coupled with a particle-capture model to explore particle/metal interactions during solidification. Three composites (Al + TiCp) with and without Ni were cast at different cooling rates. The first composite without Ni cast at a lower cooling rate showed macro-segregation and agglomeration of TiCp along the grain boundaries. The second composite without Ni cast at a higher cooling rate exhibited grain refinement and reduced macro-segregation of TiCp. The third composite alloyed with 1 wt pct Ni and cast at the same higher cooling rate had an improved distribution, and particles > 2 µm in size were captured in the grains. The composite with 1 wt pct Ni had a 45 pct higher melt viscosity and a 31 pct lower critical velocity for capture of TiCp, demonstrating a synergetic effect of increasing viscosity and cooling rate on improving particle dispersion in MMCs.

Original languageEnglish
Pages (from-to)3736-3747
Number of pages12
JournalMetallurgical and Materials Transactions A: Physical Metallurgy and Materials Science
Volume50
Issue number8
DOIs
StatePublished - Aug 15 2019
Externally publishedYes

Funding

The authors gratefully acknowledge the financial support from the Melt R2-2 project funded by LIFT (Lightweight Innovations For Tomorrow), a Manufacturing Institute under the contract from the Office of Naval Research. We thank Prof. Brajendra Mishra and his graduate student Jeremy Fedors (Worcester Polytechnic Institute) for providing the pure Al + TiC samples. We also thank graduate students Emre Cinkilic, Yan Lu, and Xuejun Huang (The Ohio State University) for their help with discussions and technical contributions. p The authors gratefully acknowledge the financial support from the Melt R2-2 project funded by LIFT (Lightweight Innovations For Tomorrow), a Manufacturing Institute under the contract from the Office of Naval Research. We thank Prof. Brajendra Mishra and his graduate student Jeremy Fedors (Worcester Polytechnic Institute) for providing the pure Al + TiCp samples. We also thank graduate students Emre Cinkilic, Yan Lu, and Xuejun Huang (The Ohio State University) for their help with discussions and technical contributions.

Fingerprint

Dive into the research topics of 'Controlling Particle/Metal Interactions in Metal Matrix Composites During Solidification: The Role of Melt Viscosity and Cooling Rate'. Together they form a unique fingerprint.

Cite this