Microstructure and Properties of Aluminum-Graphene-SiC Matrix Composites after Friction Stir Processing.

Enhancing the mechanical properties of conventional ceramic particles-reinforced aluminum (Al 1060) metal matrix composites (AMCs) with lower detrimental phases is difficult. In this research work, AMCs are reinforced with graphene nanosheet (GNS) and hybrid reinforcement (GNS combined with 20% SiC, synthesized by shift-speed ball milling (SSBM), and further fabricated by two-pass friction stir processing (FSP). The effect of GNS content and the addition of SiC on the microstructure and mechanical properties of AMCs are studied. The microstructure, elemental, and phase composition of the developed composite are examined using SEM, EDS, and XRD techniques, respectively. Mechanical properties such as hardness, wear, and tensile strength are analyzed. The experimental results show that the GNS and the SiC are fairly distributed in the Al matrix via SSBM, which is beneficial for the mechanical properties of the composites. The maximum tensile strength of the composites is approximately 171.3 MPa in AMCs reinforced by hybrid reinforcements. The tensile strength of the GNS/Al composites increases when the GNS content increases from 0 to 1%, but then reduces with the further increase in GNS content. The hardness increases by 2.3%, 24.9%, 28.9%, and 41.8% when the Al 1060 is reinforced with 0.5, 1, 2% GNS, and a hybrid of SiC and GNS, respectively. The SiC provides further enhancement of the hardness of AMCs reinforced by GNS. The coefficient of friction decreases by about 7%, 13%, and 17% with the reinforcement of 0.5, 1, and 2% GNS, respectively. Hybrid reinforcement has the lowest friction coefficient (0.41). The decreasing friction coefficient contributes to the self-lubrication of GNSs, the reduction in the contact area with the substrate, and the load-bearing ability of ceramic particles. According to this study, the strengthening mechanisms of the composites may be due to thermal mismatch, grain refinement, and Orowan looping. In summary, such hybrid reinforcements effectively improve the mechanical and tribological properties of the composites.

Improving the Mechanical Properties of a Lattice Structure Composed of Struts with a Tri-Directional Elliptical Cylindrical Section via Selective Laser Melting.

In recent years, lattice structures produced via additive manufacturing have been increasingly investigated for their unique mechanical properties and the flexible and diverse approaches available to design them. The design of a strut with variable cross-sections in a lattice structure is required to improve the mechanical properties. In this study, a lattice structure design method based on a strut cross-section composed of a mixture of three ellipses named a tri-directional elliptical cylindrical section (TEC) is proposed. The lattice structures were fabricated via the selective laser melting of 316L alloy. The finite element analysis results show that the TEC strut possessed the high mechanical properties of lattice structures. Compression experiments confirmed that the novel lattice structure with the TEC strut exhibited increases in the elastic modulus, compressive yield strength, and energy absorption capacity of 24.99%, 21.66%, and 20.50%, respectively, compared with the conventional lattice structure at an equal level of porosity.

Effect of Nanofiller on the Mechanical Properties of Carbon Fiber/Epoxy Composites under Different Aging Conditions.

In this study, carbon fiber-reinforced epoxy composites (CFRPs) containing multi-walled carbon nanotube (MWCNT) and halloysite nanoclay were fabricated. The effects of these nanofillers (MWCNT and nanoclay) on the tensile and flexural properties of the CFRPs under different aging conditions were studied. These aging conditions included water soaking, acid soaking, alkali soaking, and thermal shock cycling. The experimental results showed that, after accelerated aging, the mechanical performance of the CFRPs decreased. The performance degradation in the soaking environment depends on the immersion temperature and immersion medium. High-temperature accelerated the aging behavior of the CFRPs, resulting in low strength and modulus. The CFRPs were more vulnerable to acid soaking and alkali soaking than water soaking. The MWCNT and halloysite nanoclay are beneficial to improve the immersion aging resistance of the CFRPs, and the additions of nanofillers delayed the performance degradation under immersion aging conditions. However, nanofillers hardly improve the aging resistance of the CFRPs under thermal shock cycling condition. The fracture morphologies were observed by scanning electron microscopy (SEM) to reflect the failure modes of the CFRPs under various aging conditions. Differential scanning calorimeter (DSC) and fourier transform infrared (FTIR) spectroscopy tests were used to estimate the changes in the chemical structures and properties of epoxy resin and its composites under different conditions.

Microstructure and Mechanical Properties of Friction Stir-Welded Dissimilar Joints of ZK60 and Mg-4.6Al-1.2Sn-0.7Zn Alloys.

In order to clarify the microstructural evolution and the mechanical property of dissimilar friction stir-welded joints of ZK60 and Mg-4.6Al-1.2Sn-0.7Zn magnesium alloys, two types of arrangement with ZK60 at advancing side (AS) or retreating side (RS) were adopted. The macrostructure and the microstructure of the dissimilar welded joints were discussed, and the microhardness and the transverse tensile properties of the joints were measured. There are three stirring sub-zones with different compositions and two clear interfaces within the joints. Due to the effect of both the original grain size of base materials and the growth of recrystallized grains, in the stir zone (SZ), the grain size of ZK60 increased slightly, while the grain size of Mg-4.6Al-1.2Sn-0.7Zn decreased significantly. The dissolution of precipitates was gradually significant from RS to AS within the SZ due to the gradual increase in strain and heat. The grain refinement led to an increase in hardness, while the dissolution of precipitates resulted in a decrease in hardness. The performance of the joints obtained with ZK60 placed on the RS is slightly better than that of that on the AS. The tensile fracture of both joints occurred at the interface between SZ and the thermos-mechanical affected zone at the AS, and showed a quasi-dissociative fracture.

Compressive Properties of Open-Cell Al Hybrid Foams at Different Temperatures.

Hybrid Ni/Al foams were fabricated by depositing electroless Ni-P (EN) coatings on open-cell Al foam substrate to obtain enhanced mechanical properties. The microstructure, chemical components and phases of the hybrid foams were observed and analyzed by scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS) and X-ray diffraction (XRD), respectively. The mechanical properties of the foams were studied by compressive tests at different temperatures. The experiment results show that the coating is mainly composed of Ni and P elements. There was neither defect at the interface nor crack in the coatings, indicating that the EN coatings had fine adhesion to the Al substrate. The compressive strengths and energy absorption capacities of the as-received foam and hybrid foams decrease with the increasing testing temperatures, but the hybrid foams exhibit a lower decrement rate than the as-received foam. This might be attributed to the different failure mechanisms at different testing temperatures, which is conformed by fractography observation.

Sound Absorption Characteristics of Aluminum Foams Treated by Plasma Electrolytic Oxidation.

Open-celled aluminum foams with different pore sizes were fabricated. A plasma electrolytic oxidation (PEO) treatment was applied on the aluminum foams to create a layer of ceramic coating. The sound absorption coefficients of the foams were measured by an impedance tube and they were calculated by a transfer function method. The experimental results show that the sound absorption coefficient of the foam increases gradually with the decrease of pore size. Additionally, when the porosity of the foam increases, the sound absorption coefficient also increases. The PEO coating surface is rough and porous, which is beneficial for improvement in sound absorption. After PEO treatment, the maximum sound absorption of the foam is improved to some extent.

Influence of Sulfate-Reducing Bacteria on the Corrosion Residual Strength of an AZ91D Magnesium Alloy.

In this paper, the corrosion residual strength of the AZ91D magnesium alloy in the presence of sulfate-reducing bacteria is studied. In the experiments, the chemical composition of corrosion film was analyzed by a scanning electron microscope with energy dispersive X-ray spectroscopy. In addition, a series of instruments, such as scanning electronic microscope, pH-meter and an AG-10TA materials test machine, were applied to test and record the morphology of the corrosion product, fracture texture and mechanical properties of the AZ91D magnesium alloy. The experiments show that the sulfate-reducing bacteria (SRB) play an important role in the corrosion process of the AZ91D magnesium alloy. Pitting corrosion was enhanced by sulfate-reducing bacteria. Corrosion pits are important defects that could lead to a significant stress concentration in the tensile process. As a result, sulfate-reducing bacteria influence the corrosion residual strength of the AZ91D magnesium alloy by accelerating pitting corrosion.