This study investigated the role of Sic particles in the mechanical behaviour of a metal matrix composite (Al-SiC). Measurements of the development and magnitude of internal stresses were performed from Bauschinger experiments in the aluminum matrix A-356 reinforced with the Sic particles. The behavior of the Al matrix itself was also analyzed. The level of internal stresses in the particulate reinforced composite was found to saturate after 0.9% plastic strain and after 1.3% in the unreinforced matrix. The initial development of the unrelaxed internal stresses was analyzed using both microscopic and macroscopic models of the load-bearing role of the Sic particles. The Sic particles were found to have little influence on the plastic flow of the composite beyond the initial plastic deformation as the size and distribution of the Sic is very non-uniform. The effect of the Sic phase was compared to continuous fibers embedded in a metallic matrix. A model system of pure copper reinforced with continuous tungsten fibers was used for this purpose. The effect of the internal stresses on the dimensional stability of the particulate reinforced and the unreinforced matrix was also investigated. The generation of dislocations arising from the thermal cycling of those materials was also analyzed by reference to the increase in flow stress observed after thermal cycling and from a model based on dislocations production due to the difference in coefficient of thermal expansion of the phases. / Thesis / Master of Engineering (ME)

Severe plastic deformation (SPD) results in ultra-fine grain sizes in metals and alloys. Equal channel angular pressing (ECAP) is one of the special SPD methods aiming to introduce high plastic strains into the bulk materials without changing their cross section. ECAP results in improvement in hardness and strength while still satisfying acceptable ductility level. The combined effects of ECAP and subsequent heat treatments, i.e. post-aging and post-annealing, on the microstructure and hardness of the 2024 aluminum alloy were investigated. An ECAP die with 120&amp / #730 / channel angle was constructed. Subgrain formation, increase in dislocation density and dislocation tangling were observed after ECAP, and subgrain growth was detected after post annealing. The specimens revealed higher hardness values after ECAP at room temperature, and further increase in hardness was observed following post-aging at 80&amp / #730 / C, 100&amp / #730 / C and 190&amp / #730 / C. Effect of the aging temperature on the deformed specimens was investigated, and the aging behaviors of the severely deformed and undeformed samples at 190&amp / #730 / C were compared.

Dissimilar Channel Angular Pressing (DCAP) method is an effective Severe Plastic Deformation (SPD) technique to improve the mechanical properties of sheets or strips by producing ultrafine grains. The aim of this study is to investigate the evolution of the microstructure and the improvement in mechanical properties of 6061 Al-alloy strips deformed by DCAP up to 5 passes. Mechanical properties such as hardness and strength have been observed to increase up to a certain strain level depending on the microstructural evolution. These microstructural changes were investigated by the characterization studies of XRD, SEM and TEM analysis of the DCAPed samples indicating the subgrain formation, changes in the dislocation density and dislocation behaviors.

Al based alloy powders (Al₈₅Ni₅Y₆Co₂Fe₂) are produced by spray atomization method. High energy ball milling is done to modify the surface topology and particle size for better electrochemical performance. X ray diffraction (XRD), differential scanning calorimeter (DSC), scanning electron microscope (SEM) and transmission electron microscope (TEM) were conducted to characterize the microstructure of the alloys after ball milling. It is found that 5 hours ball milling gives the minimum crystallization and structure change. Thin film sample is also deposited on stainless steel substrate by pulsed laser deposition (PLD) method for electrochemical test. The capacity and reversibility for different samples are compared and discussed. A capacity of 200mAh/g is obtained for the battery with thin film sample as anode and a capacity of 140mAh/g is obtained for that with electrode from powder sample. Both of the batteries give up to 94% capacity retention after 20 cycles. / Singapore-MIT Alliance (SMA)

No description available.

Friction Stir Processing (FSP) has the potential for locally enhancing the properties of Al-Si alloy castings, for demanding applications within the automotive industry. In this thesis, the effect of FSP has been examined on three different cast Al-Si alloys:i) A Hypoeutectic Al-8.9wt%Si Alloyii) A Hypereutectic Al-12.1wt%Si Alloyiii) A Hypereutectic Al-12.1wt%Si-2.4wt%Ni AlloyThe influence of different processing parameters has been investigated at a fundamental level. Image analysis of particle size distributions and growth method of tessellation were used to quantify the level of particle refinement and the homogeneity of the second phase spatial distribution. Stop-action experiments were also carried out, to allow the microstructural changes around the tool during FSP to be studied. Two computer models have been explored, in order to predict the temperature distribution and the material flow behaviour. Furthermore, the stability of the microstructure of the friction stir processed material was studied after being heat treated at elevated temperatures. The changes in particle size and grain structure were examined, hardness measurements were taken across the PZ, and tensile testing were carried out at room and elevated temperatures.After FSP, the microstructure of the cast Al-Si alloys was greatly refined. However, differences in microstructure have been observed throughout the PZ, which tended to be better refined and distributed on the advancing side, than the retreating side of the PZ. Changing the processing parameters also influenced the size and spatial distribution of the second phase particles. By studying the changes in microstructure around the tool from the stop-action experiments, and comparing the results to the thermal distribution and material flow behaviour predicted by the computer models, it has been shown that the flow stress, pitch, and temperature of processing, all needed to be considered, when determining the effects that FSP have on the microstructure. FSP caused very little changes to the hardness of the material, while tensile properties were greatly improved, due to the elimination of porosity and refinement of large flawed particles. In terms of the stability of the microstructure after FSP, particle coarsening and abnormal grain growth has been observed during high temperatures heat treatment. Furthermore, the Al2Cu phase was found to dissolve into solid solution at elevated temperatures, so GPZs and solute clustering can then develop within the alloy during natural ageing.

No description available.

No description available.

The Thin Slab Cast Direct Rolling (TSCDR) process offers several economic and environmental advantages. The elimination of slab reheating and roughing deformation, however, leave fewer opportunities for grain refinement and some large grains persist in the microstructure. To solve this problem, a new chemistry which leads to a two-phase mixture of ferrite and austenite over a wide temperature range was introduced by Zhou et al. The two phase mixture is highly resistant to grain coarsening leading to a small initial grain size compared with the grain size of conventional TSCDR slab. In addition, ferrite and austenite co-exist over wide range of temperature in many third generation steels, making it extremely important to understand the hot deformation behavior of these materials, which have traditionally received less attention in the literature. In order to investigate the microstructure evolution of ferrite-austenite mixtures during thermomechanical processing, an Al containing model alloy, for which the two phases co-exist over a wide temperature range, was designed. Two types of experiments were carried out: the first involved single hit hot compression tests; and the second involved stress relaxation tests. According to the microstructure observation the main change of austenite microstructure under deformation conditions was a decrease in the spacing of the austenite particles within the ferrite matrix. In other words the austenite phase behaved as hard particles inside a soft ferrite matrix. Hot deformation led to the static recrystallization of the ferrite matrix. The most favourable nucleation sites were in the vicinity of the old grain boundaries and the around austenite particles. The recovery and recrystallization kinetics of ferrite were analyzed using the stress relaxation test. Based on analysis of the stress relaxation tests, more than 95% of stored energy was consumed by recovery, while static recrystallization consumed less than 5% of the stored energy. The retardation of recrystallization in the model alloy is attributed to both the high rate of recovery in BCC materials and texture effects. / Thesis / Master of Applied Science (MASc) / The Thin Slab Cast Direct Rolling (TSCDR) process offers several economic and environmental advantages. The elimination of slab reheating and roughing deformation, however, leave fewer opportunities for grain refinement and some large grains persist in the microstructure. To solve this problem, a new chemistry which leads to a two-phase mixture of ferrite and austenite over a wide temperature range was introduced by Zhou et al. The two phase mixture is highly resistant to grain coarsening leading to a small initial grain size compared with the grain size of conventional TSCDR slab. In addition, ferrite and austenite co-exist over wide range of temperature in many third generation steels, making it extremely important to understand the hot deformation behavior of these materials, which have traditionally received less attention in the literature. In order to investigate the microstructure evolution of ferrite-austenite mixtures during thermomechanical processing, an Al containing model alloy, for which the two phases co-exist over a wide temperature range, was designed. Two types of experiments were carried out: the first involved single hit hot compression tests; and the second involved stress relaxation tests. According to the microstructure observation the main change of austenite microstructure under deformation conditions was a decrease in the spacing of the austenite particles within the ferrite matrix. In other words the austenite phase behaved as hard particles inside a soft ferrite matrix. Hot deformation led to the static recrystallization of the ferrite matrix. The most favourable nucleation sites were in the vicinity of the old grain boundaries and the around austenite particles. The recovery and recrystallization kinetics of ferrite were analyzed using the stress relaxation test. Based on analysis of the stress relaxation tests, more than 95% of stored energy was consumed by recovery, while static recrystallization consumed less than 5% of the stored energy. The retardation of recrystallization in the model alloy is attributed to both the high rate of recovery in BCC materials and texture effects.

The behaviors of short fatigue crack (SFC) propagation through grain boundaries (GBs) were monitored during high cycle fatigue in an Al-Li alloy AA8090. The growth behaviors of SFCs were found to be mainly controlled by the twist components (α) of crack plane deflection across each of up to first 20 GBs along the crack path. The crack plane twist at the GB can result in a resistance against SFC growth; therefore SFC propagation preferred to follow a path with minimum α at each GB. In addition to the grain orientation, the tilting of GB could also affect α. An experiment focusing on quantifying GB-resistance was conducted on an Al-Cu alloy AA2024-T351. With a focused ion beam (FIB) and electron backscatter diffraction (EBSD), the micro-notches were made in front of the selected GBs which had a wide range of α, followed by monitoring the interaction of crack propagation from the notches with the GBs during fatigue. The crack growth rate was observed to decrease at each GB it had passed; and such growth-rate decrease was proportional to α. The resistance of the GB was determined to vary as a Weibull-type function of α. Based on these discoveries, a microstructure-based 3-D model was developed to quantify the SFC growth in high-strength Al alloys, allowing the prediction of crack front advancement in 3-D and the quantification of growth rate along the crack front. The simulation results yielded a good agreement with the experimental results about the SFC growth rate on the surface of the AA8090 Al alloy. The model was also used to predict the life of SFC growth statistically in different textures, showing potential application to texture design of alloys. Fatigue crack initiation at constituent particles (β-phase) was preliminarily studied in the AA2024-T351 Al alloy. Cross-sectioning with the FIB revealed that the 3-D geometry, especially the thickness, of fractured constituent particles (β-phase) was the key factor controlling the driving force for micro-crack growth. The resistance to micro-crack growth, mainly associated with crack plane twist at the particle/matrix interface, also influenced the growth behaviors of the micro-cracks at the particles on the surface.