Copper-alumina composites were developed for testing in abrasive wear applications. The composites featured a porous continuous ceramic-preform network infiltrated by a liquid metal to form the final consolidated composite. The liquid metal phase was pure copper. Six different ceramic preform variants were tested. Ceramic volume fractions of 40, 50 and 60% were used, of two preform types; one pure-alumina, and one with additional 2wt% copper(I) oxide (CU20), functioning as an infiltration aid, the effects of which were determined in a previous study; the copper-oxide reduced infiltration pressure and allowed the use of higher ceramic phase volume fraction in the final composite. Abrasive wear tests against two automotive braking system materials were conducted. Grey cast iron of alloy type GG15 was used to establish a baseline for behaviour of the six different composite samples and compare them. Following this, the three volume fraction variants of samples using the copper-oxide infiltration aid were trialled against a commercially-available European passenger vehicle brake pad friction material; ABEX 6091. Wear tests were conducted on a pin-on-disc tribometer. Hemispherical-headed pins were made from the composite and tested against rotating discs of the grey cast iron and the ABEX friction material. Contact velocity was kept constant at Ims-?? at room temperature in air, and contact loads up to 15N were used. Test loads of 1-4N were used against grey cast iron, and 15N against the ABEX friction material. Optical micrography was used to monitor the wear rate of samples tested against grey cast iron. Scanning electron microscopy (SEM) was used to characterise bulk microstructures and evaluate surface wear features. Transmission electron microscopy (TEM) was used for further microstructural investigation of the sintering and interfacial features of the undamaged pin samples, as well as damage zones and tribofilm compositions. Focussed ion beam (FIB) milling was used to create subsurface cross-sections of wear regions and prepare TEM samples. The wear performance of the different sample types was compared by ceramic content and preform additives. It was found that the wear resistance of pure-alumina preform composites was dependent on ceramic volume fraction. Increasing ceramic content lead to increased wear resistance. The lower sinter temperature of the samples with the copper oxide additive led to reduced wear resistance compared with the monolithic alumina preforms and changes in ceramic volume fractions were not discernable in wear resistance against grey cast iron. This could be further supported by qualitative micrographic observations. All tests against grey cast iron were dominated by tribochemical film formation, which was determined to be oxidation of the iron which formed at the composite pin contact surface. Further testing of the copper-oxide containing samples against the ABEX friction material revealed a mixed result; the 50 and 60% ceramic volume samples produced near-identical wear performance, while the 40% sample suffered poor wear resistance. The dominant wear mechanism of composite pins tested against the ABEX friction material was abrasive wear. Sub-surface analysis of wear pins revealed a prominent damage layer forming at the contact surface of all pin samples which progressively grew into the bulk material. This layer was believed to have an important effect on the wear behaviour of the materials.

Copper-alumina composites were developed for testing in abrasive wear applications. The composites featured a porous continuous ceramic-preform network infiltrated by a liquid metal to form the final consolidated composite. The liquid metal phase was pure copper. Six different ceramic preform variants were tested. Ceramic volume fractions of 40, 50 and 60% were used, of two preform types; one pure-alumina, and one with additional 2wt% copper(I) oxide (CU20), functioning as an infiltration aid, the effects of which were determined in a previous study; the copper-oxide reduced infiltration pressure and allowed the use of higher ceramic phase volume fraction in the final composite. Abrasive wear tests against two automotive braking system materials were conducted. Grey cast iron of alloy type GG15 was used to establish a baseline for behaviour of the six different composite samples and compare them. Following this, the three volume fraction variants of samples using the copper-oxide infiltration aid were trialled against a commercially-available European passenger vehicle brake pad friction material; ABEX 6091. Wear tests were conducted on a pin-on-disc tribometer. Hemispherical-headed pins were made from the composite and tested against rotating discs of the grey cast iron and the ABEX friction material. Contact velocity was kept constant at Ims-?? at room temperature in air, and contact loads up to 15N were used. Test loads of 1-4N were used against grey cast iron, and 15N against the ABEX friction material. Optical micrography was used to monitor the wear rate of samples tested against grey cast iron. Scanning electron microscopy (SEM) was used to characterise bulk microstructures and evaluate surface wear features. Transmission electron microscopy (TEM) was used for further microstructural investigation of the sintering and interfacial features of the undamaged pin samples, as well as damage zones and tribofilm compositions. Focussed ion beam (FIB) milling was used to create subsurface cross-sections of wear regions and prepare TEM samples. The wear performance of the different sample types was compared by ceramic content and preform additives. It was found that the wear resistance of pure-alumina preform composites was dependent on ceramic volume fraction. Increasing ceramic content lead to increased wear resistance. The lower sinter temperature of the samples with the copper oxide additive led to reduced wear resistance compared with the monolithic alumina preforms and changes in ceramic volume fractions were not discernable in wear resistance against grey cast iron. This could be further supported by qualitative micrographic observations. All tests against grey cast iron were dominated by tribochemical film formation, which was determined to be oxidation of the iron which formed at the composite pin contact surface. Further testing of the copper-oxide containing samples against the ABEX friction material revealed a mixed result; the 50 and 60% ceramic volume samples produced near-identical wear performance, while the 40% sample suffered poor wear resistance. The dominant wear mechanism of composite pins tested against the ABEX friction material was abrasive wear. Sub-surface analysis of wear pins revealed a prominent damage layer forming at the contact surface of all pin samples which progressively grew into the bulk material. This layer was believed to have an important effect on the wear behaviour of the materials.

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<p>The superior high-temperature elastic-plastic properties coupled with greater damage tolerance when compared with monolithic ceramics make ceramic matrix composites, CMCs, promising candidates for challenging applications such as engine components, rocket nozzles, cutting tools and nuclear energy reactor core components. Anelastic recovery is the time-dependent back strain observed upon the load removal following creep. In whisker-reinforced CMCs this can be a factor limiting operating conditions. Plastic strain misfit between two phases is thought to be the main driver in terms of the interactions within a percolating network. However, the network deformation mechanisms are still unclear and a previous neutron diffraction study showed an unexpected decrease of peak width after creep contradicting the theoretical predictions.</p> <p>In this contribution, the finite element method (FEM) is applied to a representative volume element (RVE) with proper boundary conditions in order to simulate the creep deformation and hot pressing processes. Three geometries have been generated and studied: a 3D randomly-oriented short-fiber unit cell without fiber to fiber contact, generated by a random sequential adsorption algorithm; 3D regularly aligned single fiber unit cells; and 2D regularly aligned percolating unit cells. Deformation mechanism has been studied from an energy point of view and compared with a modified analytical model. Then a virtual diffraction model has been developed providing a framework to transfer information between the FEM simulations (strain fields) and the diffraction pattern in terms of the peak width (full width at half maximum: <strong><em>FWHM</em></strong>) and peak position as a measure of stress distribution and mean stress state respectively. Furthermore, the coupling effects of external stress, deformation mode, and thermal stress on the diffraction patterns have been studied.</p> <p>The critical importance of a percolating whisker network for the anelastic recovery is demonstrated based on the 3D multi-whisker random unit cell. Whisker bending is shown to be the dominant mechanism over contact effects during the creep deformation of a composite containing a well aligned percolating whisker network based on the 2D unit cell model. Good qualitative agreement was found between our FEM simulations and the analytical model of Wilkinson and Pompe with regards to the maximum recoverable strain and the characteristic relaxation time. The analytical model captures all the critical factors characterizing the strain recovery, e.g., the effect of creep pre-exponent constant, whisker Young’s modulus and aspect ratio. Furthermore, it is found that the deformation from an initial stress-free state inevitably introduces peak broadening of whiskers inside the matrix. Several factors determine the peak-width and -shift, i.e., creep strain, applied stress, aspect ratio and geometry. However, thermal stress from the cooling stages following creep and hot pressing processes shelters this broadening effect and complicates the trends. Wide-ranging peak-width changes from narrowing to broadening are predicted depending on the geometry and applied stress. The peak position is shifted to a lower angle due to this thermal effect. This clearly explains the contradicting phenomena motivating this work and leads to that recommendation that a diffraction source with high angular resolution is needed to detect the subtle change of peak profile during creep.</p> / Doctor of Philosophy (PhD)