Thesis (Ph. D.)--Ohio State University, 2006. / Title from first page of PDF file. Includes bibliographical references (p. 346-353).

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Carbon nanotubes (CNTs) have captured a great deal of attention worldwide since their discovery in 1991. CNTs are considered to be the stiffest and strongest material due to their perfect atomic arrangement and intrinsic strong in-plane sp 2—sp 2 covalent bonds between carbon atoms. In addition to mechanical properties, CNTs have also shown exceptional chemical, electrical and thermal properties. All these aspects make CNTs promising candidates in the development of novel multi-functional nanocomposites. Utilizing CNTs as fillers to develop advanced nanocomposites still remains a challenge, due to the lack of fundamental understanding of both material processing at the nanometer scale and the resultant material properties. In this work, a new model was developed to investigate the amount of control specific parameters have on the mechanical properties of CNT composites. The new theory can be used to guide the development of advanced composites using carbon nanotubes, as well as other nano-fibers, with any matrices (ceramic, metal, or polymer). Our study has shown that the varying effect based on changes in CNT dimensions and concentration fit the model predictions very well. Metallic CNT composites using both single-walled carbon nanotubes (SWNT) and multi-walled carbon nanotubes (MWNT), have been developed through a novel electrochemical co-deposition process. Copper and nickel matrix composites were developed by using pulse-reverse electrochemical co-deposition. Uniaxial tensile test results showed that a more than 300% increase in strength compared to that of the pure metal had been achieved. For example, the ultimate tensile strength of Ni/CNTs composites reached as high as about 2GPa. These are best experimental results ever reported within this field. The mechanical results are mainly attributed iv to the good interfacial bonding between the CNTs and the metal matrices and good dispersion of carbon nanotubes within the matrices. Experimental results have also shown that the strength is inversely dependent on the diameter of carbon nanotubes. In addition to the mechanical strength, carbon nanotube reinforced metallic composites are excellent multifunctional materials in terms of electrical and thermal conduction. The electrical resistivity of carbon nanotube/copper composites produces electrical resistivity of about 1.0~1.2 x10-6 ohm-cm, which is about 40% less than the pure copper. The reduced electrical resistivity is also attributed to the good interfacial bonding between carbon nanotubes and metal matrices, realized by the electrochemical co-deposition.

Discontinuously reinforced MMCs with optimized microstructure are sought after for exceptional high strain rate behavior. The microstructure evolution of a stir-cast A359 aluminum composite reinforced with 30 vol.% SiCp after isothermal anneal, successive hot-rolling, and high strain rate deformation has been investigated. Quantitative microstructural analysis was carried out for the as-cast, annealed (470°C, 538°C and 570°C) and successively hot rolled specimens (64, 75, 88, and 96% rolling reductions). Selected composites were also examined after high strain rate deformation. X-ray diffraction, optical microscopy, scanning electron microscopy and transmission electron microscopy were employed for microstructural characterization. The strength and ductility of the A359 Al alloys, and the composite, were greatly influenced by the brittle eutectic silicon phase and its morphology. Lamellar eutectic silicon spheroidized with isothermal anneal and successive hot rolling with a corresponding decrease in hardness. The hot rolling process also considerably decreased the SiC particle size (approximately 20% after 96% reduction) by breaking-up the hard SiC particles. However, this break-up of particles increased the homogeneity of SiCp size distribution. Successive hot rolling also healed voids due to solidification shrinkage, incomplete infiltration of molten Al and defects originating from fractured particles. Four selected specimens of composites were examined after high strain rate deformation. Fractography and metallographic analysis for the craters, voids, and relevant regions affected by the high velocity impact were carried out. The deposition of impact residuals was frequently iv observed on the exposed fracture surfaces. These residuals were typically observed as “moltenand-solidified” as a consequence of excessive heat generated during and after the damage. Particularly in regions of entry and exit of impact, intermixing of residuals and composite constituents were observed, demonstrating that the Al matrix of the composite also had melted. In all samples examined, cracks were observed to propagate through the eutectic Si network while a small number of broken reinforcement particles were observed. A slight variation in failure mechanisms was observed (e.g., radial, fragmentation, petalling) corresponding to the variation in ductility against high strain rate deformation. In selected specimens, parallel sub-cracks at the exit were observed at 45° and 30°. These sub-cracks were again filled with intermixed constituents from projectile residuals and composites. This observation suggests that the melting of composite constituents that leads to intermixing occured after the crack propagation and other damage.

Magnesium (Mg) Metal matrix composites (MMCs) reinforced by ceramic reinforcements are being developed for a variety of applications in automotive and aerospace because of their strength-to-weight ratio. Reinforcement being considered includes SiC, Al2O3, Carbon fiber and B4C in order to improve the mechanical properties of MMCs. Microstructural and interfacial characteristics of MMCs can play a critical role in controlling the MMCs’ mechanical properties. This study was carried out to understand the microstructural and interfacial development between Mg-9wt.Al-1wt.Zn (AZ91) alloy matrix and several reinforcements including SiC, Al2O3, Carbon fibers and B4C. X-ray diffraction, scanning electron microscopy and transmission electron microscopy was employed to investigate the microstructure and interfaces. Al increase in hardness due to the presence of reinforcements was also documented via Vicker’s hardness measurements. Thermodynamic consideration based on Gibbs free energy was employed along with experimental results to describe the interfacial characteristics of MMCs. Reaction products from AZ91-SiC and AZ91-Al2O3 interfaces were identified as MgO, since the surface of SiC particles is typically covered with SiO2 and the MgO is the most thermodynamically stable phase in these systems. The AZ91-Carbon fiber interface consist of Al4C3 and this carbide phase is considered detrimental to the mechanical toughness of MMCs. The AZ91-B4C interface was observed to contain MgB2 and MgB2C2. In general, Vicker’s hardness increased by 3X due to the presence of these reinforcements.

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Metal matrix composites have two important interfacial problems between the matrix and the reinforcement which can reduce its desirable mechanical properties. Chemical differences between the matrix and the reinforcement can lead to reactions and deterioration of the reinforcement. Secondly, structural differences between the matrix and the reinforcement lead to bonding conditions which are far from ideal. By using a reinforcement which has a similar chemistry and local atomic structure to that of the matrix, these critical problems can be reduced. A crystalline matrix reinforced with an amorphous form of the matrix is a possible solution to the problem. Composites of amorphous Fe-W alloy particles reinforcing an Fe matrix were produced using mechanical alloying. Bulk samples were produced and their properties were studied. After analyzing the results, the amorphous alloys were determined to be effective strengtheners. However, porosity in the composites led to a reduction of the strengthening imparted by the reinforcement. / Master of Science

Not available until OCRd / Master of Science

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