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The present work studies the microstructure and corrosion behaviour of 25 vol.% SiCp/AA2124-T4 metal matrix composites (MMCs) and AA2124-T4 aluminium alloy; and also the capability of excimer laser surface melting (LSM) to improve the corrosion resistance of the SiCp/AA2124 MMC and the monolithic alloy (MA). Microstructural characterization has shown significant influence of the presence and size of SiC particles on the fine Al2Cu precipitate and Mg segregation at SiC/Al interfacial regions. Such precipitates are revealed to be active sites for corrosion initiation in the MMCs, while the preferential sites for corrosion initiation in the MA are the coarse intermetallics. Corrosion evaluation performed in a 0.6 M NaCl solution suggests that the corrosion resistance of the MMC reinforced with micrometre-sized SiC particles is inferior to that of the MA and the MMC reinforced with submicrometre-sized SiC particles. The submicrometre-sized SiC particles have little adverse effect on the corrosion resistance of the MMC due to the reduced interfacial precipitates. Thin films of up to several micrometres have been achieved by excimer LSM on both the MMC and the MA. The surface roughness and the thickness of the melted layer increase with increasing laser fluence. High number of pulses (40 P) results in significant porosity in the MA and networks of cracking in the MMC. A homogeneous layer without chemical segregation except the Cu-rich segregation bands has been obtained on the MA; while complex microstructures are observed for the MMC, including the Cu-rich segregation bands, Al-Si eutectic structure and microsegregation-free structure laid in sequence from the bottom of the melted layer to the top surface. The modelling work suggest that the presence of SiC particles gives rise in high temperatures in the melt pool, which is useful to explain the materials responses upon laser irradiation, such as decomposition of SiC, evaporation of matrix alloy, and oxides formation. The fast cooling rate up to 1011 K/s is responsible for the formation of microsegregation-free structure. Corrosion evaluation has indicated improvement of corrosion resistance of the MMC and the MA after excimer LSM due to the reduction of the intermetallics. For the laser-melted MA, the corrosion behaviour is governed by the surface morphology and the porosity. The significant rippled structure obtained under high laser fluence could lead to crevice corrosion in the valley between the ripples whilst the pores could provide penetrating routes for the chloride solution to reach the Cu-rich segregation bands, leading to the delamination of the melted layer. For the laser-melted MMC, corrosion mainly initiated at the SiC remnants, which are rich in Si. The corrosion sites of the laser-melted MMC are in the form of small cracked blisters.

Composites have been developed with great success by the use of fiber reinforcements in metallic materials. Fiber reinforced metal matrices possess great potential to be the next generation of advanced composites offering many advantages compared to fiber reinforced polymers. Specific advantages include high temperature capability, superior environmental stability, better transverse modulus, shear and fatigue properties. Although many Metal Matrix Composites (MMCs) are attractive for use in different industrial applications, Aluminium Matrix Composites (AMCs) are the most used in advanced applications because they combine acceptable strength, low density, durability, machinability, availability, effectiveness and cost. The present study focuses on the fabrication of aluminium matrix composite plates by squeeze casting using plain weave carbon fiber preform (AS4 Hexcel) as reinforcement and a matrix of wrought aluminium alloy 1235-H19. The objective is to investigate the process feasibility and resulting materials properties such as hardness at macro- and micro-scale, impact and bend strength. The properties obtained are compared with those of 6061/1235-H19 aluminium plates that were manufactured under the same fabrication conditions. The effect of fiber volume fraction on the properties is also investigated. Furthermore, the characterization of the microstructure is done using Optical Microscopy (OM) and Scanning Electron Microscopy (SEM) in order to establish relationships between the quality of the fiber/aluminium interface bond and mechanical properties of the composites. In conclusion, aluminium matrix composite laminate plates were successfully produced. The composites show a good chemical bond between the fiber and the aluminium matrix. This bond resulted from heterogeneous precipitation of aluminium carbides (Al4C3) at the interface between aluminium matrix and carbon fiber. The hardness at macro- and micro-scale of the composites increases by over 50% and the flexural modulus increases by about 55%. The toughness of the composite decreases due to the presence of brittle phases which can be improved by better oxidation prevention. Also, an optimal carbon volume fraction was observed that provides optimal properties including peak hardness, peak stiffness and peak toughness.

Composites have been developed with great success by the use of fiber reinforcements in metallic materials. Fiber reinforced metal matrices possess great potential to be the next generation of advanced composites offering many advantages compared to fiber reinforced polymers. Specific advantages include high temperature capability, superior environmental stability, better transverse modulus, shear and fatigue properties. Although many Metal Matrix Composites (MMCs) are attractive for use in different industrial applications, Aluminium Matrix Composites (AMCs) are the most used in advanced applications because they combine acceptable strength, low density, durability, machinability, availability, effectiveness and cost. The present study focuses on the fabrication of aluminium matrix composite plates by squeeze casting using plain weave carbon fiber preform (AS4 Hexcel) as reinforcement and a matrix of wrought aluminium alloy 1235-H19. The objective is to investigate the process feasibility and resulting materials properties such as hardness at macro- and micro-scale, impact and bend strength. The properties obtained are compared with those of 6061/1235-H19 aluminium plates that were manufactured under the same fabrication conditions. The effect of fiber volume fraction on the properties is also investigated. Furthermore, the characterization of the microstructure is done using Optical Microscopy (OM) and Scanning Electron Microscopy (SEM) in order to establish relationships between the quality of the fiber/aluminium interface bond and mechanical properties of the composites. In conclusion, aluminium matrix composite laminate plates were successfully produced. The composites show a good chemical bond between the fiber and the aluminium matrix. This bond resulted from heterogeneous precipitation of aluminium carbides (Al4C3) at the interface between aluminium matrix and carbon fiber. The hardness at macro- and micro-scale of the composites increases by over 50% and the flexural modulus increases by about 55%. The toughness of the composite decreases due to the presence of brittle phases which can be improved by better oxidation prevention. Also, an optimal carbon volume fraction was observed that provides optimal properties including peak hardness, peak stiffness and peak toughness.

Composites have been developed with great success by the use of fiber reinforcements in metallic materials. Fiber reinforced metal matrices possess great potential to be the next generation of advanced composites offering many advantages compared to fiber reinforced polymers. Specific advantages include high temperature capability, superior environmental stability, better transverse modulus, shear and fatigue properties. Although many Metal Matrix Composites (MMCs) are attractive for use in different industrial applications, Aluminium Matrix Composites (AMCs) are the most used in advanced applications because they combine acceptable strength, low density, durability, machinability, availability, effectiveness and cost. The present study focuses on the fabrication of aluminium matrix composite plates by squeeze casting using plain weave carbon fiber preform (AS4 Hexcel) as reinforcement and a matrix of wrought aluminium alloy 1235-H19. The objective is to investigate the process feasibility and resulting materials properties such as hardness at macro- and micro-scale, impact and bend strength. The properties obtained are compared with those of 6061/1235-H19 aluminium plates that were manufactured under the same fabrication conditions. The effect of fiber volume fraction on the properties is also investigated. Furthermore, the characterization of the microstructure is done using Optical Microscopy (OM) and Scanning Electron Microscopy (SEM) in order to establish relationships between the quality of the fiber/aluminium interface bond and mechanical properties of the composites. In conclusion, aluminium matrix composite laminate plates were successfully produced. The composites show a good chemical bond between the fiber and the aluminium matrix. This bond resulted from heterogeneous precipitation of aluminium carbides (Al4C3) at the interface between aluminium matrix and carbon fiber. The hardness at macro- and micro-scale of the composites increases by over 50% and the flexural modulus increases by about 55%. The toughness of the composite decreases due to the presence of brittle phases which can be improved by better oxidation prevention. Also, an optimal carbon volume fraction was observed that provides optimal properties including peak hardness, peak stiffness and peak toughness.

Yes / In this study, a new double pin tool was utilized for the development of AA6061/316 stainless steel reinforced composite by employing the friction stir processing technique for the first time. The microstructure, hardness, tensile, tribological, and corrosion behaviors of the fabricated composites were investigated and comparative assessments were made with the results obtained from the single-pin tool. The results showed that particle-matrix reaction did not occur in the composites irrespective of the nature of the tool profile. The double-pin tool outstandingly boosted the grain refinement (7.01–5.78 μm), particle fragmentation, and distribution within the Al matrix due to the additional pin-assisted plastic deformation, high straining, dynamic recrystallization, and Zener pinning effects. The double-pin tool improved the microhardness (127–141 HV), tensile strength (162–233 MPa), and corrosion resistance of the composite with respect to the single-pin tool counterparts. The replacement of the single pin tool with a double pin tool diminished the specific wear rate (0.38–0.22 mm3/Nm) of the composite. The double-pin tool has a favourable impact on the structure, mechanical, and corrosion behaviours of the AA6061/316 stainless steel reinforced composite. It is thus recommended for composite development.

Ces travaux de thèse concernent l’effet des hétérogénéités microstructurales sur la tenue en fatigue multiaxiale à grand nombre de cycles (FGNC) d’alliages d’Al-Si de fonderie utilisés dans un contexte automobile. Les hétérogénéités microstructurales caractéristiques de cette famille de matériau sont la matrice d’aluminium (souvent caractérisée à l’aide la DAS et/ou la SDAS et du niveau de durcissement par précipitation), les inclusions (particules de silicium, intermétalliques) et les défauts de fonderie (films d’oxyde et surtout porosités).Afin de découpler clairement ces effets, trois nuances d’alliages d’aluminium de fonderie obtenues à l’aide de différents procédés (coulée en coquille, coulée par procédé à moule perdu) et associées à plusieurs traitements thermiques (T7, Compression isostatique à chaud (CIC)) ont été étudiées. Le traitement CIC a en particulier été employé afin d’obtenir une microstructure exempte de pore. Une vaste campagne d’essais en FGNC a été conduite pour quatre modes de chargement : uniaxial (R=-1), torsion (R=-1), traction-torsion combinées (R=-1) et traction équibiaxiale (R=0.1). Les effets sur le comportement en FGNC ont été identifiés pour les matériaux avec et sans pores : effet de la multiaxialité pour les chargements à R=-1, effet de la contrainte moyenne et effet de la biaxialité en traction biaxiale à R=0.1. Une attention particulière a été portée à la caractérisation des mécanismes d’endommagement dans l’objectif de mettre en évidence le role des pores, de la matrice d’aluminium, des inclusions dans les mécanismes d’endommagement, et ceci pour les différentes modes de chargement.Deux approches analytiques ont ensuite été proposées. La première concerne la modélisation de l’effet de volume sollicité sur la tenue en fatigue sous chargement uniaxial en présence de pore en se basant sur une approche de prédiction de la taille maximale de pore dans un volume donné. La seconde, basée sur une approche probabiliste, est dédiée à la simulation du diagramme de Kitagawa-Takahashi pour différents modes de chargement. Ces deux approches conduisent à des résultats en accord avec l’expérience, ceci pour les différents matériaux et conditions étudiées.La dernière partie propose une analyse 3D par éléments finis de l’effet des pores sur la résistance en fatigue. L’analyse repose sur l’utilisation de la géométrie réelle des pores, obtenue à l’aide d’observations en micro-tomographie RX 3D. Ce travail a pour but d’évaluer la possibilité de prédire la limite de fatigue à l’échelle macrosopique à partir de la réponse mécanique "locale" au voisinage des pores critiques. / This work treats the influence of the microstructural heterogeneities on the multiaxial high cycle fatigue (HCF) strength of cast aluminium alloys used in an automobile context. The characteristic microstructural heterogeneities present in this family of materials are the aluminium matrix (often characterised by the SDAS and/or the DAS and the precipitation hardening level), inclusions (silicon particles and intermetallics) and casting defects (oxide films and casting porosity).In order to clearly decouple these effects, three cast Al-Si alloys, obtained thank to different casting processes (gravity die casting and lost foam die casting) and associated with several heat treatments (T7 and Hot isostatic pressing-HIP), have been investigated. The HIP treatment is used in order to obtain a porosity free alloy. A vast experimental HCF campaign, including four loading modes (uniaxial (R=-1), torsion (R=-1), combined tension-torsion (R=-1) and equibiaxial tension (R=0.1)) has been undertaken. The following effects on the HCF behaviour have been characterised for the porosity free alloy as well as porosity containing alloys: (a) the effect of the multiaxiality (for the loading modes at R=-1), (b) the effect of the mean stress and (c) the effect of the biaxality (for equibiaxial tensile loads at R=0.1). The fatigue damage mechanisms have been studied in order to highlight the roles of the casting pores, the aluminium matrix and the inclusions on the fatigue damage mechanisms.Two analytical fatigue models are proposed. The first one concerns the effect of the loaded volume on the uniaxial fatigue strength of the porosity containing alloys using an approach to predict of the maximum pore size in a given volume. The second model, based on a probabilistic approach, takes into account the competition between the different observed damage mechanisms and leads to a Kitagawa-Takahashi type diagrams for different loading modes. It is shown that these analytical models result in good predictions for the three materials investigated and the four loading modes.A numerical study, presented in the last section, is related to the 3D finite element analysis of real pores. Real pore geometries are obtained thank to micro-tomography observations. The principal aim of this study is to evaluate the possibility of predicting the fatigue strength at the macroscopic scale thanks to the local mechanical behaviour around critical pores.

No description available.

Metal matrix composites (MMCs) are emerging as advanced engineering materials for application in aerospace, defence, automotive and consumer industries (sports goods etc.). In MMCs, a metallic base material is reinforced with ceramic fiber, whisker or particulate in order to achieve a combination of properties not attainable by either constituent individually. Aluminium or its alloy is favoured as metallic matrix material because of its low density, easy fabricability and good engineering properties. In general, the benefits of aluminium metal matrix composites (AMCs) over unreinforced aluminium alloy are increased specific stiffness, improved wear resistance and decreased coefficient of thermal expansion. The conventional reinforcement materials for AMCs are SiC and AI2O3. In the present work, boron carbide (B4C) particles of average size 40μm were chosen as reinforcement because of its higher hardness (very close to diamond) than the conventional reinforcement like SiC, AI2O3 etc. and of its density (2.52 g cm"3) very close to Al alloy matrix. In addition, due to high neutron capture cross-section of 10B isotope, composites containing B4C particle reinforcement have the potential for use in nuclear reactors as neutron shielding and control rod material. Al-5%Mg alloy was chosen as matrix alloy to utilize the beneficial role of Mg in improving wettability between B4C particles and the alloy melt. (Al-5%Mg)-B4C composites containing 10 and 20 vol% B4C particles were fabricated. For the purpose of inter-comparison, unreinforced Al-5%Mg alloy was also prepared and characterized. The Stir Cast technique, commonly utilized for preparation of Al-SiC, was adapted in this investigation.The Composites thus prepared was subsequently hot extruded with the objective of homogenization and healing minor casting defects. Finally the unreinforced alloy and its composites were characterized in terms of their microstructure, mechanical and thermo-physical properties, sliding wear behaviour and neutron absorption characteristics. The microstructures of the composites were evaluated by both optical microscope and scanning electron microscope (SEM). The micrographs revealed a relatively uniform distribution of B4C particles and good interfacial integrity between matrix and B4C particles. The hot hardness in the range of 25°C to 500°C and indentation creep data in the range of 300°C to 400°C show that hot hardness and creep resistance of Al-Mg alloy is enhanced by the presence of B4C particles. Measurement of coefficient of thermal expansion (CTE) of composites and unreinforced alloy upto 450°C showed that CTE values decrease with increase in volume fraction of reinforcement. Compression tests at strain rates, 0.1, 10 and 100 s-1 in the temperature range 25 - 450 °C showed that the flow stress values of composites were, in general, greater than those of unreinforced alloy at all strain rates. These tests also depicted that the compressive strength increases with increase in volume fraction of reinforcements. True stress values of composites and unreinforced alloy has been found to be a strong function of temperature and strain rate. The kinetic analysis of elevated temperature plasticity of composites revealed higher stress exponent values compared to unreinforced alloy. Similarly, apparent activation energy values for hot deformation of composites were found to be higher than that of self-diffusion in Al-Mg alloy. Tensile test data revealed that the modulus and 0.2% proof stress of composites increase with increase in volume fraction of the reinforcements. Composites containing 10%BUC showed higher ultimate tensile strength values (UTS) compared to unreinforced alloy. However, composites with 20%B4C showed lower UTS compared to that of the unreinforced alloy. This could be attributed to increased level of stress concentration and high level of plastic constraint imposed by the reinforcing jparticles or due to the presence solidification-induced defects (pores and B4C agglomerates ). Sliding wear characteristics were evaluated at a speed of 1 m/s and at loads ranging from 0.5 to 3.5kg using a pin-on-disc set up. Results show that wear resistance of Al-5%Mg increases with the addition of B4C particles. Significant improvement in wear resistance of Al-5%Mg is achieved with the addition of 20% B4C particles. SEM examination of worn surfaces showed no pull-out of reinforcing particles even at the highest load of 3.5 kg, thus confirming good interfacial bonding between dispersed B4C particles and Al alloy matrix. The neutron radiography data proved that (Al-5%Mg)-B4C composites possess good neutron absorbing characteristics. From the experimental data evaluated in the "study, it may be concluded that (Al-5%Mg)-B4C composites could be a candidate material for neutron shielding and control rod application. The enhanced elevated temperature-strength and favourable neutron absorption characteristics of these composites are strong points in favour of this material.

Aluminium matrix composites are among the most promising candidate materials for light weight and high strength applications such as transportation and armour. In a previous study 6061 aluminum matrix composites reinforced with plain weave carbon fiber preform (AS4 Hexcel) were successfully fabricated by squeeze casting using the laminate fabrication technique. This research aims at optimizing the fabrication process in order to achieve improved strength and mechanical properties. It focuses on the liquid infiltration squeeze casting method. Good mechanical bonding between fiber and aluminium is achieved thanks to improved infiltration and impregnation of the fabric by liquid aluminium. Oxidation products at fiber/aluminium interface and porosity are reduced. As a result, composites are produced with overall improved mechanical properties. The flexural strength is increased by up to 19.9% and 15.4% compared to the laminate approach and the reference 6061 aluminium alloy squeeze cast under identical conditions, respectively. Similarly, overall hardness is improved. However, the impact strength is reduced by 7.76% and 25.78% when compared to casts fabricated by the laminate method and the reference aluminium alloy, respectively. The thesis constitutes a good basis for further research on fiber and particle reinforced aluminium matrix composites with the goal of further improving fracture toughness, particularly for gradient materials used in armour applications.