M.Tech. / The mining industry exerts ever increasing demand for components with high wear resistance to the extent that plain ferrous alloys are falling short. Innovative metal-matrix composites nonferrous metals have been widely researched and used. Casting composites based on ferrous alloys pose monumental challenges in casting. Firstly, the density differential results in large resistant forces on the ceramic such that unless a rigid structure is configured, the less dense ceramic floats on the metal stream. Secondly, the poor wetting properties between metal and ceramic will result in inferior bonding of the matrix, hence separation of solids in service.This study presents the feasibility of manufacturing ceramic based metal matrix composites (MMC) for multi-purpose industrial application including wettability and the bonding between the matrix and the composite. The cold rods of alumina positioned in the mould prior to casting cracked as soon as they came in contact with hot metal. Because of the density difference between ceramic and liquid metal the alumina tended to float under the influence of Ferro static pressure. Infiltration of zirconia (ZrO2) and alumina (Al2O3) in ferrous matrix was investigated. Infiltration of liquid metal in ceramic filters increased with porosity of filters i.e. greater infiltration occurred in filters with larger pore volume fraction measured in terms of number of pores per linear inch (ppi). Thus, there was high infiltration in casting with 10ppi followed by 30ppi and there was poor infiltration in 50ppi ceramics. Infiltration increased with increasing temperature of the ceramics. A temperature of 1000oC was found to be superior to 800oC. The wetting behaviour of molten iron on the substrates of Al2O3 was investigated. Titanium in high chromium white cast iron was found to improve the wetting characteristics on alumina. The wetting angle decreased with increased titanium content. The wear properties of ferrous alloys used were not significantly improved by the ceramic used to make the composite. Filters are produced by a deposition process and hence are not densified for the purpose of manufacturing hard composites
| Identifer | oai:union.ndltd.org:netd.ac.za/oai:union.ndltd.org:uj/uj:7294 |
| Date | 02 November 2012 |
| Creators | Madzivhandila, Takalani |
| Source Sets | South African National ETD Portal |
| Detected Language | English |
| Type | Thesis |
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