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Materials and Design 24 (2003) 671679

Preparation and some properties of SiC particle reinforced aluminium alloy composites
Y. Sahin*
Department of Mechanical Education, Faculty of Technical Education, Gazi University, Ankara 06500, Turkey

Abstract Aluminium alloy composites containing various particle sizes of 10 and 20 wt.% SiC particles were prepared by molten metal mixing and squeeze casting method under argon gas. The stirring was carried out with graphite impeller during addition of particle. The molten mixture was poured into a die when the stirring was completed and metal matrix composites were produced by applying the pressure. Optical microscopic examination, hardness, density and porosity measurement were carried out. Moreover, metal matrix composites were machined at various cutting speeds under a fixed depth of cut and feed rate using different cutting tools. It is observed that there was a reasonably uniform dispersion of particles in the matrix alloy. The density decreased with decreasing particle sizes, but porosity decreased considerably with increasing particle size. In addition, the tool life decreased considerably with increasing cutting speeds for all tests. Among cutting tools, the wear resistance of Al2O3 coated tools showed better performance than those of the other tools without chip breaker geometries in the machining of SiCp-reinforced composites. 2003 Elsevier Science Ltd. All rights reserved.
Keywords: Metal matrix composite; SiC particle; Molten metal mixing; Porosity; Tool wear

1. Introduction Aluminium matrix composites possess many advantages such as low specific density, high strength and good wear resistance with the development of some non-continuous reinforcement materials, whisker, fibres or particles. In particular, the particulate reinforced aluminium matrix composites not only have good mechanical and wear properties, but are also economically viable w14x. Therefore, SiC-particulate-reinforced aluminium composites have found many applications in the aerospace and automotive industry. There are many methods for fabrication of particulate reinforced metal matrix composites (MMCs) such as powder metallurgy w5x, squeeze casting w69x, compocasting w1013x and so on. For the metal matrix composites, molten metal mixing is a cost effective method while powder metallurgy is costly, and squeeze casting provides good infiltration quality of chopped preforms w1416x. From the available literatures on MMCs, it is obvious that the morphology, distribution and volume fraction of the reinforcement phase as well as the matrix
*Tel.yfax: q52-777-329-3016. E-mail address: ysahin@gazi.edu.tr (Y. Sahin).

properties are all factors that affect the overall mechanical and cutting properties. The literature review showed that the wear characteristics of various cutting tools during machining of aluminium based composites, reinforced by SiCp, SiCw, SiC y Al2O3 w1725x and coated cutting tools w2536x were studied with respect to tool wear and surface finish. The purpose of the current study, therefore, is to: (a) produce particle-reinforced metal matrix composites by developing the method; (b) measure the density, hardness and porosity of the composites; and (c) investigate the tool wear in the turning of SiCp-reinforced aluminium matrix composites. 2. Experimental procedure 2.1. Fabrication of composite Metal matrix composites including various volume fractions of SiC particles were produced by liquid metallurgy method. 2014 Al alloy was used as the matrix material, while SiC particles with an average size of 110, 45 or 29 mm were used as the reinforcement material. The SiCp in the experiments were supplied by Norton Co. The chemical composition of Al-2014 alloy

0261-3069/03/$ - see front matter 2003 Elsevier Science Ltd. All rights reserved. doi:10.1016/S0261-306903.00156-0

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Table 1 The chemical composition of aluminium alloy Types of alloy Al-2014 Si Fe wt.(%) 0.66 0.504 Mn 0.62 Mg 0.6 Zn 0.11 Cr 0.03 Cu 4.49 Al 92.9

used in this study is presented in Table 1. The composites were fabricated by a molten metal of aluminium alloy using an electric induction furnace, which is 2 kW power under protected argon gas. For manufacturing of MMCs, 10 and 20 wt.% SiC particles were used. Approximately, 350 g of Al-2014 alloy part with a 110mm diameter was charged into the crucible made from graphite and heated up from 200 to 750 8C for melting. The inside diameter of crucible was 55 mm and the diameter of the impeller was varied from 38 to 48 mm during the mixing process. The top of the furnace was covered with insulation board of alumina. When the melting temperature reached to 500 8C, the graphite mixer fixed on the mandreal of the drilling machine was inserted into the crucible, and started to stir the molten alloy at approximately 700 rev. y min speed. Three methods were used for adding SiC particles into the composites. First method is to use a tunnel-type pipe. Small amount of SiC particles were introduced into the matrix during the adding time by using this method since some particles distributed around or some others remained at bottom or y and top of the furnace. Second adding method, a block of alloy was used and many holes on the matrix were drilled with a 10-mm diameter drill. The particles were filled in the hole according to the desired amount. After completed the filling operation, these blocks were put into the crucible and remained to be melt. After melting was completed, mixing process started. However, the mixing process could not be achieved properly and some of particles were agglomerated or chemical reaction between the particle and matrix was more visible. Finally, SiC particles were oxidized at a temperature of 1100 8C at 2 h before introducing the melting process. Approximately, 58 g of silicon carbide particles were inserted on an aluminium foil by forming a packet. The packet was added into molten metal of crucible when the vortex was formed at every 1525 s. The packet of mixture melted and the particles started to distribute around the alloy sample. This method enabled a full and homogenous distribution of the particles in the matrix alloy. After completing the particle addition, the mixer was turned off and the molten mixture was poured into the pre-heated mould. Thermo-couples were inserted into the melt and furnace to measure the temperature. Argon gas is divided into two channels and one is sent to over the crucible in order to prevent molten metal with atmosphere while another one is fixed on reinforcement unit to control the

flow rate of the reinforcements. The experimental setup used for the production of MMCs is shown in Fig. 1. The fabricated billets are of 40-mm diameter and of 160-mm height, the mold made from cast iron and pouring process is done from the bottom of mold. To minimize porosity of the MMCs, 3000 kg of force by hydraulic press was applied mechanically before taken from the mold. The pressure was carried out at a period of 7 min and mold was taken from the press to cool down at approximately 20 min. Details of the experimental study can be found in Ref. w37,38x. 2.2. Metallography The samples were sectioned and examined by an optical microscopy. Specimens for metallographic observation were prepared by grinding through 800 grit papers followed by polishing with 6 mm diamond paste. 2.3. Density and hardness measurement The density of the composites was obtained by the Archimedian principle of weighing small pieces cut from the composite disc first in air and then in water. Then, theoretical density of composite and its alloy was calculated from the chemical analysis data. The porosity of the composites was also determined. The hardnesses of the composites and matrix alloy were measured after polishing to a 3 mm finish. 2.4. Cutting conditions Machining tests were carried out to determine the tool wear or tool life under various cutting conditions when cutting three types of composites and their alloy matrix. The tests were conducted under different cutting conditions using a Boxford 250 CNC lathe machine, which is 5 kW power. The cutting speed was derived from the measured spindle speed and the diameter of the surface of the workpiece. All tests were carried out without coolant at a depth of cut equal to 0.6 mm and feed rate of 0.12 mm rev.y1. The cutting conditions and tool geometry used in the experiment are listed in Table 2. The inserts were clamped mechanically in a rigid tool holder of CTANR 2525-M16 type. Different tools, including an Al2O3 coating on K15 carbide grade denoted by the term of tool A, not having any chip breaker geometry and an Al2O3 coated on K15 carbide grade, denoted by the term of tool B, which is a chip breaker geometry and TiN coated on P15 carbide (TP100) cutting tool denoted by tool C in this study, have been used. All tools are commercially available inserts, according to ISO code, TNMA 160412, TNMG 160412 and TNMG 160412-MF2 were supplied by Sandvick and Seco, respectively, during the machining tests. The

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Fig. 1. Schematic diagram of experimental set-up for manufacturing MMCs.

work material to be machined is the SiC reinforced MMCs. After each test, the worn cutting tool is measured with the optical tool microscope to determine the degree of flank wear. For these tests, tool life criteria were taken as 0.6 mm. 3. Results and discussion 3.1. Microstructure The properties of the MMCs depend not only on the matrix, particle, and the volume fraction, but also on distribution of reinforcing particles and interface bonding between the particle and matrix. In practical way, to achieve a homogenous distribution is difficult. Thus, the above process parameters should be optimized. The optical micrograph of the aluminium composite reinforced with approximately 10 wt.% of SiCp is shown in
Table 2 Cutting tools used in the experiments Type of the tool Tool A Tool B Tool C Cutting tool designation TNMA 160412 TNMG 160412-23 TNMG160412-MF2 Chemical composition of coatings

Fig. 2a, b and c, respectively. The distribution of SiCp in these composites is uniform. These results show that this process can be used to produce MMCs when the volume percent was less than the 30%. For the microstructure of these composite specimens, no pores existed in these specimens due to the improvement of wettability when the Al-2014 alloy was used. Fig. 2b shows the microstructure of the composite reinforced with 45 mm particle size. It indicates that no evidence of the presence of cavities neither at interfaces nor in the matrix was found with optical microscopy, which indicates that a good bonding between the matrix and ceramic particulate was obtained by using the molten mixing method. Fig. 2c also shows the 110 mm particulate reinforced aluminium composite. The SiC particles are observed to be angular in shape. A careful examination of Fig. 2c indicates that apart from the large SiC particles, fine SiC particles less than 25 mm size are also present. In the case of 20 wt.% of SiCp reinforced composites, Fig.

Cutting fluids Dry Dry Dry

Cutting speed (mymin) 40, 60, 80 40, 60, 80 40, 60, 80

DOC (mm) 0.6 0.6 0.6

TiCqAl2O3 TiCqAl2O3 Al2O3qTi (C,N)qTiN

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Fig. 2. Optical micrographs of the metal matrix composites. 10 wt.% SiCp with 29 mm particles (a); 10 wt.% SiCp with 45 mm size (b); 10 wt.% SiC with 110 mm particles (c); 20 wt.% SiCp with 29 mm (d); 20 wt.% SiCp with 45 mm (e); and 20 wt.% SiCp with 110 mm (f).

2d, e and f shows optical micrographs of these composites reinforced with 29 mm, 45 mm and 110 mm particulate sizes, respectively. Again these micrographs reveal that the interface between the matrix and particle to be from porosity. The homogenous distribution was obtained for the composite reinforced with a 110 mm particle when compared with other particle reinforced composites. Some agglomeration is also observed when volume fraction and particle size is less than 110 mm. However, in general, the particle size distribution was nearly identical in all the composites. The micrograph taken under high magnification also revealed that ceramic particles were covered and were wetted by the matrix alloy.

3.2. Hardness and density measurement The variations of hardness of the composites are shown in Fig. 3. The hardness of the MMCs increased more or less linearly with the volume fraction of particulates in the alloy matrix due to the increasing ceramic phase of the matrix alloy. A significant improvement in both strength and hardness of squeeze cast AlSi alloy reinforced with alumina short fibres and Al-4.4%Cu alloy reinforced with continuous boron fibes has been reported w4,7x. The introducing alumina short fibres into the Al matrix resulted in increase in mechanical properties such as hardness and compressive strength w8x.

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composites, because of the decrease in the inner-particles spacing. In other words, with increasing the volume fraction of MMCs during the production stage, it is required that the longer particle addition time is combined with decreasing the particle size. The porosity level increased, since the contact surface area was increased. It is also reported by the early work w5,8x. The porosity of the composite was found between 1 and 2.1 vol.%. This is due to application of pressure on the mixed slurry or oxidation of SiCp before introduction to the matrix alloy during the fabrication stage. Those values indicate that the porosities of the composites are at acceptable levels for low volume fraction of composites. Kok et al. w8x who demonstrated that metal matrix composites were produced using the same technique and porosity level was found approximately 4%. In his work, Al-2024 alloy was reinforced by Al2O3, but oxidation process could not be applied on the SiC particles before introduction of particles into the molten alloy.
Fig. 3. Variation of hardness with volume fraction of particle.

3.3. Tool wear and surface observation The relationships between the tool life for various cutting tools under different cutting speeds are shown in Fig. 5. Tests were carried out on the 10 wt.% composite reinforced with 45 mm particle size. It can be seen that tool life decreased with increasing the cutting speed in all cutting conditions. The result showed that tool A sustained the least flank wear due to the extreme hardness and not having a chip breaker geometry or the result of chemical stability of this tool. The tool C is found to be very unsatisfactory and sustain the most severe flank wear. This might be due to a triplelayer-coating tool and increasing the stress concentration effect on tool during machining of the MMCs. The tool life also depends upon the cutting conditions. For

The density of the composite is shown in Fig. 4a. As shown in the figure, the density increased with increasing the volume fraction of particulates. The increase in density indicates that particle breakage may not have any significant influence on the composites. It is believed to achieve an improvement of the bonding between the particle and matrix. The porosities of composites were evaluated from the difference between the expected and the observed density of each sample. The variations of porosity level in these composites are also shown in Fig. 4b. This figure indicates that increasing amount of porosity is observed with increasing the volume fraction, especially for low particle sizes of

Fig. 4. Variation of density with volume fraction of particle (a), and variation of porosity level with volume fraction particle (b).

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Fig. 5. Variation of flank wear with cutting speed for the 45 mm particle-reinforced composites. Tool A (a), Tool B (b) and Tool C (c).

example, tool lives for cutting tools of A, C were 47, 24 s when the test conducted at a speed of 40 m miny1. There was an appreciable reduction at higher cutting speeds for all inserts. The reason for this may be due to high cutting temperature generated during machining. The increase in temperature coupled with the high compressive stresses near the cutting edge, could accelerate tool wear and lead to the shorter tool life at high speed. The tool C lasted at 7 s at a cutting speed of 80 m miny1. The reason is that the cutting ability of SiCp distribution in the composites increased and behaved as an abrasive particle. In the machining of conventional metals, the cutting tools are abraded by the strain-hardened chips and the workpiece surface generated in machining process. Since, the pressure

between the workpiece and the cutting tool is very high, much heat is generated and the cutting tools becomes softer and sometimes chemical diffusion occurs between the cutting tool when the shape of the chip is of discontinuous type. However, the chip generated in the machining of particle-reinforced composite materials is of shattered type. The hardness of these particles is approximately 2600 Hv, while the microhardness of the aluminium alloy matrix ranges from 90 to 120 BHN. However, the hardness of carbide insert (1700 MPa) or ceramic tool (2100 MPa) was lower than that of the particles. Therefore, the coating was removed from the tools when cutting the MMCs with coated carbides and the dominating wear occurred on the flank face of the tool.

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Fig. 6. Wear surface of tool when machining the 10 wt.%SiCp-reinforced composite with 45 mm particle size, tested at 60 mymin speed under 0.12 mmyrev. feed rate and 0.6 mm depth of cut. (a) Tool A and (b) Tool C.

Tribological characteristics of coated tools were investigated experimentally by several authors w2936x. Tomac et al. w35x suggested that coatings with less hardness than that of Al2O3 and SiC offerred little or no advantage during the machining of SiC y Al composites. The performance of chemical vapor deposition (CVD) inserts to that of TiN, Ti (C,N) and Al2O3 coated tools were compared with same authors. These offered better performance than that of other tools. Quigley et al. w28x found that a triple-coated carbide, having a top layer of TiN performed best in terms of flank wear, but gave the poorest surface finish when machining the SiCp-reinforced composite. Monaghan and OReilly w20x indicated that the polycrystalline diamond (PCD) tipped tools were superior to the carbide tools and they were much better than the coated and uncoated HSS drills w22x. The PCD tools provided satisfactory tool life compared to alumina and coated carbide tools, where the latter tools suffered from excessive edge chipping and crater wear for machining of SiC y Al composites to select the optimum tool material, tool geometry and cutting parameters w23x. Previous work carried out by Sahin et al. w33x showed that the machining of the 10, 20 and 30 wt.%Al2O3 particlereinforced composites was conducted at 100 m miny1 cutting speed using different tools, the flank wear associated with BUE formation in addition to broken layer of coated material of TiN (K10) coated tool. This suggests that a-triple-layer coating was more resistant than a-double-coated layer based on the tool life, which is not the case for the present study. However, the tool having chip breaker geometry played a predominant role in decreasing the tool life and wear. For the TP30 tool, however, amount of chipping on the cutting edge was observed, smooth flank wear and small amount of

adhering material on flank face were observed and no such a BUE was formed here. Similar results were reported by Brun et al. w21x, who related the tool wear rate, mainly due to abrasion as in the case of our present study. As far as considering the wear surface of the composite, Fig. 6a,b shows wear surfaces of the tool A and B when the test carried out at 60 m miny1 speed in machining of the same weight fraction of the composite. It can be seen that a quite smooth surface in Fig. 6a can be observed in comparison to Fig. 6b. Some particles were removed from the rake face and abrasive grooving lengths slightly decreased for tool B. This might be due to related to the contacting area of the tool with workpiece specimen. Similar observations can be made but depth and length of abrasive grooves was less and surface also looks uniform (Fig. 6a). However, it is observed that amount of erosion was evidenced due to combination of high temperature and adhesion wear (Fig. 6b). It can be concluded that the main wear mechanism is the result of abrasion of SiC particles. Similar results were found by Yanming et al. w22x, for cutting SiCp-reinforced Al matrix composites. The MMCs could not be deformed plastically since the SiC particles are harder than carbide inserts or ceramic tools. When they cut by these tools, the SiCp particles in the composites also microcut these tools randomly and densely in the formation between the workpiece and the tool. 4. Conclusions The microstructure and machinability of SiCp-reinforced aluminium alloy composites were investigated.

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Y. Sahin / Materials and Design 24 (2003) 671679 ference on fabrication of particles reinforced MMCs, Montreal, Canada, September 1720, 1990; pp. 6378. Chong Y, Atkins HV, Jones H. Effect of ceramic particle size, melt superheat, impurities and alloy conditions on threshold pressure for infiltration of SiC powder compacts by al-based melts. J Mater Sci Eng 1993;A173:232 237. Fukunaga H, Goda K. Fabrication of fibre-reinforced metal by squeeze casting. Bull JSME 1984;27(228):1245 1250. Bardal A. Wettability and interface reaction producing in the AlSiMg surface oxidized SiC system. J Mater Sci Eng 1992;A159:119 123. Llyod DJ. Particle-reinforced aluminium and magnesium matrix composites. Int Mater Rev 1994;39(1):1 23. Mansur LJ, Mortensen A, Cornic JA, Flemings MC. Infiltration of fibrous preforms by a pure metal: part II-experiment. Metall Trans A 1998;20A:2547 2553. Zhang Z, Long S, Flower HM. Light alloy composite production by liquid metal infiltration. Composites 1994;25(5):380 392. Kanada H, Choh T. Fabrication of particle-reinforced magnesium composites by applying a spontanous infiltration pressure. J Mater Sci 1997;32:47 56. Maxwell PB, Martins GP, Olson DL, Edward GR. Infiltration of Al and Mg alloys with SiC particles. Mater Trans 1990;21B:475 482. Rohatgi PK, Asthana R, Das S. Solidification, structures and properties of a cast metal ceramic particle composites. Int Mater Rev 1986;31, 115(3):88 92. Lane CT. Machining characteristics of particle-reinforced aluminium. Proceedings of Conference fabrication of particulate reinforced metal composites, Montreal, Canada, September 17 19, 1990. Monaghan J, OReilly P. Machinability of Al alloyySiC metal matrix composite. Process Adv Mater 1992;2:37 46. Brun MK, Lee M, Gorsler F. Wear characteristics of various hard materials for machining SiCp reinforced aluminium alloy. Wear 1985;104:21 29. Yanming Q, Zehna Z. Tool wear and its mechanism for cutting SiCp reinforced Al matrix composites. J Mater Process Technol 2000;100:194 199. El-Gallab M, Sklad M. Machining of AlySiCp metal matrix composites part-I:tool performance. J Mater Process Technol 1998;83:151 158. Looney LA, Monaghan JM, OReilly P, Taplin DMR. The turning of an AlySiC metal composite. J Mater Process Technol 1992;33:453 468. Hung NP, Boey FYC, Khor KA, Oh CA, Lee HF. Machinability of cast and powder formed aluminium alloys reinforced with SiC particles. J Mater Process Technol 1995;48(14):291 297. Lin JT, Bhattacharyya D, Lane C. Machinability of a silicon carbide reinforced aluminium metal matrix composite. Wear 1995;181:883 888. Yang B-H, Wang C-C. Machinability of SiCp reinforced Al alloy composite materials. Light Met 1993;43(4):187 192. Quigley Q, Monaghan J, OReilly P. Factors affecting the machinability of an AlySiC metal matrix composites. J Mater Process Technol 1994;43:21 36. T, Ikeda S. Machinability of Al2O3 SiC short fibreSaga reinforced Al alloy composites. J Jpn Int Light Met 1991;41(4):264 269. Guu YY, Lin J. Comparison of the tribological characteristics of titanium and titanium carbon nitride coating films. Surf Coat Technol 1996;85:146 155. Berganan E, Kaufmoin H, Schmid R, Vogel J. Ion-plate titanium carbon nitride films. Surf Coat Technol 1990;42:237 251.

The hardness, density and porosity were also measured. The following conclusions have been drawn. 1. A liquid metallurgy route was developed for manufacturing the metal matrix composites by adding SiC particles as packets. The pouring process was conducted from the bottom of the crucible in the electrical furnace after mixing process completed. 2. MMCs consisting of 10 and 20 wt.% SiC particles with various sizes could be produced successfully by molten metal mixing method and subsequently the pressure applied. 3. Microstructural examination showed that the SiCp distributions were homogeneous and no interface porosity could be observed. Hardness of the aluminium alloy improved significantly by addition of SiC particles into it, while density of the composite also increased almost linearly with the weight fraction of particles. However, porosity level increased slightly with increasing particulate content and decreased with increasing particle size. 4. It is shown that the tool life decreased with increasing the cutting speeds in all cutting conditions. The life of the tool A was significantly longer that that of tool B. In addition, it was observed that the major wear form of the tool was the mild abrasion and edge chipping on the flank face of the tools.

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Acknowledgments This research project was financed by the National Turkish University of Gazi in Turkey. The author also wishes to acknowledge the technical assistance by Mr G. Sur for carrying out this work. References
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w36x Chambers AR, Stephens SE. Machining of Al-5Mg reinforced with 5 vol.%Saffil and 15 vol.%SiC fibres. J Mater Sci Eng 1990;A135:287 290. w37x Sur G, M.Sc. Thesis, Aluminyum esasli metal matriksli kom pozitlerin uretimi, mekanik ozellikleri ve islenebilirliginin aras Gazi Universitesi, Ankaray tirilmasi, Fen Bilimleri Enstitusu, 2002. Turkey, Eylul w38x Sahin Y. Production and machinability of SiCp-reinforced metal matrix composites, Research Report of Gazi University, TEF 07y01-20 Number of Coded Project, Ankara yTurkey, July 2003.

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