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Lecture9 MaterPhysII Composites

Prof Zsolt

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Baha Jawad
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12 views26 pages

Lecture9 MaterPhysII Composites

Prof Zsolt

Uploaded by

Baha Jawad
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Materials Physics II

Contents:
1. Diffusion and concentration dependent diffusion
2. Role of crystal defects in diffusion
3. Solidification of pure materials: nucleation and crystal growth
4. Solidification of solid solutions and eutectic phase mixtures
5. Precipitation
6. Metastable phases and spinodal decomposition
7. Solid solution hardening
8. Plastic deformation of multicomponent systems
9. Diffusion free phase transformations
10. Ceramics, covalent (ionic) crystals and glasses
11. Composites
Composites
Applications in space, air and car industries from the 1970’s
Metal matrix composites (MMC)
●
MMC can be classified as continuous fiber composites and
non-continuous fiber composites
●
matrix is typically Al, Mg, Cu, Ti, TiAl, Ni or NiAl alloys, Ni
superalloys or Fe alloys
●
Al-matrix composites are used most widely

I. Non-continuous fiber composites


production techniques:
1. powder metallurgy (PM)
2. casting

II. Continuous fiber composites


Non-continuous
Non- fiber composites
1. PM composites
Strengthening phase can be
●
Wishker
●
Short or chopped fibers
●
Particles (e.g. SiC)
Advantage: traditional solidification technologies can be applied
first step in PM, the oxide films on the surface should be broken
up like in Al powder metallurgy.

Whiskers: (from 1965)


Al2O3 is expensive and it hardly forms strong bonds with the matrix
SiC is even more expensive, but it forms better bonds with the
matrix.

Particles: (from 1970)


For example SiC with Young’s modulus 380 GPa, density 3.21 g/cm3
Non-continuous
Non- fiber composites
SiC composites

particle size disribution


Non-continuous
Non- fiber composites
Comparison of particles and whiskers containing MMCs (1984)
with the same volume fraction
with the same matrix alloy
with similar processing and heat treatments

Whiskers: the Young’s modulus, the yield stress is higher,


and the ultimate stress (UTS) are higher in fiber direction,
but the plastic deformability is smaller
in the perpendicular directions all these parameters
give worse performance
production is more expensive (specific space applications)

Other strengthening materials:


SAFFIL: short polycrystalline fibers of Al2O3
- RT strength is not improved, but high temp. strength is better
- E is higher, e.g. it is used in Toyota diesel piston
Non-continuous
Non- fiber composites
2. MMCs made by castings (from 1985) SiC/Al-matrix MMCs

Tsolidus<T<Tliquidus
Non-continuous
Non- fiber composites
If the volume fraction (f) of the fiber increases, the viscosity
decreases, therefore typically: f<20%
There is no problem with surface oxides in casting methods,
contrary to PM MMCs.
However, the microstructure depends on the casting procedure
Isotropic E, yields stress and UTS are smaller than that for PM MMCs

Precipitations form in the matrix change due to the ceramic phase:


- dislocation density become larger, due to the different coefficients
of thermal expansion (CTE)
- surface can be vacancy sink or can enhance nucleation
- chemical reactions may take place between the two phases
Non-continuous
Non- fiber composites
Surface reactions in Al2O3/SiO2 composites: spinel formation

2SiO2(S) + 2Al(L)+ Mg(L) → MgAl2O4(S) + 2Si(L)


2Al2O3(S) + SiO2(S)+ 2Mg(L) → 2MgAl2O4(S) + Si(L)L)
Non-continuous
Non- fiber composites
To reduce cost, in-situ composites were developed: XDTM process
(based on directional solidification of eutectic alloys)

X Y T >T m( A)
A
exotherm reaction
X,Y compound phase Submicron size carbide,
A metallic solvent nitride, boride particles or
their mixture
For example: Al-TiB2 (XD)
40% higher elastic moduli, better high temperature strength,
fatigue strength and wear resistance

Designer XD materials with hard dispersoids for strength


(whiskers for creep resistance) and with soft phases for
increased toughness
Continuous fiber composites

Large anisotropy

A) fibers with large diameter


e.g. SiC or B with W core, or Al2O3 single crystal (expensive)

B) graphite fibers
Ti or B surface is vapor deposited to a graphite fiber
then infiltrated by the liquid alloy

Zero CTE can be produced in this way


Good thermal conductivity and high moduli and strength

fibers cca 2000USD/kg


application: Hubble antenna (graphite/Al tube + B4C/Al connections)
Continuous fiber composites
Mechanical behavior: Elastic modulus parallel to the fibers

Good contact between the fiber and the matrix


Deformation is the same in both component
Δl
εc =ε f =ε m= σ f = E f εc σ m= E m εc
l

P c= P f + P m σ c Ac =( E f A f + E m Am) εc

σ c Ac =σ f A f +σ m Am σc Af Am
Ec = ε = E f + Em
c Ac Ac

Voight limit E c =E f V f + E m V m =E ∥

σ c =σ f V f +σ m V m
Continuous fiber composites
Mechanical behavior: Elastic modulus perpendicular to the fibers

σ c =σ f =σ m 1
Δ l c =Δ l m + Δ l f ⋅
lc
Δ lc Δ lm Δ l f lc
εc = = +
lc lc lc

lm lf
εc =ε m +ε f
lc lc εc =ε m V m +ε f V f

Vm V σc σc σc
f = V m+ V f
Ec Em Ef
Reuss limit 1 Vm V f 1
= + =
E c E m E f E zz
Continuous fiber composites
Shear and compression moduli for n phase composites

lower limit upper limit

K1≤Kr≤Kn and G1≤Gr≤Gn


Continuous fiber composites
Shear and compression moduli for two phase composites

lower limit upper limit


Design of composite materials
Optimal selection of components, characteristics can be designed
Performance indexes based on Ashby diagrams

For example: bending of a beam (constant l length, variable A area)

Performance index:
Design of composite materials
Basic characteristics

characteristic typical notation (unit)


density
Youngs
Young’s modulus
modulus
yield strength
fracture toughness
linear thermal expansion
heat capacity
thermal conductivity
thermal diffusivity
Design of composite materials
Performance indexes

Special requirements Performance index


elongation under small weight
bending of a column with small weight
bending of a plate with small weight
tensile strength under weight
torsional strength under weight
bending limit of a plate under weight
fracture resistance for fast loading
fracture resistance for fast deformation
fracture resistance against high energy
minimal thermal distortion
Design of composite materials
Ashby diagrams for material selection: deformation and yield
Design of composite materials
Ashby diagrams

density
modulus

strength
Design of composite materials
Design of composite materials
Design of
composite materials
Optimize for minimal thermal distortion
Functionally graded materials
Hints: optimized, hierarchical functionally gradient structures
in nature: e.g. bamboo, barley, corn
Functionally graded materials
Large gradients are mostly disadvantageous in composite materials,
because they leads to local stress/heat concentrations
These gradients are smoother and designed in functionally graded materials

Inverse design: the final products determined the local microstructure


Functionally graded materials
Production methods for functionally graded materials:

Plasma spraying
Functionally graded materials
Plasma spraying: flexible method for designed gradients

Additive manufacturing, 3D printing

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