Review on the possible tool materials for friction stir welding of steel plates

The friction stir welding (FSW) process is mainly used in industrial applications for joining low melting temperature materials such as aluminium and magnesium. FSW has many advantages in comparison with conventional fusion arc welding. Therefore the interest to use this technique for joining steel plates has grown. However such usage is still limited because of the lack of adequate tool materials. This review gives an overview of possible tool materials for FSW of steels focussing on tungsten, tungsten carbide, pcBN and a few ultra-high temperature ceramics

Zirconia toughened SiC whisker reinforced alumina composites small business innovation research

The objective of this phase 1 project was to develop a ceramic composite with superior fracture toughness and high strength, based on combining two toughness inducing materials: zirconia for transformation toughening and SiC whiskers for reinforcement, in a controlled microstructure alumina matrix. The controlled matrix microstructure is obtained by controlling the nucleation frequency of the alumina gel with seeds (submicron alpha-alumina). The results demonstrate the technical feasibility of producing superior binary composites (Al2O3-ZrO2) and tertiary composites (Al2O3-ZrO2-SiC). Thirty-two composites were prepared, consolidated, and fracture toughness tested. Statistical analysis of the results showed that: (1) the SiC type is the key statistically significant factor for increased toughness; (2) sol-gel processing with a-alumina seed had a statistically significant effect on increasing toughness of the binary and tertiary composites compared to the corresponding mixed powder processing; and (3) ZrO2 content within the range investigated had a minor effect. Binary composites with an average critical fracture toughness of 6.6MPam sup 1/2, were obtained. Tertiary composites with critical fracture toughness in the range of 9.3 to 10.1 MPam sup 1/2 were obtained. Results indicate that these composites are superior to zirconia toughened alumina and SiC whisker reinforced alumina ceramic composites produced by conventional techniques with similar composition from published data

A critical review of experimental accomplishments in the field of filament-reinforced metal matrix composites Bimonthly progress report

Critical review of experimental accomplishments in filament reinforced metal-matrix composite

A study of low density, high strength high modulus filaments and composites

Filament and whisker reinforcement of low density, high strength, high modulus composites - metallic and ceramic layers alternated in multilaminar composite

Ti3SiC2-Cf composites by spark plasma sintering: Processing, microstructure and thermo-mechanical properties

MAX phases, and particularly Ti3SiC2, are interesting for high temperature applications. The addition of carbon fibers can be used to reduce the density and to modify the properties of the matrix. This work presents the densification and characterization of Ti3SiC2 based composites with short carbon fibers using a fast and simple fabrication approach: dry mixing and densification by Spark Plasma Sintering. Good densification level was obtained below 1400 °C even with a high amount of fibers. The reaction of the fibers with the matrix is limited thanks to the fast processing time and depends on the amount of fibers in the composite. Bending strength at room temperature, between 437 and 120 MPa, is in the range of conventional CMCs with short fibers and according to the resistance of the matrix and the presence of residual porosity. Thermo-mechanical properties of the composites up to 1500 °C are also presented.This work has received funding from the European Union’s Horizon2020 “Research and innovation programme” under grant agreement No 685594 (C3HARME

Sinter forging of zirconia toughened alumina

Sinter forging experiments have been carried out on powder compacts of zirconia toughened alumina (ZTA) Ceramics Alumina-15 wt% zirconia was prepared by a gel precipitation method and calcined at temperatures of 900 or 1100°C. Full densification of ZTA ceramics was obtained within 15 min at 1400°C and 40 MPa. A homogeneous microstructure can be observed with an alumina grain size of 0.7 mgrm and a zirconia grain size of 0.2 mgrm. Almost no textural evolution occurred in the microstructure. During sinter forging the densification behaviour of the compacts was improved by an effective shear strain, for which values of more than 100% could be obtained. As a result of the shear deformation the densification of ZTA in the agr alumina phase stage shifted to lower temperature. During pressureless sintering the gamma to agr alumina transformation temperature was dependent of the preceding calcination temperature, while during sinter forging this phase transformation was independent of calcination temperature and took place at a lower temperature

Tribological characteristics of silicon carbide whisker-reinforced alumina at elevated temperatures

The enhanced fracture toughness of whisker reinforced ceramics makes them attractive candidates for sliding components of advanced hear engines. Examples include piston rings and valve stems for Stirling engines and other low heat rejection devices. However, the tribological behavior of whisker reinforced ceramics is largely unknown. This is especially true for the applications described where use temperatures can vary from below ambient to well over 1000 C. An experimental research program to identify the dominant wear mechanism(s) for a silicon carbide whisker reinforced alumina composite, SiCw-Al2O3 is described. In addition, a wear mechanism model is developed to explain and corroborate the experimental results and to provide insight for material improvement

Compressive strength degradation in ZrB2-based ultra-high temperature ceramic composites

The high temperature compressive strength behavior of zirconium diboride (ZrB2)-silicon carbide (SiC) particulate composites containing either carbon powder or SCS-9a silicon carbide fibers was evaluated in air. Constant strain rate compression tests have been performed on these materials at room temperature, 1400, and 1550°C. The degradation of the mechanical properties as a result of atmospheric air exposure at high temperatures has also been studied as a function of exposure time. The ZrB2-SiC material shows excellent strength of 3.1±0.2GPa at room temperature and 0.9±0.1GPa at 1400°C when external defects are eliminated by surface finishing. The presence of C is detrimental to the compressive strength of the ZrB2-SiC-C material, as carbon burns out at high temperatures in air. As-fabricated SCS-9a SiC fiber reinforced ZrB2-SiC composites contain significant matrix microcracking due to residual thermal stresses, and show poor mechanical properties and oxidation resistance. After exposure to air at high temperatures an external SiO2 layer is formed, beneath which ZrB2 oxidizes to ZrO2. A significant reduction in room temperature strength occurs after 16-24h of exposure to air at 1400°C for the ZrB2-SiC material, while for the ZrB2-SiC-C composition this reduction is observed after less than 16h. The thickness of the oxide layer was measured as a function of exposure time and temperatures and the details of oxidation process has been discussed.The European Office of Aerospace Research and Development, Air Force Office of Scientific Research, Air Force Research Laboratory, FA8655-07-1-308

Processing and properties of ultra-refractory composites based on Zr- and Hf-borides: state of the art and perspectives

High performance Ultra-High-Temperature Composites (based on zirconium and hafnium borides) are characterized by relevant and unique thermo-physical and thermo-mechanical properties, suitable for applications in Thermal Protection - Durable TPS and hot structure for reusable vehicles and in Hypersonics - Leading edges, cooled scramjet panels, struts, cowls, and nozzles. In spite of the difficult sinterability Zr- and Hf- diborides, recent results highlighted that these ceramics can be produced with full density, fine microstructure and controlled mechanical and thermal properties, through different procedures: pressureless sintering and hot pressing combined with the use of proper sintering aids, reactive synthesis/sintering procedures starting from precursors, field assisted technologies like spark plasma sintering (SPS). The selection of reinforcing phase (SiC, B4C, TaSi2, MoSi2, etc) is suitable to improve mechanical properties and oxidation resistance of ceramic composites based on ZrB2 and HfB2. Strength as high as ~ 800MPa at room temperature and up to 600 MPa at 1500?C in air were obtained, consequently to tailored compositions and processing control. SPS proved to be a very rapid fabrication process leading to refined microstructure and high properties of ultra-refractory diborides -based composite