Microstructure of metal matrix composites reinforced by ceramic microballoons

Metal matrix composites reinforced by ceramic hollow microspheres were produced as special porous metals, called metal matrix syntactic foams (MMSFs). In this paper the microstructure of the ceramic hollow microspheres as reinforcing element was investigated in connection with the production of MMSFs by pressure infiltration. SL150 and SL300 type ceramic microspheres from Envirospheres Ltd. (Australia) were investigated. They contained various oxide ceramics, mainly Al2O3 and SiO2. The chemical composition and the microstructure of the microspheres had strong effect on their infiltration characteristics; therefore in the view of MMSF production it was very important to know microstructural details about the microspheres. Due to this energy dispersive X-ray spectroscopy maps were recorded from the cross sections of the microspheres’ wall. The results showed that the Al2O3 and SiO2 distribution was not equal; the Al2O3 phase was embedded in the surrounding mullite and SiO2 phase in the form of needles. Line energy dispersive X-ray spectroscopy measurements were performed in order to investigate the possible reaction between the different aluminium alloy matrices and the ceramic microspheres. The results showed that, due to the uneven distribution of Al2O3 rich particles, the molten aluminium could reduce the SiO2 rich parts of the microspheres and the wall of the hollow microspheres became damaged and degraded. This chemical reaction between the microspheres and the walls could make the infiltration easier, but the resulting mechanical properties will be lower due to the damaged microsphere walls

Development and evaluation of hybrid aluminium matrix syntactic foams

A special class of metallic foams, the so called metal matrix syntactic foams was produced by pressure infiltration technique. Metal matrix syntactic foams consist of a light-weight metal matrix and a set of hollow spheres. Microstructural investigatons were done on polished specimens. The results showed almost perfect infiltration and thin interface layer between the matrix and the reinforcement. Quasi-static compression tests were also done to get basic information about the mechanical properties of metal matrix syntactic foam. The results showed outstanding mechanical properties among other metallic foams. The tests were performed in order to prepare pin-on-disc wear tests

On the microstructure of ceramic hollow microspheres

Metal matrix syntactic foams (MMSFs) are relatively new materials which have increasing interest in the field of aviation and packaging industry. They are metal matrix composites, and their porosity is ensured by the incorporation of ceramic hollow microspheres. In this paper the microstructure of the ceramic hollow microspheres as reinforcing element was investigated. SL150, SLG and SL300 type ceramic microspheres were investigated. They contain various oxides, mainly Al_2O_2 and SiO_2. Energy dispersive X-ray spectroscopy (EDS) maps were recorded from the sections of the microspheres´ wall. The results showed that the Al_2O_3 and SiO_2 distribution was not equal; the Al_2O_3 phase was embedded in the surrounding mullite and SiO_2 phase in the form of needles. EDS along a line in aluminium matrix syntactic foams was carried out in order to investigate the possible reaction between the aluminium matrix and the ceramic microspheres. Due to the uneven distribution of Al_2O_3 rich particles, the molten aluminium can reduce the SiO_2 rich parts of the microspheres and the wall of the microspheres become damaged and degraded. This chemical reaction between the microspheres and the walls can make the infiltration easier, but the resulting mechanical properties will be lower due to the damaged microsphere walls

Characterisation of hybrid metal matrix syntactic foams

High quality aluminium matrix syntactic foams (AMSFs) were produced by pressure infiltration. This method can ensure the maximal volume fraction of the reinforcing hollow spheres and very low amount of unwanted or matrix porosities. By this method hybrid MMSFs with mixed metal and ceramic hollow spheres were also produced. The matrix material was AlSi12 alloy and two different types – produced by Hollomet GmbH in Germany – of hollow spheres were used: Globomet (GM) and Globocer (GC). The geometrical properties of the hollow spheres were similar (average outer diameter), but their base material was pure iron and Al2O3+SiO2 in the case of GM and GC hollow spheres respectively. The volume fraction of the reinforcing hollow spheres were maintained at ~65 vol%, but the ratio of them was altered in 20% steps (100% GM + 0% GC, 80% GM + 20% GC…). The results of the compression tests showed, that the compressive strength, yield strength, plateau strength, structural stiffness and the absorbed mechanical energy values increased with higher ceramic hollow sphere reinforcement ratio. The fracture strains of the investigated MMSFs decreased with the higher GC ratio. Generally the strength values also increased with higher diameter to height (H/D) ratio from H/D=1 to H/D=1.5 and 2

Effect of grain boundary structure on the intercrystalline damaging of austenic steel during brazing

During brazing of austenitic stainless steel with copper based brazing material a common failure occurs, namely that the brazing material solutes along grain boundaries, which looks like cracks. This unfortunate effect occurred when AISI 304 and 310 steels are brazing. To avoid this unwanted effect - since the cracks propagate mainly on high angle grain boundaries - our goal was to enhance the number of special coincident site lattice type grain boundaries with thermomechanical treatment. Experiments were performed for 1, 48 and 72 hour heat treatments on materials cold rolled at different levels. After the thermomechanical treatment significant decrease in the crack size was found in depth and width, respectively

Effect of leaser treatment on the surface of cast iron cylinder bores

The environmental and pollution materials emission standards in Europe are going to be more strict. In order to meet the standards, a European automotive manufacturer performs a finishing laser treatment on the honed cast iron cylinder bores of their V-engine blocks. Samples of laser treated cast iron cylinder bores with lamellar graphite were investigated. Due to the growing popularity and high efficiency of fiber lasers, samples treated with Yb-fiber lasers were investigated. In order to evaluate the microstructure and grain size of the laser treated layer, scanning electron microscopic images were taken on cross sectioned samples with a scanning electron microscope/focused ion beam dual beam electron microscope. The samples were found to be ultra fine grained. Nanoindentation hardness measurements of the surface layer showed a clear linear trend between the laser power density in the applied range and the measured hardness. Additional micro hardness measurements suggest an annealed region beneath the surfa ce