AU2021104792A4

AU2021104792A4 - An Aluminum Hybrid Metal Matrix Composite And Method Of Preparation Thereof

Info

Publication number: AU2021104792A4
Application number: AU2021104792A
Authority: AU
Inventors: Ayusman Behera; Rajesh Behera; Anshuman Das; Sudhansu Ranjan Das; Bishnu Prasad Mishra; Kamalakanta Muduli; Noorhafiza Binti Muhammad; Sarat Chandra Panigrahi; Arun Kumar Parida; Debabrata Rath; Karthi S.; Santosh Kumar Sahu; Ananya SAMAL; Birajendu Samal
Original assignee: Individual
Current assignee: Individual
Priority date: 2021-08-02
Filing date: 2021-08-02
Publication date: 2022-05-19
Anticipated expiration: 2029-08-02

Abstract

The current invention recommended to an aluminum metal-matrix hybrid composite (AMMHC) prepared using powder metallurgy method. In particular, the invention relates to a newly developed hybrid composite containing powders of aluminum mixed with silicon, magnesium, copper, and ceramic powders of silicon carbide and graphite in a precisely controlled amount that improves mechanical properties and/or physical properties. The composites have attractive characteristics including high-strength, light-weight, corrosion resistance, significant density, and low cost of manufacturing. The aluminum hybrid composite containing aluminum as the main matrix metal and a plurality of inter-metallic particles distributed in the metal-matrix in an amount ranging from 0.5% by weight to about 10% by weight, while this matrix material is combined with reinforced materials of silicon, magnesium, copper, silicon carbide and graphite as inter-metallic particles. 1/11 100 102 104 106 comp__ed _g_ 108 I 110 HAMMC - _ FIGURE 1

Description

1/11

100

102

104

106

comp__ed _g_ 108

I 110

HAMMC - _

FIGURE 1

AUSTRALIA

Patents Act 1990

COMPLETE SPECIFICATION AN ALUMINUM HYBRID METAL MATRIX COMPOSITE AND METHOD OF PREPARATION THEREOF

The following statement is a full description of this invention, including the best method of performing it known to me

AN ALUMINUM HYBRID METAL MATRIX COMPOSITE AND METHOD OF PREPARATION THEREOF BACKGROUND

[001] Field of the invention

[002] Embodiments of the present invention generally relate to an aluminum hybrid metal matrix composite and the method of preparation thereof.

[003] Description of Related Art

[004] The world of modern materials requires serious research to create varieties of lightweight, high-strength composite materials with better mechanical properties. Typically, a hybrid composite with an aluminum metal matrix will exhibit improvements in properties such as strength, stiffness, resistance to contact wear compared to a metal matrix over mono-lithic forms. But to the extent, this property can be achieved depends very much on the particular metal powders, their weight, volume or mass fraction, and the method, how the composite is fabricated. The aluminum metal-matrix hybrid composites (AMMHCs) are reinforced with ceramic powders like silicon-carbide and graphite in the form of particles, flakes, or whiskers due to their greater rigidity, wear resistance and durability at an elevated temperature as compared to aluminum and others.

[005] Many attempts have been made in the art to form metal matrix hybrid composites in various ways. The prior art describes various metallurgical processes for the production of hybrid aluminum composites in solid or liquid routes. When using a solid route that is in powder metallurgy (P/M) processes, the metal matrix powders are mixed with the reinforcing powders in any form followed by cold compaction and sintering. The maximum volume or weight fraction of the ceramic powders such as silicon carbide and graphite reinforced in aluminum matrix composite obtained by P/M process is about 25 percent whiskers by weight or volume and less than 40 percent by weight or volume in the case of a powder particles.

[006] In the prior art, Rohatgi et al., European patent. EP0567284B1 teaches that the composite is prepared by administering carbide powders with graphite as a lubricant in the molten state of aluminum alloy to form aluminum-based composite. The carbide and the carbon particles are mixed in the aluminum mixture evenly distributing in the molten aluminum. The carbide-particles increase the modulus of elasticity, strength, and hardness, thus improving wear resistance.

[007] In another prior art, Carden et al., US Nos. US005980602A teaches that the invention exhibits an advanced composite of a metal matrix, wherein boron-carbide is used as a reinforced ceramic to the basic metal which shows better features such as a reduced weight, increased durability, hardness, and strength.

[008] In another prior art, Wada et al. US Patent No. US4657065A describes the production of a composite material with a magnesium matrix or its alloys and reinforced by discrete particles of silicon-carbide, which are made by casting. The hardness of the composite increased about 25 %, which was achieved by strengthening the SiC. Other properties such as tensile strength and wear resistance are also improved by the addition of SiC.

[009] In another prior art, Zedalis et al., OMPI (PCT) Pat. WO1989006287A2 discloses that the invention relates to a process for improving the mechanical properties of metals and, in particular, to a process for manufacturing aluminum composite with a metal matrix and a reinforcing phase by a powder process. They made aluminum metal matrix-based composite with reinforcing filler material of about 0.1- 50% by volume. The filler was consolidated to obtain a powder compact having a moldable mass, essentially without void, with better wear resistance.

[0010] In another prior art, Carlson, US Patent No. US 3,471,270A describes the invention to provide an improved composite metal material reinforced with high-strength metal support members and an aluminum base structure reinforced with improved metal fibers that can be used in temperatures up to 500 degrees Fahrenheit.

[0011] In another prior art, Behera et al., Radhika and surappa [1-9] reported that the most commonly used composite system, with a metal matrix of silicon carbide (SiC), magnesium, copper, and silicon reinforced aluminum, produces an aluminum-matrix composite. Powder metallurgy (P/M) metal, which is a new type of composite material having the required properties such as lower density, high rigidity and strength, good coefficient of thermal expansion, better corrosion resistance, fatigue, and excellent stability to dimension at elevated temperatures.

[0012] In another prior art, Mazakheri and Shabani [10] suggested that an aluminum alloy has excellent mechanical properties bearing less density, higher thermal conductivity, good strength to weight ratio, ductility as well as good corrosion resistance.

[0013 In yet another prior art, Rohatgi et al. [11] invented a composite body with different properties, which was obtained by forming a molten slurry of filler and die metal and placing the molten slurry in a profiled mold cavity.

[0014] In the present invention, the production of new and novel composites (Al-0.5Si 0.5Mg-2.5Cu-10SiC-2.5Gr) using traditional processes of powder metallurgy with a specified die design has been developed to manufacture the products. The weight fraction of the reinforced ceramic particles of (SiC) and graphite (Gr) powders in the composite is about 10 and 2.5% by weight respectively.

APPLICATIONS

[0015] The invention of aluminum metal-matrix hybrid composite proclaims improved performance and properties over recent commercially available materials. Present study has been attempted to fabricate an attractive hybrid composite with higher in strength, light-weight, more corrosion resistance, significant density and low cost in manufacturing. These composites can be used in manufacture of various components in the automotive, aerospace, defense, window frames, irrigation, pipeline, petro chemical and special-purpose machinery industries.

[0016] The novel AMMHCs can also be used in different areas, such as: Owing to the fact in electronic packaging and temperature control, aluminum-based hybrid composites have more demands in automobiles and avionics because of higher thermal-conductivity and where the lightness is required.

[0017] In sports and leisure products, these will be used in cycling, baseball, skiing, golf etc. because of the performance and lesser cost.

[0018] In robotics, medicine, biomedicine and the nuclear-material protection industry, AMMHCs have been considered for its huge applications because the amalgamation of mechanical-properties makes them particularly suitable.

SUMMARY

[0019] Embodiments in accordance with the present invention provide an aluminum hybrid metal matrix composite (AMMHCs) incorporating essentially a matrix-metal of aluminum as parent-metal of about 84% by weight and a plurality of inter-metallic particles reinforced in the matrix metal with an amount ranging from 0.5% by weight to about 10% by weight, wherein the said matrix metal is combined with reinforced particles of silicon, magnesium, copper, silicon carbide and graphite.

[0020] Embodiments in accordance with the present invention further provide a method of manufacturing aluminum hybrid metal matrix composite (AMMHCs), including the following steps: a mixture of powder of metallic aluminum and a variety of inter-metallic metal powder particles, including silicon, magnesium, copper, silicon carbide and graphite as reinforcing particles, forming a powder mixture; the said reinforced particles of silicon carbide (SiC) and graphite (Gr) with a proportion of 10% and 2.5% respectively by weight, are mixed properly in the powder mixture of Al-Si-Mg-Cu in a weight-fractions of (84-0.5-0.5-2.5)% are poured inside the designed die cavity at a pressure up to 521.87 MPa with the rate of loading 0.3 KN /sec; and after compaction, the green compacted hybrid composite products are removed from the die cavity and sintered at a temperature of about 6200 C and then annealed for 24 hours.

[0021] The preceding is a simplified summary to provide an understanding of some embodiments of the present invention. This summary is neither an extensive nor exhaustive overview of the present invention and its various embodiments. The summary presents selected concepts of the embodiments of the present invention in a simplified form as an introduction to the more detailed description presented below. As will be appreciated, other embodiments of the present invention are possible utilizing, alone or in combination, one or more of the features set forth above or described in detail below.

BRIEF DESCRIPTION OF THE DRAWINGS

[0022] The above and still further features and advantages of embodiments of the present invention will become apparent upon consideration of the following detailed description of embodiments thereof, especially when taken in conjunction with the accompanying drawings, and wherein:

[0023] Figure 1 illustrates the flowchart of the method for production of hybrid aluminum metal matrix composite using powder metallurgy method, according to an embodiment of the present invention;

[0024] Figure 2 illustrates the different metal powders reinforcing with aluminum metal powder producing a novel hybrid composite where aluminum acts as the matrix metal according to an embodiment of the present invention;

[0025] Figure 3 illustrates the step-wise pictorial representation for production of hybrid aluminum metal matrix composite, according to an embodiment of the present invention;

[0026] Figure 4 illustrates metal powders and their mixtures, according to an embodiment of the present invention;

[0027] Figure 5 illustrates a schematic diagram for manufacturing of die sets, according to an embodiment of the present invention;

[0028] Figure 6 illustrates die sets manufactured, according to an embodiment of the present invention;

[0029] Figure 7 illustrates digital compression testing machine and their readings, according to an embodiment of the present invention;

[0030] Figure 8 illustrates the removal of green aluminum hybrid metal matrix composites (AMMHCs) from the die cavity, according to an embodiment of the present invention;

[0031] Figure 9 illustrates sintering of green aluminum hybrid metal matrix composites at 6200 C, according to an embodiment of the present invention;

[0032] Figure 10 illustrates the aluminum hybrid metal matrix composites, according to an embodiment of the present invention; and

[0033] Figure 11 illustrates the scanning electron microscope (SEM) micrograph, according to an embodiment of the present invention.

[0034] The headings used herein are for organizational purposes only and are not meant to be used to limit the scope of the description or the claims. As used throughout this application, the word "may" is used in a permissive sense (i.e., meaning having the potential to), rather than the mandatory sense (i.e., meaning must). Similarly, the words "include", "including", and "includes" mean including but not limited to. To facilitate understanding, reference numerals have been used, where possible, to designate elements common to the figures. Optional portions of the figures may be illustrated using dashed or dotted lines unless the context of usage indicates otherwise.

DETAILED DESCRIPTION

[0035] The following description includes the preferred best mode of one embodiment of the present invention. It will be clear from this description of the invention that the invention is not limited to these illustrated embodiments but that the invention also includes a variety of modifications and embodiments thereto. Therefore, the present description should be seen as illustrative and not limiting. While the invention is susceptible to various modifications and alternative constructions, it should be understood, that there is no intention to limit the invention to the specific form disclosed, but, on the contrary, the invention is to cover all modifications, alternative constructions, and equivalents faling within the spirit and scope of the invention as defined in the claims.

[0036] In any embodiment described herein, the open-ended terms "comprising," "comprises," and the like (which are synonymous with "including," "having" and "characterized by") may be replaced by the respective partially closed phrases ''consisting essentially of," consists essentially of," and the like or the respective closed phrases "consisting of," "consists of, the like.

[0037] As used herein, the singular forms "a", "an", and "the" designate both the singular and the plural, unless expressly stated to designate the singular only.

[0038] Figure 1 illustrates the flowchart of the method for production of hybrid aluminum metal matrix composite using powder metallurgy method, according to an embodiment of the present invention.

[0039]At step 102, aluminum powders with a purity of 99.55% and 44 micron particles size are mixed with powders of metal alloys such as silicon, magnesium, copper, and reinforced with ceramic powders of silicon carbide and graphite in precisely controlled amounts (as shown in Figure 4). Therefore, as described herein, there is an aluminum metal matrix reinforced hybrid composite consisting essentially of aluminum as the parent matrix metal; and many other inter-metallic particles. Inter-metallic particles having a size of 149 microns to about 44 microns and reinforced in a metal matrix in an amount of from 0.5 percent by weight to about 10 percent by weight, said ceramic materials (SiC+Gr) are reinforced with a matrix metal along with silicon, magnesium, copper in the form of inter-metallic particles.

[0040] AMMHCs product manufacture cannot be possible without the help of appropriate die-sets in the solid-state of the powder-metallurgy process. Therefore, at step 104 dies is designed before machining because each parameter of the die directly affects the final products. The designing considerations such as stress-concentration and crack-propagation were taken into account for the production of the die. The schematic diagram of die sets and their final product are shown in Figure 5 and 6 respectively.

[0041] At step 106, powders of metal aluminum and a plurality of inter-metallic particles, in particular silicon, magnesium, copper and ceramics of SiC and Gr are mixed.

[0042] At step 108, the specified powder mixture is filled and compacted. The compaction of the specified powder mixture may be performed under pressure with loading-rate of 0.3 kilo-Newton per second and a pressure of about 521.87 MPa to form the required shape as shown in Figure 7.

[0043]At step 110, sintering of the specified shape at a temperature of about 6200 C may be performed. Further, the sintered shape may be annealed for 24 hours. Furthermore, the said reinforced powders are uniformly distributed among said alloying metal to form a hybrid composite having a uniform metal matrix hybrid composite.

[0044] Figure 2 illustrates the different metal powders reinforcing with aluminum metal powder producing a novel hybrid composite where aluminum acts as the matrix metal according to an embodiment of the present invention. The invention shows, a novel aluminum hybrid-composite wherein the reinforcing materials are binary inter-metallic compounds in the form of particles. The binary inter-metallic reinforcing compounds exhibit the same nature as the base metal of the aluminum. The particle sizes of the particulate in binary inter-metallic reinforcing metal powders are considered about 44 microns. Preferably, the inter-metallic reinforcing powder particles are attending in the said composite about 0.5% to 10% by weight. The base metal of the matrix aluminum combines with ceramics and other metals, including Si, Mg, Cu, SiC, and Gr to form a reinforced hybrid composite. In the present invention where powder metallurgy process is used for AMMHCs manufacturing with the reinforcing powders and the matrix aluminum powders. The hybrid composite product was prepared with a process starting from the selection of metal powders, weighing, mixing/mixing, cold compacting, and sintering.

[0045] Figure 3 illustrates the step-wise pictorial representation for production of hybrid aluminum metal matrix composite, according to an embodiment of the present invention.

[0046] AMMHCs were reinforced with 10% SiC along with 2.5% Gr by weight. Silicon powders of 44 microns with purity 99.87%, Magnesium powders of 149 microns with purity 99.80%, Copper powders of 44 microns with purity 99.77%, Silicon carbide powders of 44 microns with purity 99.55%, and graphite powders of 44 microns with 99.87% purity are mixed with aluminum powder of 44 microns particle size of 99.55% purity. SiC powder particles with a weight fraction of 10% and Gr powder particles with a weight fraction of 2.5% are blended properly with a mixture of Al-Si-Mg-Cu in weight fractions of 84-0.5-0.5-2.5 percent.

[0047] The mixed/blended powder mixtures were compressed in a digital compression tester using C-45 steel die having a loading-rate, 0.3 kilo-Newton/second, and a compaction pressure of up to 521.87 MPa. The green compacted AMMHCs products have been ejected from the die cavity (see, Figure 8) and are ready for sintering.

[0048] The new aluminum metal matrix hybrid composite made from these specified metal powder compositions with better distribution of reinforcements were obtained by powder metallurgy method as given in Figure 10 and showed better outcomes if Silicon carbide was reinforced 10% by weight and Gr with 2.5% by weight. Further, the product is tested using a Vicker hardness testing machine where it was found that its hardness was a maximum of 84 VHN. The density of AMMHC was calculated as 2.83 gm / cm3 which is better than the currently available aluminum composites. Hardness in hybrid composite increases with increasing silicon-carbide and graphite, but decreases in a decrease in silicon carbide and graphite reinforcements. To achieve maximum hardness, a suitable proportion of the reinforced material is used.

[0049] Reinforcement of silicon carbide and graphite in the matrix element shows, the pores are very small when properly mixed in the powder mixture. The pores were seen under Scanning Electron Microscope (SEM). The SEM micrograph shows in Figure 11 indicates the porosity of the hybrid-composites decreased with the mixing of SiC and Gr. Increasing the SiC particle size reduces the porosity, volumetric loss, and friction co efficient of the composite. In addition, hybrid composites showed very little wear rate and co-efficient friction. During sintering, the introduction of SiC particles, as well as Gr particles, inhibits the growth of a-aluminum grains which forms site nucleation. The increased percentage of SiC and Gr powders, the greater in the number of center nucleation and the maximum number of grains of aluminum solidify into it. The distribution of intragranular SiC-Gr powder particles may be seen in micrographs of hybrid aluminum composites, which apparently have the best mechanical, physical and tribological behaviors based upon the compaction and sintering processes. As the densities of both matrix particle and the reinforcing powder particles are different but in the semi-solid states of P/M product gives uniform scattering of the particles especially SiC-Gr particles are almost uniformly reinforced throughout the aluminum-matrix represented in the micrograph.

[0050] The hybrid composite contains Cu which improves the hardness, ultimate tensile strength and minimizes the impact resistance in the composite. AMMHCs provide wear resistance by adding silicon. Wettability and lightness were found through the addition of magnesium to metal matrix composites.

[0051] AMMHCs represent a great opportunity and many possibilities for design/material engineers. There are currently many chances to replace this novel hybrid composite material over conventional material to meet specific mechanical properties to improve strength and stability. The experimental development indicates AMMHCs will utilize in present and near future industries. From past researches it is clear that, in upcoming age the product applications of AMMHCs is very shining for each commercial and industrial uses. Various investigators are also suggesting, aluminum metal matrix hybrid composites are the best cost-reduction process over conventional available materials like ferrous alloys, aluminum alloys and others.

[0052] Engineering viability of hybrid aluminum metal matrix composites (AMMHCs) in a number of applications is expected to be long overdue. AMMHCs consisting a special type of reinforcement which obtained by solid route, will use in many engineering applications. Particle-reinforced composites with a metal matrix of aluminum, produced by powder metallurgy (P/M) at an industrial level with different reinforcements are successfully utilized with components production for automobiles, as well as in the aerospace and thermal control industries. Here, a novel SiC and graphite particle reinforcement composite can assist in the fabrication of various parts of the above areas. For high-volume applications, particle-reinforced AMMHCs will be used in the braking systems of trains and vehicles and other automotive applications include gears, valves, suspension parts and crankshafts. In sports and recreational industries, AMMHCs can be applied in a variety of sports products like golf-stick, skate shoes, base-ball sleeves and bi-cycle frames. Aluminum metal matrix hybrid composites allow smaller flywheels than polymer based composites. As compared to iron-alloy, AMMHCs with SiC and Gr reinforcement offers the advantages of better damping and lower weight in brake-calipers.

[0053] The novel AMMHCs offers high strength equivalent to steel, with a density of less than half and retain their resistance at a high temperature. In major advanced vehicles, consisting Tata, Hero and Honda, Toyota and General-Motors are using silicon carbide reinforced aluminum brake discs. Further, cost to the weight-savings method will be achieved by introducing the powder metallurgy (P/M) to manufacture aluminum hybrid composite which will subjected to extreme stress. Also, in automobile suspension system, the application of aluminum hybrid composites will result in a decrease in unsprung weight and as a result, improved vehicle dynamics. Significant weight savings will achieve in the suspension system, wheels, braking system and chassis by the use of AMMHCs. Adding SiC and Gr to an aluminum alloy also decreases its co-efficient of thermal-expansion and enhances its resistance to wear, while preparing the material lighter as well as cheaper. Aerospace propulsion systems and propulsion systems constantly place increasing demands on load-bearing materials. The materials used must be lightweight and bears high temperature for long run operations in the aggressive environment. So, this novel hybrid aluminum metal-matrix composite can meet a wide range of these requirements.

[0054] While the invention has been described in connection with what is presently considered to be the most practical and various embodiments, it is to be understood that the invention is not to be limited to the disclosed embodiments, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.

[0055] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined in the claims and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements within substantial differences from the literal languages of the claims.

Claims

1. An aluminum hybrid metal matrix composite (AMMHCs) incorporating essentially a matrix-metal of aluminium as parent-metal of about 84% by weight; and a plurality of inter-metallic particles reinforced in the matrix metal with an amount ranging from 0.5% by weight to about 10% by weight, wherein the said matrix metal is combined with reinforced particles of silicon, magnesium, copper, silicon carbide and graphite.

2. Reinforced composite with a metal matrix of aluminum according to claim 1, wherein said aluminum hybrid metal matrix composite constitutes:

aluminium powder of 44 microns particle size with 99.55% purity

silicon powder of particle size 44 microns with 99.87% purity;

magnesium powder of 149 microns particle size with 99.80% purity;

copper powder of 44 microns particle sizes having 99.77% purity;

silicon carbide powder of 44 microns particle size with 99.55% purity; and

graphite powder of 44 microns particle size with 99.87% purity.

3. The presented composite according to the previous claim 1 characterized, wherein the said reinforced particles of silicon carbide (SiC) and graphite (Gr) with a proportion of 10% and 2.5% respectively by weight, is mixed properly in the powder mixture of Al-Si-Mg-Cu in a weight-fractions of (84-0.5-0.5-2.5) %.

4. Reinforced hybrid composite with a metal matrix of aluminium according to claim 1 wherein the said hybrid composite material is obtained by mixing / blending of powders of the selected matrix metal and reinforcing particles, followed by compaction and sintering.

5. A method of manufacturing AMMHCs, including the following steps: a mixture of powder of metallic aluminium and a variety of inter-metallic metal powder particles, including silicon, magnesium, copper, silicon carbide, and graphite as reinforcing particles, forming a powder mixture; the said powder mixture as stated in claim 3, are poured inside the designed die cavity at a pressure up to 521.87 MPa with rate of loading 0.3 KN /sec; after compaction, the green compacted hybrid composite products are removed from the die cavity and sintered at a temperature of about 6200 C, and then annealed for 24 hours.

6. A method of producing a reinforced aluminium hybrid composite with a metal matrix according to claim 5, characterized in that said particles of silicon carbide and graphite with a weight fraction of 10% and 2.5% are blended properly in a metal powder-mixture of Al-Si-Mg-Cu shares (84-0.5-0.5-2.5) % by weight.

7. The process for preparing a reinforced aluminium hybrid metal matrix composite as claimed in claim 5, wherein said hybrid composite material is prepared by mixing/blending of selected matrix metal powder with inter-metallic particles followed by compacting and sintering.