This document discusses the future needs and state of materials for structural applications. It focuses on metals and their mechanical properties at room temperature. Weight and energy savings will be increasingly important, leading to more use of lighter but stronger materials like aluminum alloys and magnesium alloys to replace some steel parts. Further weight reductions will come from carbon fiber composites and new high-strength titanium alloys. Fundamental research is still needed to better understand the properties of multiphase materials and nanostructured materials and how to optimize their strength.
Experimental evaluations and performance of the aluminum silicon carbide par...IAEME Publication
This document summarizes an experimental study on aluminum-silicon carbide particle metal matrix composites. Ring-shaped composites were fabricated using solid-state processing with varying sintering temperatures and times. The composites were subjected to thermal shock at +800C and -800C, and their radial crushing strength was tested. Micrographs of the fractured surfaces were analyzed. Thermal shock from sub-ambient temperatures was found to be more damaging than from elevated temperatures. Failure from elevated temperatures was dominated by cavity formation at interfaces, while sub-ambient temperatures caused more interfacial and matrix damage. The study evaluated the effect of reinforcement particles on the mechanical properties of the composites.
IRJET- Evaluation of Mechanical and Wear Properties of Aluminium /Al2O3 Compo...IRJET Journal
This document summarizes research on evaluating the mechanical and wear properties of an aluminium-alumina composite material for use as an automobile brake rotor. The composite is fabricated through stir casting with 10%, 15%, and 20% alumina by weight added to an aluminium 6082 alloy matrix. Mechanical properties like tensile strength and hardness are found to increase with the addition of alumina. Wear rate is also found to decrease when alumina is added. The composite materials will be tested under different loads and sliding velocities to study their tribological properties and potential for use as a lighter weight alternative to cast iron brake rotors.
This document summarizes a site visit by students to an Ajiya glass and metal factory. It focuses on properties of steel, which the group chose as their topic. Steel has many applications in construction like floor decks, frames, trusses, and cladding. It has advantages like strength and recyclability but disadvantages like cost and need for maintenance. The document discusses physical and chemical properties, sustainability, aesthetics, performance in fires and earthquakes, and maintenance needs to prolong steel's lifespan. It concludes the site visit benefited students' understanding of building materials.
Aluminium Based Metal Matrix Composites for Aerospace Application: A Literatu...iosrjce
IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE) is a double blind peer reviewed International Journal that provides rapid publication (within a month) of articles in all areas of mechanical and civil engineering and its applications. The journal welcomes publications of high quality papers on theoretical developments and practical applications in mechanical and civil engineering. Original research papers, state-of-the-art reviews, and high quality technical notes are invited for publications.
IRJET- A Review on Experimental Analysis of Flexural Behaviour of RC Beams b...IRJET Journal
1) The document reviews the experimental analysis of flexural behavior of reinforced concrete beams using high-strength steel.
2) It discusses how using high-strength steel TMT bars in RC beams can help reduce steel congestion and improve constructability by reducing the quantity of steel required.
3) The literature review covers past studies that have investigated the flexural capacity and behavior of RC beams reinforced with high-strength steel through experimental testing and finite element analysis.
This document summarizes a study on the production and properties of aluminum-fly ash composite materials. Fly ash, a byproduct of coal combustion, was added to an aluminum matrix at concentrations from 5-20% by weight using stir casting. The composites were characterized for hardness, tensile strength, and density. Hardness and tensile strength increased with fly ash content up to 15%, while density decreased with increased fly ash loading. The maximum properties were obtained at a 15% fly ash composition, indicating potential use of these aluminum-fly ash composites in applications seeking improved mechanical properties at lower weight.
This document discusses key challenges in fabricating metal matrix nanocomposites (MMNCs) reinforced with graphene nanoplatelets (GNPs). The main technical challenges are: (1) selecting high-quality GNP reinforcements, (2) uniformly dispersing GNPs within the metal matrix, (3) preventing reactivity between GNPs and the metal matrix, (4) achieving strong interfacial bonding between the metal and GNPs, and (5) preventing preferred orientation of GNPs that could lead to anisotropic properties. Addressing these challenges is important to take full advantage of GNPs' properties and improve the performance of MMNCs.
a review performance study of electrochemical machining on metalNEERAJKUMAR1898
1) The document discusses aluminum matrix composites (AMCs), which have promising properties for industrial applications but are challenging to machine.
2) Electrochemical micromachining (EMM) is presented as a potential machining method for AMCs as it provides good surface finish, avoids tool wear and thermal damage, and can machine complex shapes in hard materials.
3) The document reviews literature on AMCs fabricated through stir casting, as well as experimental studies on EMM processes for micro-machining composites.
Experimental evaluations and performance of the aluminum silicon carbide par...IAEME Publication
This document summarizes an experimental study on aluminum-silicon carbide particle metal matrix composites. Ring-shaped composites were fabricated using solid-state processing with varying sintering temperatures and times. The composites were subjected to thermal shock at +800C and -800C, and their radial crushing strength was tested. Micrographs of the fractured surfaces were analyzed. Thermal shock from sub-ambient temperatures was found to be more damaging than from elevated temperatures. Failure from elevated temperatures was dominated by cavity formation at interfaces, while sub-ambient temperatures caused more interfacial and matrix damage. The study evaluated the effect of reinforcement particles on the mechanical properties of the composites.
IRJET- Evaluation of Mechanical and Wear Properties of Aluminium /Al2O3 Compo...IRJET Journal
This document summarizes research on evaluating the mechanical and wear properties of an aluminium-alumina composite material for use as an automobile brake rotor. The composite is fabricated through stir casting with 10%, 15%, and 20% alumina by weight added to an aluminium 6082 alloy matrix. Mechanical properties like tensile strength and hardness are found to increase with the addition of alumina. Wear rate is also found to decrease when alumina is added. The composite materials will be tested under different loads and sliding velocities to study their tribological properties and potential for use as a lighter weight alternative to cast iron brake rotors.
This document summarizes a site visit by students to an Ajiya glass and metal factory. It focuses on properties of steel, which the group chose as their topic. Steel has many applications in construction like floor decks, frames, trusses, and cladding. It has advantages like strength and recyclability but disadvantages like cost and need for maintenance. The document discusses physical and chemical properties, sustainability, aesthetics, performance in fires and earthquakes, and maintenance needs to prolong steel's lifespan. It concludes the site visit benefited students' understanding of building materials.
Aluminium Based Metal Matrix Composites for Aerospace Application: A Literatu...iosrjce
IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE) is a double blind peer reviewed International Journal that provides rapid publication (within a month) of articles in all areas of mechanical and civil engineering and its applications. The journal welcomes publications of high quality papers on theoretical developments and practical applications in mechanical and civil engineering. Original research papers, state-of-the-art reviews, and high quality technical notes are invited for publications.
IRJET- A Review on Experimental Analysis of Flexural Behaviour of RC Beams b...IRJET Journal
1) The document reviews the experimental analysis of flexural behavior of reinforced concrete beams using high-strength steel.
2) It discusses how using high-strength steel TMT bars in RC beams can help reduce steel congestion and improve constructability by reducing the quantity of steel required.
3) The literature review covers past studies that have investigated the flexural capacity and behavior of RC beams reinforced with high-strength steel through experimental testing and finite element analysis.
This document summarizes a study on the production and properties of aluminum-fly ash composite materials. Fly ash, a byproduct of coal combustion, was added to an aluminum matrix at concentrations from 5-20% by weight using stir casting. The composites were characterized for hardness, tensile strength, and density. Hardness and tensile strength increased with fly ash content up to 15%, while density decreased with increased fly ash loading. The maximum properties were obtained at a 15% fly ash composition, indicating potential use of these aluminum-fly ash composites in applications seeking improved mechanical properties at lower weight.
This document discusses key challenges in fabricating metal matrix nanocomposites (MMNCs) reinforced with graphene nanoplatelets (GNPs). The main technical challenges are: (1) selecting high-quality GNP reinforcements, (2) uniformly dispersing GNPs within the metal matrix, (3) preventing reactivity between GNPs and the metal matrix, (4) achieving strong interfacial bonding between the metal and GNPs, and (5) preventing preferred orientation of GNPs that could lead to anisotropic properties. Addressing these challenges is important to take full advantage of GNPs' properties and improve the performance of MMNCs.
a review performance study of electrochemical machining on metalNEERAJKUMAR1898
1) The document discusses aluminum matrix composites (AMCs), which have promising properties for industrial applications but are challenging to machine.
2) Electrochemical micromachining (EMM) is presented as a potential machining method for AMCs as it provides good surface finish, avoids tool wear and thermal damage, and can machine complex shapes in hard materials.
3) The document reviews literature on AMCs fabricated through stir casting, as well as experimental studies on EMM processes for micro-machining composites.
Design and Fabrication of a Stir Casting Furnace Set-UpIJERA Editor
Now-a-days a large variety of heating techniques/furnaces are available. There may be many method for supplying heat to the work but heat is produced either by combustion of fuel or electric resistance heating. Taking into consideration the effect of cost, safety, simplicity and ease of construction we are going for an electrical resistance heating furnace with indirect heating provisions. The stir casting furnace has two main parts that enable to perform all its operations, they are: Furnace Elements and Control Panel. This paper shows the design and fabrication of stir-casting furnace and aluminium melted and casted to form.
Experimental Study of Wear Rate Coefficient of Aluminium Hybrid Composites Ma...AM Publications
In current decade, demand in material characteristics like light weight, superior strength to weight ratio, improved surface properties and enhanced wear resistance for complex engineering applications like automobile, aerospace and nuclear are researcher’s interest. However, performance of hybrid composites depends on right combination of reinforcements. Silicon carbide, silicon nitride, boron nitride and titanium carbide are few reinforcements available at present. In this work, Al356 is reinforced with SiC and B4C to enhance the mechanical properties, surface hardness and wear resistance. This hybrid composite is prepared by stir casting technique and the morphology of composite is studied using optical microscope to investigate the dispersion of reinforcements. In the present study, the wear and friction characteristics of hybrid composites are investigated using pin on disc dry wear tests by varying the load and speed and the results are tabulated for load vs mass loss, load vs wear rate and load vs wear coefficient. The results report that wear rate of hybrid composites are lower than that of binary composites. Mechanical properties, surface hardness and wear characteristics of aluminium hybrid composites are compared with that of aluminium binary composites available at present.
Effect of Nano-Magnesium Oxide and Graphite Particles on Mechanical Propertie...Premier Publishers
The main objective of this present work is to determine the densification, hardness and impact strength behavior on LM09 alloy reinforced with graphite and magnesium oxide nano-particles. LM09 is lighter metal as compared to other engineering metals/alloys except magnesium and beryllium. In this research stir casting process was used to fabricate hybrid LM09 nano-composite. The composites were prepared by varying the proportion of reinforcements such as 1.2 wt.% graphite (constant) and 1.5-3.5 wt. % magnesium oxide. Densities of alloy and nano-composites were determined by using the rule of mixture and Archimedes principles. Composite with 1.2 wt. % graphite and 2.5 wt. % magnesium oxide have 95.75% of relative density. Theoretical and actual densities are closer so that the cast composites were produced with less porosity. The mechanical properties of nano-composite such as hardness and impact strength was measured and clearly show that the LM09 alloy is enhanced through the reinforcement of nano-particles. Hybrid nano-composite reinforced with 2.5 wt. % magnesium oxide dominates the hardness as compared to other composites (1.5 and 3.5 wt. % magnesium oxide) The increase in reinforcement particles enhances the impact strength proportionally. The present finding concludes that LM09 hybrid composite having 1.2 wt. % graphite and 2.5 wt. % magnesium oxide can be used for engineering applications.
This document summarizes a research study on producing an aluminum metal matrix composite with dual reinforcement of multi-walled carbon nanotubes and silicon carbide particles. Aluminum powder was mechanically milled with varying volumes of MWCNTs and SiC to improve dispersion of the nanotubes. The composite powders were then hot pressed into pellets and characterized. SEM images showed the SiC helped disperse the MWCNTs in the aluminum matrix. Hardness testing found the dual reinforced composites had significantly higher hardness than pure aluminum. The study demonstrated that powder metallurgy can be used to fabricate aluminum composites with improved properties through MWCNT and SiC reinforcement.
The document discusses the mechanical behavior of aluminum metal matrix composites reinforced with SiC and Al2O3 for shaft applications. It presents the objectives, introduction, literature survey, methodology, material selection, properties of reinforcements, parameter selection, analysis methods, and results from static and modal analyses of the composite shaft. The composite shaft showed lower deformation and equivalent stress compared to a steel shaft based on static analysis results. Modal analysis found the natural frequencies of the composite shaft to be higher than the steel shaft. Future work is planned to fabricate composites with different volume fractions of SiC and Al2O3 and test their mechanical properties.
IRJET-Fabrication And Testing Of Aluminium Metal Matrix Composites Through St...IRJET Journal
This document discusses the fabrication and testing of aluminum metal matrix composites produced through stir casting technique. Magnesium and zinc particles were added to an aluminum alloy 6061 at volume fractions of 3%, 6%, and 9%. The composites were tested for tensile strength, compression strength, hardness, and bending. Tensile testing showed that ultimate tensile strength increased with higher particle content, reaching a maximum of 26.211 MPa for the 9% composite. Compression testing yielded a maximum strength of 20.976 MPa also for the 9% composite. Hardness values ranged from 104-119 Vickers hardness. The study concluded that stir casting can successfully produce aluminum composites with improved mechanical properties over the unreinforced alloy
Experimental Analysis of Mechanical Properties of Aluminum Alloy LM-4 by Vari...IRJET Journal
The document analyzes the effects of varying copper content on the mechanical properties of aluminum alloy LM-4. Five aluminum alloy samples were produced with copper content ranging from 5% to 11% using die casting. Tensile testing showed that ultimate tensile strength increased with increasing copper content, with the highest strength achieved in the 11% copper alloy. Microstructural analysis found that copper improves strength through precipitation strengthening during heat treatment.
Composites have been part of new advances and their importance is remarkable over the years.
Apart from their limited research in aeronautical and laboratories, they have to be included in general applications extensively so as to get more effectiveness , strength,performance.
this seminar gives general idea on Metal Matrix Composites their production processes and types and their applications.
This document summarizes research on metal casting and metal matrix composites. It provides an overview of different materials, focusing on aluminum and aluminum alloys. It discusses the properties and processing methods of metal matrix composites, including fabrication techniques like powder metallurgy, diffusion bonding, and liquid-state processes. Applications are reviewed across industries like aerospace, automotive, electrical, and more. The document concludes that metal matrix composites offer improved properties and are being increasingly used in high performance applications.
IRJET- Comparative Analysis and Design of Multi-Story Composite and Conventio...IRJET Journal
This document presents a comparative analysis of multi-story composite and conventional reinforced concrete frame structures (G+21) using ETABS software. It summarizes the modeling and analysis of composite and concrete building models, and compares the results for base shear, axial force, and shear force. The analysis found that while base shear and axial force values were generally higher for concrete structures, shear force values tended to be higher for composite structures, especially at lower story levels. The document concludes the composite structure is more efficient due to benefits like reduced dead load, cost savings, and faster construction time compared to conventional reinforced concrete.
ALUMINIUM METAL MATRIX COMPOSITE BY STIR CASTING METHODSNEERAJKUMAR1898
This document provides an introduction and literature review on graphite-based aluminum metal matrix composites (AMMCs). It discusses how AMMCs overcome limitations of conventional materials by combining high strength, stiffness, and low density. The document reviews various fabrication techniques for AMMCs and their applications in industries like aerospace and automotive. It summarizes past research that studied mechanical properties of different AMMC compositions and processing methods.
Preparation and Characterization of Aluminium Metal Matrix Composite by using...IRJET Journal
1. The document describes the preparation and characterization of an aluminium metal matrix composite reinforced with welding slag using stir casting technique. Composites with 5%, 7%, and 9% weight fractions of welding slag particles were produced.
2. Hardness testing found that the hardness increased with increasing weight fraction of welding slag reinforcement. The unreinforced Al6061 alloy had a hardness of 95 BHN while the composite with 9% welding slag particles achieved a hardness of 96.9 BHN.
3. The study demonstrated that welding slag particles can effectively improve the hardness of an aluminium metal matrix composite when incorporated using stir casting, indicating potential applications where increased strength is required.
This lecture provides understanding of the state-of-the-art of aluminium matrix composite materials; it outlines the properties of aluminium matrix composite materials as a basis
for materials selection; it explains the limits of useful applications; it demonstrates the various types of aluminium matrix composites. Knowledge in metallurgy, materials science, materials engineering is assumed.
This document provides an overview of aluminum metal matrix composites with hybrid reinforcement. It discusses how aluminum alloys combine desirable properties of metals and ceramics when reinforced particles are added to the metal matrix. The document reviews the advantages of aluminum, such as its light weight, corrosion resistance, and recyclability. It also discusses aluminum alloy types and applications, as well as desirable mechanical properties for metal composites like tensile strength and yield point. The aim is to initiate new research on developing aluminum composites with hybrid reinforcements.
Editor: Eng. Mohamadreza Govahi
Mentor: Dr. Ehsan Borhani
Date of Presentation: Apr 2016, Semnan PN Univeristy
*Contents
~Introduction to MMCs
~Introduction to Aluminum MMCs (AMMCs)
~Ceramic Reinforcements in AMMCs
~Types and Morphology of Reinforcements
~Aluminum Nano-composites
~Producing Methods
~Comparison in Different Procedures
~Reviews of some Experiments And Researches
The document discusses the manufacturing of an aluminium matrix composite using stir casting. Stir casting involves dispersing a ceramic reinforcement (in this case alumina) into molten aluminium alloy using mechanical stirring. Several process parameters for stir casting are outlined, including a stirring speed of 300 rpm, temperature of 800°C, and stirring time of 5 minutes. The experimental setup used involved heating aluminium alloy to melting, adding 1% magnesium as a wetting agent, and adding preheated alumina reinforcement during stirring. The molten composite was then poured into a preheated mold. The summary concludes that stir casting is a cost-effective method for producing aluminium matrix composites with uniform distribution of reinforcement and enhanced mechanical properties.
Preparation of metal matrix composites by stir-casting methodIAEME Publication
The document discusses the preparation of metal-matrix composites (MMCs) using the stir-casting method. Specifically, it focuses on producing aluminum-silicon carbide (AlSiC) MMCs. Six samples were created with varying silicon carbide percentages from 5-30%. The samples were then tested for hardness, impact strength, and microscopic examination. Stir-casting is described as a process that involves continuously stirring reinforcing particles into molten metal before pouring and solidification. The document provides details on the equipment and process used, including a graphite crucible, coal-fired furnace, motorized stirrer, and raw materials of aluminum and silicon carbide.
This document discusses the mechanical behavior of aluminum based metal matrix composites reinforced with silicon carbide and alumina. It provides an introduction to metal matrix composites and their properties. The objective is to fabricate an aluminum matrix composite through stir casting and evaluate its mechanical properties. A literature review covers topics like microstructure and corrosion behavior of aluminum-silicon carbide composites, wear properties of aluminum composites, and aging behavior of silicon nitride reinforced aluminum composites.
Comparative Study of Structure Using Composite Members And Conventional MembersIJERA Editor
There are different methods of construction for building structure. The most popular conventional structures used are reinforced cement concrete structures, pure steel structures and Timber Structures. In the modern age the rapid growth in population and continuous influx of people from rural to metros; buildings are constructed on a large scale and with great Architectural requirement. In this paper a new type of structure is introduced which involves use of composite members. To reduce the construction time, material quantity and cost the composite members are used. The composite members here mean use of steel sections as structural steel along with timber. Here by using composite members for miscellaneous Architectural building, lot of saving has been done in material, construction time and cost. It saves approximately 20-25% cost of structure if conventional type is used. Composite members used are Structural steel and solid timber compare to conventional steel or RCC members.
Experimental evaluations and performance of the aluminum silicon carbide par...IAEME Publication
Stresses induced due to thermal mismatch between the metal matrix and the ceramic reinforcement in metal matrix composite may impart plastic deformation to the matrix there by
resulting in a reduction of the residual stresses. Thermal mismatch strains also may quite often crack
the matrix resulting in a relaxation of the residual stresses. The interface in MMCs is a porous, noncrystalline portion in comparison with the matrix or the reinforcement (metal matrix and ceramic reinforcement in this case).
This document reviews research on aluminum metal matrix composites reinforced with particulate materials. Stir casting is identified as the most common and cost-effective fabrication method. Studies have found that decreasing particle size and increasing the percentage of reinforcement leads to increases in hardness and tensile strength of the composites. Specifically, aluminum composites reinforced with 15% volume fraction of TiB2 particles showed over two times increase in tensile and yield strengths but 68% decrease in ductility compared to the aluminum alloy matrix. Adding 4% copper to the aluminum matrix along with 10% volume fraction of TiB2 reinforcement further improved tensile and yield strengths by factors of 2.5 and 2.8 respectively while maintaining higher ductility.
The document discusses materials science and engineering. It provides information on different types of materials including metals, ceramics, polymers, composites, and semiconductors. It also discusses the structure-property relationships in materials and how their properties are determined by composition and processing methods. Assessment in the course is based on assignments, midterm exam, final exam, and other factors.
Design and Fabrication of a Stir Casting Furnace Set-UpIJERA Editor
Now-a-days a large variety of heating techniques/furnaces are available. There may be many method for supplying heat to the work but heat is produced either by combustion of fuel or electric resistance heating. Taking into consideration the effect of cost, safety, simplicity and ease of construction we are going for an electrical resistance heating furnace with indirect heating provisions. The stir casting furnace has two main parts that enable to perform all its operations, they are: Furnace Elements and Control Panel. This paper shows the design and fabrication of stir-casting furnace and aluminium melted and casted to form.
Experimental Study of Wear Rate Coefficient of Aluminium Hybrid Composites Ma...AM Publications
In current decade, demand in material characteristics like light weight, superior strength to weight ratio, improved surface properties and enhanced wear resistance for complex engineering applications like automobile, aerospace and nuclear are researcher’s interest. However, performance of hybrid composites depends on right combination of reinforcements. Silicon carbide, silicon nitride, boron nitride and titanium carbide are few reinforcements available at present. In this work, Al356 is reinforced with SiC and B4C to enhance the mechanical properties, surface hardness and wear resistance. This hybrid composite is prepared by stir casting technique and the morphology of composite is studied using optical microscope to investigate the dispersion of reinforcements. In the present study, the wear and friction characteristics of hybrid composites are investigated using pin on disc dry wear tests by varying the load and speed and the results are tabulated for load vs mass loss, load vs wear rate and load vs wear coefficient. The results report that wear rate of hybrid composites are lower than that of binary composites. Mechanical properties, surface hardness and wear characteristics of aluminium hybrid composites are compared with that of aluminium binary composites available at present.
Effect of Nano-Magnesium Oxide and Graphite Particles on Mechanical Propertie...Premier Publishers
The main objective of this present work is to determine the densification, hardness and impact strength behavior on LM09 alloy reinforced with graphite and magnesium oxide nano-particles. LM09 is lighter metal as compared to other engineering metals/alloys except magnesium and beryllium. In this research stir casting process was used to fabricate hybrid LM09 nano-composite. The composites were prepared by varying the proportion of reinforcements such as 1.2 wt.% graphite (constant) and 1.5-3.5 wt. % magnesium oxide. Densities of alloy and nano-composites were determined by using the rule of mixture and Archimedes principles. Composite with 1.2 wt. % graphite and 2.5 wt. % magnesium oxide have 95.75% of relative density. Theoretical and actual densities are closer so that the cast composites were produced with less porosity. The mechanical properties of nano-composite such as hardness and impact strength was measured and clearly show that the LM09 alloy is enhanced through the reinforcement of nano-particles. Hybrid nano-composite reinforced with 2.5 wt. % magnesium oxide dominates the hardness as compared to other composites (1.5 and 3.5 wt. % magnesium oxide) The increase in reinforcement particles enhances the impact strength proportionally. The present finding concludes that LM09 hybrid composite having 1.2 wt. % graphite and 2.5 wt. % magnesium oxide can be used for engineering applications.
This document summarizes a research study on producing an aluminum metal matrix composite with dual reinforcement of multi-walled carbon nanotubes and silicon carbide particles. Aluminum powder was mechanically milled with varying volumes of MWCNTs and SiC to improve dispersion of the nanotubes. The composite powders were then hot pressed into pellets and characterized. SEM images showed the SiC helped disperse the MWCNTs in the aluminum matrix. Hardness testing found the dual reinforced composites had significantly higher hardness than pure aluminum. The study demonstrated that powder metallurgy can be used to fabricate aluminum composites with improved properties through MWCNT and SiC reinforcement.
The document discusses the mechanical behavior of aluminum metal matrix composites reinforced with SiC and Al2O3 for shaft applications. It presents the objectives, introduction, literature survey, methodology, material selection, properties of reinforcements, parameter selection, analysis methods, and results from static and modal analyses of the composite shaft. The composite shaft showed lower deformation and equivalent stress compared to a steel shaft based on static analysis results. Modal analysis found the natural frequencies of the composite shaft to be higher than the steel shaft. Future work is planned to fabricate composites with different volume fractions of SiC and Al2O3 and test their mechanical properties.
IRJET-Fabrication And Testing Of Aluminium Metal Matrix Composites Through St...IRJET Journal
This document discusses the fabrication and testing of aluminum metal matrix composites produced through stir casting technique. Magnesium and zinc particles were added to an aluminum alloy 6061 at volume fractions of 3%, 6%, and 9%. The composites were tested for tensile strength, compression strength, hardness, and bending. Tensile testing showed that ultimate tensile strength increased with higher particle content, reaching a maximum of 26.211 MPa for the 9% composite. Compression testing yielded a maximum strength of 20.976 MPa also for the 9% composite. Hardness values ranged from 104-119 Vickers hardness. The study concluded that stir casting can successfully produce aluminum composites with improved mechanical properties over the unreinforced alloy
Experimental Analysis of Mechanical Properties of Aluminum Alloy LM-4 by Vari...IRJET Journal
The document analyzes the effects of varying copper content on the mechanical properties of aluminum alloy LM-4. Five aluminum alloy samples were produced with copper content ranging from 5% to 11% using die casting. Tensile testing showed that ultimate tensile strength increased with increasing copper content, with the highest strength achieved in the 11% copper alloy. Microstructural analysis found that copper improves strength through precipitation strengthening during heat treatment.
Composites have been part of new advances and their importance is remarkable over the years.
Apart from their limited research in aeronautical and laboratories, they have to be included in general applications extensively so as to get more effectiveness , strength,performance.
this seminar gives general idea on Metal Matrix Composites their production processes and types and their applications.
This document summarizes research on metal casting and metal matrix composites. It provides an overview of different materials, focusing on aluminum and aluminum alloys. It discusses the properties and processing methods of metal matrix composites, including fabrication techniques like powder metallurgy, diffusion bonding, and liquid-state processes. Applications are reviewed across industries like aerospace, automotive, electrical, and more. The document concludes that metal matrix composites offer improved properties and are being increasingly used in high performance applications.
IRJET- Comparative Analysis and Design of Multi-Story Composite and Conventio...IRJET Journal
This document presents a comparative analysis of multi-story composite and conventional reinforced concrete frame structures (G+21) using ETABS software. It summarizes the modeling and analysis of composite and concrete building models, and compares the results for base shear, axial force, and shear force. The analysis found that while base shear and axial force values were generally higher for concrete structures, shear force values tended to be higher for composite structures, especially at lower story levels. The document concludes the composite structure is more efficient due to benefits like reduced dead load, cost savings, and faster construction time compared to conventional reinforced concrete.
ALUMINIUM METAL MATRIX COMPOSITE BY STIR CASTING METHODSNEERAJKUMAR1898
This document provides an introduction and literature review on graphite-based aluminum metal matrix composites (AMMCs). It discusses how AMMCs overcome limitations of conventional materials by combining high strength, stiffness, and low density. The document reviews various fabrication techniques for AMMCs and their applications in industries like aerospace and automotive. It summarizes past research that studied mechanical properties of different AMMC compositions and processing methods.
Preparation and Characterization of Aluminium Metal Matrix Composite by using...IRJET Journal
1. The document describes the preparation and characterization of an aluminium metal matrix composite reinforced with welding slag using stir casting technique. Composites with 5%, 7%, and 9% weight fractions of welding slag particles were produced.
2. Hardness testing found that the hardness increased with increasing weight fraction of welding slag reinforcement. The unreinforced Al6061 alloy had a hardness of 95 BHN while the composite with 9% welding slag particles achieved a hardness of 96.9 BHN.
3. The study demonstrated that welding slag particles can effectively improve the hardness of an aluminium metal matrix composite when incorporated using stir casting, indicating potential applications where increased strength is required.
This lecture provides understanding of the state-of-the-art of aluminium matrix composite materials; it outlines the properties of aluminium matrix composite materials as a basis
for materials selection; it explains the limits of useful applications; it demonstrates the various types of aluminium matrix composites. Knowledge in metallurgy, materials science, materials engineering is assumed.
This document provides an overview of aluminum metal matrix composites with hybrid reinforcement. It discusses how aluminum alloys combine desirable properties of metals and ceramics when reinforced particles are added to the metal matrix. The document reviews the advantages of aluminum, such as its light weight, corrosion resistance, and recyclability. It also discusses aluminum alloy types and applications, as well as desirable mechanical properties for metal composites like tensile strength and yield point. The aim is to initiate new research on developing aluminum composites with hybrid reinforcements.
Editor: Eng. Mohamadreza Govahi
Mentor: Dr. Ehsan Borhani
Date of Presentation: Apr 2016, Semnan PN Univeristy
*Contents
~Introduction to MMCs
~Introduction to Aluminum MMCs (AMMCs)
~Ceramic Reinforcements in AMMCs
~Types and Morphology of Reinforcements
~Aluminum Nano-composites
~Producing Methods
~Comparison in Different Procedures
~Reviews of some Experiments And Researches
The document discusses the manufacturing of an aluminium matrix composite using stir casting. Stir casting involves dispersing a ceramic reinforcement (in this case alumina) into molten aluminium alloy using mechanical stirring. Several process parameters for stir casting are outlined, including a stirring speed of 300 rpm, temperature of 800°C, and stirring time of 5 minutes. The experimental setup used involved heating aluminium alloy to melting, adding 1% magnesium as a wetting agent, and adding preheated alumina reinforcement during stirring. The molten composite was then poured into a preheated mold. The summary concludes that stir casting is a cost-effective method for producing aluminium matrix composites with uniform distribution of reinforcement and enhanced mechanical properties.
Preparation of metal matrix composites by stir-casting methodIAEME Publication
The document discusses the preparation of metal-matrix composites (MMCs) using the stir-casting method. Specifically, it focuses on producing aluminum-silicon carbide (AlSiC) MMCs. Six samples were created with varying silicon carbide percentages from 5-30%. The samples were then tested for hardness, impact strength, and microscopic examination. Stir-casting is described as a process that involves continuously stirring reinforcing particles into molten metal before pouring and solidification. The document provides details on the equipment and process used, including a graphite crucible, coal-fired furnace, motorized stirrer, and raw materials of aluminum and silicon carbide.
This document discusses the mechanical behavior of aluminum based metal matrix composites reinforced with silicon carbide and alumina. It provides an introduction to metal matrix composites and their properties. The objective is to fabricate an aluminum matrix composite through stir casting and evaluate its mechanical properties. A literature review covers topics like microstructure and corrosion behavior of aluminum-silicon carbide composites, wear properties of aluminum composites, and aging behavior of silicon nitride reinforced aluminum composites.
Comparative Study of Structure Using Composite Members And Conventional MembersIJERA Editor
There are different methods of construction for building structure. The most popular conventional structures used are reinforced cement concrete structures, pure steel structures and Timber Structures. In the modern age the rapid growth in population and continuous influx of people from rural to metros; buildings are constructed on a large scale and with great Architectural requirement. In this paper a new type of structure is introduced which involves use of composite members. To reduce the construction time, material quantity and cost the composite members are used. The composite members here mean use of steel sections as structural steel along with timber. Here by using composite members for miscellaneous Architectural building, lot of saving has been done in material, construction time and cost. It saves approximately 20-25% cost of structure if conventional type is used. Composite members used are Structural steel and solid timber compare to conventional steel or RCC members.
Experimental evaluations and performance of the aluminum silicon carbide par...IAEME Publication
Stresses induced due to thermal mismatch between the metal matrix and the ceramic reinforcement in metal matrix composite may impart plastic deformation to the matrix there by
resulting in a reduction of the residual stresses. Thermal mismatch strains also may quite often crack
the matrix resulting in a relaxation of the residual stresses. The interface in MMCs is a porous, noncrystalline portion in comparison with the matrix or the reinforcement (metal matrix and ceramic reinforcement in this case).
This document reviews research on aluminum metal matrix composites reinforced with particulate materials. Stir casting is identified as the most common and cost-effective fabrication method. Studies have found that decreasing particle size and increasing the percentage of reinforcement leads to increases in hardness and tensile strength of the composites. Specifically, aluminum composites reinforced with 15% volume fraction of TiB2 particles showed over two times increase in tensile and yield strengths but 68% decrease in ductility compared to the aluminum alloy matrix. Adding 4% copper to the aluminum matrix along with 10% volume fraction of TiB2 reinforcement further improved tensile and yield strengths by factors of 2.5 and 2.8 respectively while maintaining higher ductility.
The document discusses materials science and engineering. It provides information on different types of materials including metals, ceramics, polymers, composites, and semiconductors. It also discusses the structure-property relationships in materials and how their properties are determined by composition and processing methods. Assessment in the course is based on assignments, midterm exam, final exam, and other factors.
ThermophysicalProperties of Cellular Aluminium andCeramic Particulate / Alumi...IJERA Editor
In this paper, the thermophysical properties of cellular Al and Ceramic Particulate / Al Composites were
explored. Thermophysical properties are defined as material properties that vary with temperature without
altering the material's chemical identity including thermal conductivity (TC), coefficient of thermal expansion
(CTE), energy absorption, porosity and relative density. The significance of cellular Al and AMMCs reinforced
by ceramic particles lies in their propertieswhich are difficult to be available combined in other engineering
materials. New cellular AMMCs that meet the needs of the required engineering applications could be
synthesized by selection an appropriate reinforcements. Different kinds of ceramic particles such as oxides,
carbides, nitrides, as well as carbon nanotubes can be utilized as reinforcements for manufacturing of cellular
AMMCs. Thermophysicalproperties of cellular AMMCs consisting of Al as continuous matrix phase and
ceramic particles as reinforcements are directly influenced by type, size, and geometry of dispersions, also the
RVR. In addition, the constituents of ceramic particulate / aluminium composites characterized by different heat
transfer mechanisms, wherethe TC mechanism in metals is attributed to free electrons, while phonons are
primarily responsible for TC in nonmetallic materials, as well as an interfacial thermal barrier resistance
influence effectively on heat transfer inside the composite and thus the thermophysical properties. In this paper,
based on the literature review, thermophysical properties of cellular Al and AMMCs reinforced by ceramic
particles were discussed.
tA composite material can be defined as a combination of two or more materials that gives better properties than those of the individual components used alone. In contrast to metal-lic alloys, each material retains its separate chemical, physical, and mechanical properties.The two constituents are reinforcement and a matrix. The main advantages of compositematerials are their high strength and stiffness combined with low density when comparedto classical materials. Micromechanical approach is found to be more suitable for the anal-ysis of composite materials because it studies the volume proportions of the constituentsfor the desired lamina stiffness and strength.It is found that the manufacturing processes are responsible of many defects which mayarise in fibers, matrix and lamina. These defects, if they exist include misalignment of fibers,cracks in matrix, non uniform distribution of the fibers in the matrix, voids in fibers andmatrix, delaminated regions, and initial stress in the lamina as a result of its manufactureand further treatment.The above mentioned defects tend to propagate as the lamina is loaded causing an accel-erated rate of failure. The experimental and theoretical results in this case tend to differ.Hence, due to the limitations necessary in the idealization of the lamina components, estimated should be proved experimentally.
Wear Analysis of Al7068 Metal Matrix Composite Reinforced with Silicon NitrideIRJET Journal
This document summarizes a study that analyzed the wear performance of an aluminum alloy (Al7068) reinforced with silicon nitride at varying percentages. The composite material was fabricated using stir casting and tested using pin-on-disk wear analysis. The study found that adding silicon nitride improved the hardness and wear resistance of the aluminum alloy base material. Specifically, higher percentages of silicon nitride reinforcement resulted in less wear and better performance in applications involving friction and sliding contact. The composite material showed potential for use in automobile, aerospace, and marine applications requiring durability and strength.
Modelling and Analysis of Hybrid Composite Joint Using Fem in ANSYSIJMER
Composite materials are widely used in the various Fields. Due to the high strength they
arewidelyusedinthelowweightconstructionsandalsousedasasuitablealternativetometals.Invariousapplicat
ionsAnd also for joining various composite parts together, they are fastened together using adhesives or
Mechanical fasteners. Modelling and static analysis of 3-D Models of joints such as bonded, riveted and
hybrid. The results were found in terms of von-mises stress, shear stress and normal stress for stress
distribution. ANSYS FEA tool has been used for stress distribution characteristics of various
configurations of double riveted single lap joint with three joining methods namely bonded, riveted and
hybrid the present study deals with the analysis of single lap joint subjected to the given tensile load and
the stress distribution in the members under various design conditions are found
A Review: Production of Third Generation Advance High Strength Steelsijsrd.com
To fulfill the requirement for steel with higher strength while retaining its formability, advanced high strength steels (AHSS) was developed. Several authors worked on the first generation AHSS steels with Dual phase structure and successfully achieved high strengths as compared to conventional counter-parts but could not achieve good formability. Several authors worked to overcome this problem and substantially improved the ductility and strength by forming second generation AHSS. However, DP steels were not formed (in second generation). Second generation steels (included ASS, TWIP steels etc.) were dependent on expensive alloy additions and were not cost effective. Authors became successful in achieving good strength and ductility but because of alloying, the weldability suffered. Finally, a few authors have reported their work on third generation AHSS, where first generation dual phase steels have been modified through suitable alloy additions to improve formability, strength and toughness. Work has been reported where carbon has been reduced to improve weldability. There is extremely limited work has been done for production of dual phase multipurpose steels with controlled cooling.
This document discusses joining metals and plastics, specifically friction stir welding of nylon-6 plastic to aluminum alloy 6061. It begins by introducing the benefits of metal-plastic joints for lightweight construction. Friction stir welding is described as a common technique for joining metals like aluminum without filler material through frictional heating and deformation. The document outlines the properties of nylon and aluminum alloy 6061 that make them suitable for this application. The aim of the research is to understand how welding parameters affect joint strength when joining nylon-6 to 6061 using friction lap welding with various surface indentations. Objectives are to evaluate joint properties under different loads and examine fractured surfaces. Potential applications are mentioned in automotive, construction and industrial
This document provides an overview of composite materials, including their advantages over traditional materials like metals. It discusses key topics such as the constituents of composites, different manufacturing methods, mechanical properties, applications, and challenges. The goal of the course is for students to gain an understanding of composite terminology, develop models to predict mechanical response, and be able to optimally design composite structures.
This document evaluates the mechanical properties of aluminum 2024-based hybrid metal composites. It discusses how aluminum 2024 alloy is commonly used in aircraft structures due to its high strength and fatigue resistance. The document then describes creating aluminum 2024-based composites reinforced with E-glass fibers and fly ash using stir casting. Tensile and compression tests were performed on the composite materials and aluminum 2024 alloy to compare their mechanical properties. The results showed that the composite materials achieved better tensile and compression strength compared to aluminum 2024 alloy alone.
This document presents a project on aluminum metal matrix composites. It discusses why composite materials were chosen as the major project topic due to their properties like high strength and stiffness. It then provides an overview of applications of composites in various industries. The document outlines the plan of presentation which includes introducing metal matrix composites and aluminum MMCs as well as discussing the materials, manufacturing process, and conclusions from previous work.
MECHANICAL BEHAVIOUR OF COMPOSITE MATERIALS IN METALIAEME Publication
Composite materials have gained traction in the world today and are becoming of common use in industrial and specialized applications in general due to their flexible nature that involves mixing through layers or matrixes the components of various substances and therefore, a percentage of each substance’s physical properties. In recent years there has been an increasing concern for industries to use cost effective reinforcement for metal materials like aluminum which is abundant cheap, with various desirable properties like its lightness, but lacks the strength for various applications – ceramic materials such as SiC and aluminum oxide are used generally for reinforcing the aluminum MMC. There is a good probability, backed up by tests for certain materials, that reinforcing metals with composites can increase failure displacement, fatigue life, ultimate failure load and energy absorption capacity, amongst many others by substantial amounts.
This document summarizes an experimental study on the flexural behavior of ferrocement concrete beams. Ferrocement is a type of thin concrete reinforced with closely spaced wire mesh. The study tested concrete beam prototypes made of reinforced concrete overlaid with a thin layer of ferrocement under the main reinforcement. Testing showed that the ferrocement layers significantly enhanced the flexural strength and cracking behavior of the beams compared to control specimens without ferrocement. Beams with closely spaced ferrocement reinforcement exhibited higher flexural strength and smaller crack widths than other specimens. The results of this study provide useful information for determining the strength and crack width of ferrocement beams.
Friction stir welding (FSW) was investigated as a potential joining method for aluminum metal matrix composites reinforced with boron carbide (MMC 6061-XX% B4C) due to issues with traditional fusion welding methods. Preliminary results showed that FSW produced superior mechanical properties compared to gas tungsten arc welding (GTAW), with FSW joints exhibiting similar tensile properties to the base material. However, tool wear was found to be severe, preventing long welds. Overall, the study demonstrated that FSW is a viable process for joining MMC 6061-XX% B4C, offering benefits over conventional fusion welding by reducing defects and improving mechanical properties.
Damping Of Composite Material Structures with Riveted JointsIJMER
Vibration and noise reduction are crucial in maintaining high performance level and
prolonging the useful life of machinery, automobiles, aerodynamic and spacecraft structures. It is
observed that damping in materials occur due to energy release due to micro-slips along frictional
interfaces and due to varying strain regions and interaction between the metals. But it was found
that the damping effect in metals is quite small that it can be neglected. Damping in metals is due to
the micro-slips along frictional interfaces. Composites, however, have better damping properties
than structural metals and cannot be neglected. Typically, the range of composite damping begins
where the best damped metal stops.In the present work, theoretical analysis was done on various
polymer matrix composite (glass fibre polyesters) with riveted joints by varying initial conditions.
Strain energy loss was calculated to calculate the damping in composites. Using FEA model, load
variation w.r.t time was observed and the strain energy loss calculated was utilised in finding the
material damping for Carbon fibre epoxy with riveted joints. Various simulations were performed in
ANSYS and these results were utilised to calculate the loss factor, Rayleigh‘s damping constants
and logarithmic decrement.
Energy Absorption Characteristics of Thin Walled Metallic and Foam Filled Tub...IRJET Journal
This document discusses a numerical study comparing the energy absorption characteristics of thin-walled metallic tubular structures with different cross-sectional geometries, both empty and foam-filled. Finite element models of circular, triangular, hexagonal and square tubes undergoing quasi-static axial crushing were created and analyzed. The results show that circular tubes absorbed the most energy of the empty metallic tubes, while foam-filled tubes had higher energy absorption than empty tubes of the same geometry.
This document provides an introduction to composite materials. It defines composites as materials made of two or more inherently different materials that when combined produce properties exceeding the individual components. The matrix holds the reinforcement and transfers load, while the reinforcement provides properties like strength and stiffness. Common matrix materials include epoxies, metals, and ceramics. Fiber reinforcements include glass, carbon, and aramid fibers. The document discusses different types of composites and their applications, advantages like high strength and design flexibility, and disadvantages like anisotropic properties and difficulties in inspection.
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This document is a report on engineering materials that was prepared by an engineering student at Al Azhar University in Egypt. It provides an introduction to engineering materials and discusses their historical uses. It describes how materials science developed with advances in physics and chemistry. It then classifies and describes different types of materials like metals, ceramics, polymers, and composites. The document focuses on properties of metals, defining terms like hardness, brittleness, malleability, ductility, elasticity, toughness, density, fusibility, and conductivity. It provides examples to illustrate each property.
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Mechanical Properties of Metals and Composites
1. MATERIALSPHENOMENA
183
5.7. Mechanical Properties of Metals and Composites
5.7.1. Introduction
Topics such as elastic properties of materials, fracture
toughness, fatigue crack propagation, plastic yielding at
room temperature, at elevated temperatures, creep,
viscous flow etc. all belong to the concept of “Mechanical
Properties”.
Furthermore, several metal families are involved, of which
the main ones are those based on steel, on aluminium, on
copper, on titanium and on magnesium. The number of
researchers working in all these fields, and the number of
industries involved, is vast. In this text, focus will be main-
ly on metals and on plastic properties at room tempera-
ture, including strength and ductility. Even then the varie-
tyofactivities,needsandpotentialitiesisgreat.Thepresent
discussion is written with an eye to the future, and will
therefore take the future needs of society as its starting
point, rather than the present state of the art.
5.7.2. Future Needs of Society Regarding Materials for
Structural Applications
(a) Weight and energy saving
By “structural applications” we understand all applica-
tions for which the main function of the material is to
carry a load. In the transport sector (cars, trucks, trains,
aircraft), weight savings will become increasingly impor-
tant, because they are intricately connected to energy
savings by reduction of fuel consumption. But there are
other sectors as well for which weight savings are impor-
tant. For examples, by using lighter but stronger materials,
it may be possible to make bridges wider without having
to replace the foundations. Not surprisingly, the most
stringent demands for weight reductions come from
expensive products, such as sporting goods for top-level
sports, and of course aerospace.
In the decade to come, car body parts from mild steel will
partly be replaced by aluminium alloys, which on their
turn may be replaced later by special high-strength
magnesium alloys. Reinforcement parts from mild steel
are already being replaced by parts from high-strength
steels, allowing considerable weight savings.
The second decade to come will see further weight reduc-
tions by the replacement of some steel parts by carbon-
fibre reinforced plastic (composite material) or by alu-
minium-based metal matrix composites. Parts from high-
strength steel may be replaced by high-strength titanium
alloys.Finallymanypartsfromcarbonsteelwillbereplaced
by stainless steel, which not only lasts longer but also has
a higher strength.
In the hulls of recent military aircraft, the share of alu-
minium is reduced to as less as 16% and steel to 6%. They
have been replaced by advanced Ti-alloys and by polymer-
based composite materials. In the civilian aircraft indus-
try, evolution is much less drastic although the evolution
is the same.
(b) Micro- and “nano”-technology
The importance of structures and devices with sizes in
themicrometre-rangesuchasinterconnects,microvalves,
microswitches, often also deposited on Si substrates, will
become more important in the future. (This field is often
reckoned to belong the “nanotechnology” field, although
its scale obviously is that of micrometres). State of the
art is that it is now possible to make such structures or
devices. Optimization of properties has just begun. More
focus will have to be given in future to the mechanical
behaviour of these structures or devices. In interconnects
for example (material: copper or aluminium), the lifetime
and functionality are greatly affected by the residual
stresses present. The latter depend on the processing of
the component, but also on the material properties of the
interconnect, such as elastic constants, and especially the
lattice misorientations at grain boundaries. The study of
thisrequiresadvancedelectron-microscopicaltechniques
which allow for the simultaneous acquisition of topologi-
cal and crystal texture data, combined with advanced
material models such as crystal-level elasto-plastic finite
element codes. In micromachines (material: often sili-
con), the grain boundaries are equally important, as they
are potential sources of stress concentration possibly
leading to premature failure of the device.
P. Van Houtte | Catholic University Louvain, Louvain, Belgium
2. 184
MAX-PLANCK-INSTITUTFÜRMETALLFORSCHUNGSTUTTGART
5.7.3. State of the Art and Research Needs
(a) Steels
Fig. 5.7 shows the combinations of strength/ductility
which are available today for steel sheet for car bodies. The
two material families at the right (TRIP, high-strength
Dual Phase) are still under development. Such steels are
very complex; they contain several phases; the ductility is
enhanced by special effects which strongly increase work
hardening, such as transformation-induced plasticity.
Fundamental research is needed in order to obtain even
better materials, for which the bands are shifted either to
the top or to the right. These materials will probably
be multiphase materials as well, or materials with a
nanostructure, or a combination of both. For example, it
is conceivable to develop pearlitic steels with interlamellar
distances in the lower nanometre range, which will
probably have superior properties due to the effect of the
lamellar structure on both strength and work hardening.
Other types of steels which would also exploit the “lamellar
effect” are also conceivable.A discussion on the scientific
issues related to multiphase alloys is given below.
(b) Aluminium alloys
The art of using several alloying elements in order to ob-
tain much higher strength in aluminium alloys is well de-
veloped. One of the most interesting ways to achieve this
is by precipitation hardening. This “art” is now evolving to
become a “science” by doing extensive studies on these
precipitates, their crystal structure, the degree of their co-
herence with the matrix, their stability. This research will
lead in the decade to come to further substantial improve-
ments of these alloys. One of the questions to be addressed
is the study of the stability of age-hardened alloys (an appli-
cation of precipitation hardening) at temperatures in the
range of 150°C - 200 °C. High-strength aluminium alloys
which would be stable in that range would allow for impor-
tant weight and energy savings in aerospace applications.
Many advanced aluminium alloys are also multiphase
alloys. See the discussion on multiphase alloys below.
For the rest, more work has to be done on developing reli-
able constitutive models to be used in design applications.
For some alloy systems, wide-range models exist for work
hardening as a function of strain rate and temperature [1],
but not for all alloy systems. Moreover, the existing model,
how complex it may appear [1], should still be extended to
include anisotropy and strain path effects.
(c) Titanium alloys
Aerospace industry has developed some truly high-
strength Ti-based alloys with very interesting microstruc-
tures (some of them lamellar). Some of these develop-
ments are unfortunately not in the public domain (military
secrets). Companies which build both military and civil-
ian aircraft can of course apply these alloys also in civilian
application, which cannot be done by companies which
only build civilian aircraft. From a more scientific point of
view, many issues remain unresolved, again because not
enough is know of the behaviour of multiphase materials
at the micro-to nanometre scale. (See the discussion on
multiphase materials).
(d) Copper alloys
The knowledge acquired for other metals (see above) would
be used to develop copper alloys which combine a high
electricalorthermalconductivitywithahighstrength,which
might have very important technological applications.
(e) Composites
Composite materials, either based on a polymer-matrix or
on a metal matrix, and reinforced by fibres have a high po-
tential to develop materials with an extremely favourable
ratio between strength and weight. The state of the art is
there that these materials can be produced, but that pro-
cessing still needs a lot of work to improve. The true under-
standing of the mechanical properties is now emerging,
but still has to be done in many cases.Again they will very
much depend on the interaction between phases, devel-
opment of stresses, and of course on the understanding
of the behaviour of the phases themselves. In view of the
high potential of these materials, a strong effort for further
fundamental research to raise it to the same scientific
level as the research on metals, is imperative.
Fig. 5.7. Combinations of strength and ductility (elongation) for various
steel families.
200 300
0
10
20
30
40
50
60
400 500 600 700 800 1000 1100 1200
BH
P-Alloyed
DP
TRIP
MA
IF HSS
Tensile Strength (MPa)
ElongationA80(%)
3. MATERIALSPHENOMENA
185
5.7.4. Scientific Trends
(a) Multiphase and nano-structured materials
Before the material scientists at steel companies, alumin-
ium companies etc. can really design new materials which
derive a high strength from either a multiphase structure
or a nanostructure, the institutions for fundamental mate-
rials research must provide answers to a certain number of
questions.A few examples:
• By which dislocation mechanisms is work hardening
achieved in the individual phases of multiphase materials?
• What are the relations between morphology (e.g. lamel-
la orientations) and crystallography at the time that the
microstructure is first formed?
• How do the phases interact with each other during plas-
tic deformation?
• To what extent is the work hardening pressure depen-
dent?(itmightberelevantincasesforwhichphasetrans-
formations may contribute to plastic deformation)
• Down to which grain size/interlamellar distance would
dislocation glide remain the dominant mechanism of
plastic deformation? By what is it replaced in the very
low nanometre range? How does this affect work hard-
ening and resistance against crack propagation?
• What are the glide systems in phases like cementite,
bainite, martensite? What is the values of the critical
resolved shear stresses?
• Why can the fracture of cementite upon plastic defor-
mation apparently be avoided in certain materials?
• Whichphasestressesdevelopinthevariousphases,how
can they be measured, how can they be modelled? How
do they affect ductility and strength?
• How is the thermodynamic equilibrium of the various
phases (some of them metastable) affected by the pres-
ence of high stresses and high dislocation densities after
plasticdeformation?(importantquestionastothestabil-
ity in time of properties of a material strengthened by
work hardening).
(This list is not exhaustive). To be able to answer these
questions, advanced experimental techniques have to be
developed, difficult measurements have to be carried out,
and the best “tools” of fundamental material physics need
to be used. Some questions will require the use of molecu-
lar dynamics-type approaches, or, on a slightly more coarse
scale, dislocation dynamics. Scale transition schemes will
have to be used to translate the conclusions into workable
models for design applications (see below).
(b) Atomistic modelling
A promising path is the use of atomistic modelling/molec-
ular dynamics for the study of mechanical properties.
Studies are being done on
- the behaviour of dislocations in a crystal;
- the propagation of a crack in a crystal;
- the plastic deformation of nanostructured polycrystal-
line material, when the grain size becomes so small that
dislocation glide no longer is the microscopic deforma-
tion mechanisms.
(c) Dislocation dynamics
At a somewhat higher scale (106 atoms), one studies the
behaviour of several hundreds dislocations by using specific
models for the behaviour of a dislocation in a crystal lattice.
This might some day lead to a full understanding of the dis-
location patterns which are observed in deformed materials.
(d) Multiscale modelling
A successful model at atomistic scale cannot really be used
for engineering applications. Schemes based on scientific
principles have to be developed to derive a model which
can be used at a particular length scale from a model de-
veloped from a lower length scale. The transition form the
atomistic level to the dislocation level, then to the subgrain
level, then to the grain level, finally to the macroscopic lev-
el will be achieved in this way during the decade to come.
Laser induced thermal shock measurement: influence of extreme
material loading by temperature changes are simulated.
4. 186
MAX-PLANCK-INSTITUTFÜRMETALLFORSCHUNGSTUTTGART
5.7.5. Application of Modelling in Design of Components
Advanced high-strength/light weight materials will not be
used to reduce weight in cars and other systems unless de-
sign procedures in industries are adapted. This is illustrat-
ed by the following example. Suppose that a pressed part
of a car (for example, a reinforcement column used for bet-
ter protection of the passengers) is normally made from
low-carbon steel. By making it from an advanced alu-
minium alloy or a high-strength steel, one can reduce the
thickness of the plate while maintaining the same strength
before fracture. But this would strongly reduce the elastic
bending stiffness (this issue has nothing to do with frac-
ture!) if the design is not adapted for the rest. However, it
is possible to obtain a sufficient bending stiffness by ade-
quately adapting the design. Only, the designers of indus-
try are not familiar with this. Their design principles have
been optimized by decades of experience with low carbon
steel. Unfortunately, there is no time left to acquire experi-
ence in the same way with the new advanced lightweight
materials. The answer of materials scientists and research
managers to this problem is to modernize the design pro-
cess by incorporating reliable constitutive models for the
materials behaviour into finite element models for the me-
chanical behaviour of components. This makes it possible
to optimize a product and the production process needed
for it by means of computer-aided design and computer-
aided manufacturing, thereby essentially gaining one or
two decades in the introduction of advanced lightweight
materials in industrial applications.
Fig. 5.8 illustrates the role of the constitutive model for
the mechanical behaviour of the materials in such system.
The state of the art is as follows:
• advanced material models which can realistically
describe the mechanical behaviour of single-phase poly-
crystalline materials (steel, aluminium alloys, copper
alloys, ␣-Ti alloys or -Ti alloys) including important
aspects such as texture-based anisotropy and work
hardening (also at changing strain paths) are under
development at present.
• in the decade to come, it is expected that this work will
be extended to advanced multiphase materials. That
means that all the knowledge acquired by studying the
physical problems listed above (see for example the sec-
tion on multiphase and nano-structured materials)
needs to be brought to a level of quality where it can be
implemented in quantitative models. Models of this
quality level will hopefully be transferred from the la-
boratories of universities and research institutions to the
industry during the second decade of the 21st century.
• implementation of advanced non linear model like these
into FE-codes is a formidable problem by itself. Existing
codes tend to become unstable if realistic materials mod-
els are used. To solve this problem, the best that theoreti-
cal mechanics can offer is needed. Several leading groups
in the field of FE modelling are now working at this.
Fig. 5.8. Scheme of an FE-software system which can be used to design deep drawing products.
Preprocess
Postprocess
Modelling of tool geometry
and time increments
Meshing of materials into
finite elements
Constitutive model
of materials
Final shape of product Stress and strain distribution Assessment of formability
Material data baseComputer-Aided Design (CAD)
Finite element calculation
5. MATERIALSPHENOMENA
187
5.7.6. Advance of the United States as compared to Europe
A detailed analysis of this issue for all the topics listed
above would require a much longer document. So only the
most striking aspects will be given.
The Unites States certainly has an important advantage in
the following fields:
• Study of advanced Al- and Ti-alloys and composite
materials. Any institution or company working simulta-
neously on military and civilian applications, and hence
having access to “military” results for civilian applica-
tions, has a great advantage.
• Implementation of advanced material models in FE-
codes. This work too is strongly supported by the needs
of military and nuclear industry.
• “Micro” and “Nano”-technology. The United States are
currently doing a great research effort, also in the sub-
field of “microstructural applications”.
5.8.1. Present Status
Basic research in materials science includes the study of
electronic structure as the basis for all properties of mate-
rials employed in applications. Examples are electrical
properties, magnetism, optical properties, the crystal
structure, etc. Therefore, the study of microscopic elec-
tronic properties complements investigations of macro-
scopic quantities, which often are aimed directly at
improving specific properties of materials utilized in
applications. Also, the goal of understanding materials
properties comprehensively by applying variable scale
modelling requires input about electronic structure.
Materials whose specific features of the microscopic elec-
tronic structure are employed directly in applications are
semiconductors, superconductors, and magnetic materi-
als. But the electronic structure is also the root of almost
any other material property, e.g. the extraordinary me-
chanical properties of some carbides and nitrides, optical
properties, catalytic activity, etc. Therefore, the study of
electronic structure both by experimental and theoretical
investigations will be of central importance for exploring
basic phenomena, which may lead to novel applications.
For the study of electronic structure, there is a broad range
of highly developed spectroscopic methods available. The
most direct probe of electronic structure is photoemis-
sion. This is complemented by techniques such as photo-
absorption, linear and non-linear optical spectroscopy,
inverse photoemission, etc. Also on the theoretical side
considerable progress has been achieved over the last
years. This includes a higher degree of reliability and pre-
cision with respect to the ground state electronic struc-
ture, not only for simple systems, but also for ever more
complex materials. Also, the spectroscopic properties,
which inevitably involve excited states, can be described
so that in many cases very good agreement is achieved
between experiment and theory.
5.8. Electronic Structure and Correlation
J. Kirschner, U. Hillebrecht | Max-Planck-Institut für Mikrostrukturphysik, 06120 Halle (Saale), Germany
M. von Löhneysen | Universität Karlsruhe, 76128 Karlsruhe, Germany
There is no single review paper covering all the topics listed above. A
complete literature list would be many pages long. So only a few refer-
ences will be given, to allow for an estimate of the complexity of the is-
sues depicted in the present contribution.
About work hardening:
E. Nes, Progress in Materials Science, 41 (1997) 129-194.
About advanced FE modelling of polycrystalline materials (work of Paul
Dawson et al., Cornell University, Ithaca, N.Y., USA):
P.R. Dawson and A.J. Beaudoin, “Finite element simulation of metal
forming”, in “Texture and Anisotropy. Preferred Orientations in Poly-
crystals and their Effect on Material Properties,” Kocks, U.F., Tomé, C.N.,
Wenk, H.-R., Eds., . Cambridge University Press, Cambridge, U.K. (1998)
533-560.
1.
2.
References