Fabrication of Al/Ni/Cu composite by accumulative roll bonding and electroplating processes and investigation of its microstructure and mechanical properties (original) (raw)
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Application of accumulative roll bonding and anodizing process to produce Al–Cu–Al2O3 composite
Materials & Design, 2015
In the present investigation, production of Al-Cu-Al 2 O 3 composite by means of Accumulative Roll Bonding (ARB) coupled with the anodizing process was studied. For this purpose, the alumina was grown on Al sheets by electrolyte technique and then the coated Al was laid between two Cu sheets followed by roll bonding to a specific reduction. This process was repeated up to seven times in order to achieve a bulk composite. The microstructure was characterized by SEM and optical microscopy while the mechanical properties were measured by microhardness, triple point bending and tensile testing. Microstructural evolution of the produced composite revealed that alumina was fractured in the primary sandwich and distributed non-uniformly throughout the composite. However, the alumina distribution was improved as the ARB cycles proceeded. It was also found that the tensile strength was improved up to the third cycle, after which it was decreased for the fourth and fifth cycles and again, it was increased for the last cycles. The bend strength showed the same trend as the tensile strength, while the elongation represented weak values for almost all cycles. Moreover, it was observed that as strain was increased (more ARB cycles), the microhardness for both Al and Cu layers was increased by two different trends. Additionally, failure analysis revealed that the mode of fracture was governed by two mechanisms: micro crack initiation between the metallic layers and formation of micro voids mainly around the alumina particles followed by their coalescence.
Materials Science and Engineering: A, 2012
In the present work, accumulative roll bonding (ARB) process was used to produce Al/Cu p composite using Al 1100 strips and Cu fine particles. Microstructure and mechanical properties of the composites were studied during various ARB cycles by scanning electron microscopy (SEM), tensile test and the Vickers micro-hardness test. The SEM results revealed that, as the ARB cycle increases the layer of Cu particles is broken which leads to generation of elongated dense Cu clusters. At higher strains, the size of elongated clusters reduces while their uniformity and sphericity increase. This microstructure changes leads to improving the hardness, strength and elongation during ARB process. Generally, the mechanical properties of Al/Cu p composite are better than those of pure Al at the same cycle of ARB. The results also demonstrated that, the Cu reinforcement particles in the form of uniformly dispersed clusters improve simultaneously the strength and toughness of Al during the ARB process.
Materials in engineering, 2013
In this work, the aluminum/copper multilayered composite was fabricated by new severe plastic deformation method named-accumulative roll bonding and folding‖ (ARBF) process at room temperature. Evolution of structure of the composite was investigated by transmission electron microscopy (TEM). It was demonstrated that ARBF process generated nanostructured aluminum/copper multilayered composite. Occurrence of the recrystallization (both continuous and discontinuous) in the copper layers led to the formation of nano grains with an average size of ~50 nm while, the average grain size of aluminum layers was ~200 nm after twelfth cycle of ARBF process. In both the copper and aluminum layers in grains and subgrains smaller than 100 nm almost no dislocations were observed, while grains larger than 200 nm had high density of dislocations. Also, when the number of ARBF cycle increased, the grains became equiaxed. Also as the number of ARBF cycles increased, the microhardness in both aluminum and copper layers increased. Differences in microstructural evolution during processing and hardness values of aluminum and copper layer were related to their stacking fault energies.
Al/Ni metal intermetallic composite produced by accumulative roll bonding and reaction annealing
Journal of Alloys and Compounds, 2011
In this research, Al/Ni multilayers composites were produced by accumulative roll bonding and then annealed at different temperatures and durations. The structure and mechanical properties of the fabricated metal intermetallic composites (MICs) were investigated. Scanning electron microscopy and X-ray diffraction analyses were used to evaluate the structure and composition of the composite. The Al 3 Ni intermetallic phase is formed in the Al/Ni interface of the samples annealed at 300 and 400 • C. When the temperature increased to 500 • C, the Al 3 Ni 2 phase was formed in the composite structure and grew, while the Al 3 Ni and Al phases were simultaneously dissociated. At these conditions, the strength of MIC reached the highest content and was enhanced by increasing time. At 600 • C, the AlNi phase was formed and the mechanical properties of MIC were intensively degraded due to the formation of structural porosities.
International Journal of Microstructure and Materials Properties, 2015
Aluminium matrix composites containing 15, 30 and 50 vol.% of pulverized Al 62 Cu 25.5 Fe 12.5 (in at.%) melt spun ribbons have been prepared by a vacuum hot pressing (T = 673 K, P = 600 MPa). The microstructure of the initial ribbon and the composites was investigated using X-ray, scanning and transmission electron microscopy. In the as-spun ribbon the quasicrystalline icosahedral phase (i-phase) coexisted with the cubic copper rich β-Al(Cu, Fe) intermetallic compound. The phase composition of Al-Cu-Fe particles changed after consolidation process and the i-phase transformed partially to the ω-Al 70 Cu 20 Fe 10 phase. Additionally, the Θ-Al 2 Cu phase formed at the α(Al)/Al-Cu-Fe particle interfaces. With an increase in volume fraction of the reinforcement the hardness of the composites increased up to HV = 180 for the highest amount of added particles. The ultimate compression strength of the same sample reached the value of 545 MPa.
Study on Texture Evolution and Shear Behavior of an Al/Ni/Cu Composite
Journal of Materials Engineering and Performance, 2018
The microstructure, texture, and mechanical properties of the Al/Ni/Cu composite during various accumulative roll bonding (ARB) cycles were studied using optical microscopy, scanning electron microscopy, xray diffraction, shear punch test, and hardness test. In addition, ImageJ software and Rietveld software were used in order to study microstructure and dislocation density variations, respectively. It was found that Ni and Cu layers were fractured and distributed in the Al matrix due to differences in their mechanical properties. Fracture and distribution of Cu and Ni particles after cycle five led to the alteration of the composite structure from a layered to a particle-reinforced structure. ARB process leads to the formation of strong orientation along the b-fiber and also to pronounced copper and dillamore components in both Al and Cu phases. Furthermore, the shear yield stress and ultimate shear strength of the composite increased as the ARB process advanced; however, shear elongation presented a non-uniform variation. Investigation of the fracture surfaces revealed that the mechanical properties of the composite are affected not only by the strain hardening of the Cu layer, but also by the structural change in the composite during the initial ARB cycles. During the last stages of the process, however, changes in mechanical properties were mostly governed by reinforcement particles serving as strain concentration zones and the strain hardening of the Al matrix.
Powder Metallurgy and Metal Ceramics, 2018
In the present study, Al5052/Cu multi-layered composite is prepared through accumulative roll bonding (ARB) and the microstructure and mechanical properties is evaluated using optical microscopy (OM), scanning electron microscopy (SEM), tensile tests and micro-hardness measurements. The results showed that the thickness of copper layers of 1000 µm at the initial sample was reduced to ~7 µm after the fifth cycle of ARB cycles while the thickness of Al layer increases. By increasing the number of ARB cycles, the microhardness of both aluminum and copper layers was significantly increased. The tensile strength of the sandwich was enhanced continually, and the maximum value of 566.5 MPa was achieved. The higher strength of 566.5 MPa and ductility of 9.61% were achieved which were about 47% and 21 % greater than the maximum values resulted in the literature. Investigation of the tensile fracture surfaces during the ARB process, indicated by increasing the number of the ARB passes, the fracture mechanism changed to shear ductile.
International Journal of Minerals Metallurgy and Materials, 2018
Layered composites have attracted considerable interest in the recent literature on metal composites. Their mechanical properties depend on the quality of the bonding provided by the intermediate layers. In this study, we analyzed the mechanical properties and bond strengths provided by the nickel layer with respect to its thickness and nature (either powder or coating). The results suggest that bond strength decreases with an increase in the content of nickel powder. At 0.3vol% of nickel coating, we found the nature of nickel to be less efficient in terms of bond strength. A different picture arose when the content of nickel was increased and the bond strength increased in nickel coated samples. In addition, the results demonstrate that mechanical properties such as bend strength are strongly dependent on bond strength.
Journal of Materials Engineering and Performance, 2012
The present investigation is an attempt to develop metal-intermetallic laminate composites based on Ni-Al system. In this study, Ni sheets and Al foils have been used for the development of Ni-Al laminate using accumulative roll-bonding technique at 773 K. The laminate composites were then subjected to the controlled annealing to affect reactive diffusion at the Ni/Al interface leading to intermetallic compound formation. The accumulative roll-bonded laminates showed good bonding of layers. Annealing treatment at 773 K led to formation of reaction product and maintained the interface integrity. A qualitative compositional analysis at the interfaces reflected the formation of Al-Ni compounds, and a gradual compositional gradient also across the interface. This process seems to be of promise so far as the continuous production of large scale metal-intermetallic laminate composites is concerned.
Materials Science and Engineering A-structural Materials Properties Microstructure and Processing, 2010
In the present work, accumulative roll bonding (ARB) process was used as an effective alternative method for manufacturing high-strength, finely dispersed and highly uniform copper/alumina metal matrix composite (MMC). The microstructural evolution and mechanical properties of the Cu/15 vol.% Al 2 O 3 composite during various ARB cycles are reported. The produced MMC by nine ARB cycles showed a homogeneous distribution and strong bonding between particles and matrix without any porosity. Also, it was found that when the number of cycles increased, not only did elongation increase but also the tensile strength of the composite improved by 2.5 times compared to that of the annealed copper used as the original raw material. Strengthening in the produced composites was explained by strain hardening, grain refinement, reinforcing role of particles, uniformity, bonding quality and size of particles. The findings also revealed that after the first cycle, hardness rapidly increased, then dwindled and finally saturated by further rolling.