Microstructural, mechanical, and tribological characteristics of ceramic reinforced Al/Cu hybrid matrix composites

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Abstract

Al and its alloys have a wide range of applications thanks to their low density, cost, and superior specific strength. Especially Al–Cu matrix composites are promising alloys with superior microstructural and mechanical performance. Thanks to the formation of the intermetallic due to the contained Cu, they significantly improve the properties of their Al-based alloys. In this study, Pure aluminum reinforced mainly with Cu and SiC and ZrO2 oxide and carbide-based ceramic particles were prepared by powder metallurgy. Three different values were determined for the Al–Cu content of the compositions, and these were produced in tube furnaces at 380°C and 580°C for 4 hours under an inert atmosphere using liquid phase sintering. According to the data of SEM and EDS analyses, microstructures formed in all samples were homogeneous. It was found that increasing sintering temperature increased microstructural densification. Adding mainly Cu and ceramic reinforcements to the microstructure significantly improved the hardness up to 2.05 times. Due to their intermetallic formation, the highest hardness values were determined in the samples containing high amounts of Cu, such as 173.73 HV. In the wear tests, it was observed that the samples sintered at high temperatures showed superior tribological performance. Also, the high Cu content improved the samples' friction behavior (COF). Since the increasing Cu content enhances intermetallic formation, superior wear resistance was observed in the samples containing a high amount of Cu sintered at higher temperatures up to 1.59 and 5.94 times. Optimum production parameters and chemical compositions were determined per the tests performed.

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About the authors

Esad Kaya

Eskişehir Osmangazi University

Author for correspondence.
Email: esatkaya@ogu.edu.tr

Department of Mechanical Engineering

Turkey, Eskişehir, 26480

Pelin Çağım Tokat Birgin

Kütahya Dumlupınar University

Email: esatkaya@ogu.edu.tr

Department of Metallurgy and Material Engineering

Turkey, Kütahya, 43020

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Supplementary files

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2. Fig. 1. Density values ​​of samples.

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3. Fig. 2. X-ray diffraction patterns of samples obtained at different sintering temperatures: (a) 380°C; (b) 580°C. [along the abscissa axis 2θ, deg.

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4. Fig. 3. Optical images of the microstructure of the manufactured samples: (a) sample 1; (b) sample 2; (c) sample 3; (d) sample 4; (d) sample 5; (e) sample 6.

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5. Fig. 4. Limiting optical images of intermetallic compounds present in the prepared samples: (a) sample 1; (b) sample 2; (c) sample 3; (d) sample 4; (d) sample 5; (e) sample 6.

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6. Fig. 5. SEM images of the structure of the manufactured samples: (a) sample 1; (b) sample 2; (c) sample 3; (d) sample 4; (d) sample 5; (e) sample 6.

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7. Fig. 6. (a) SEM and (b) EDX analyses and (c) schematic illustration of the compaction mechanism and (d) sintering process with the formation of intermetallic compounds in the sample.

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8. Fig. 7. Complete elemental map of sample 6.

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9. Fig. 8. Measured microhardness values ​​of samples.

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10. Fig. 9. Wear intensity and average coefficient of friction (COF) of the samples.

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11. Fig. 10. Change in COF during wear of samples.

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12. Fig. 11. SEM and EDX analysis of the surface subjected to wear (a) sample 1; (b) sample 2; (c) sample 3; (d) sample 4; (d) sample 5; (e) sample 6.

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13. Fig. 12. Comparison of microstructural, mechanical and tribological characteristics of samples with different chemical composition: a - sintered at 380°C, b - sintered at 580°C.

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