Investigations On Microstructure, Mechanical, and Tribological Behaviour of Aa 7075 - X WT.% Tic Composites For Aerospace Applications
Investigations On Microstructure, Mechanical, and Tribological Behaviour of Aa 7075 - X WT.% Tic Composites For Aerospace Applications
Investigations On Microstructure, Mechanical, and Tribological Behaviour of Aa 7075 - X WT.% Tic Composites For Aerospace Applications
ScienceDirect
Article history: This research work was dedicated to prepare AA 7075/(0, 2.5, 5 and 7.5 wt.%) TiC metal matrix
Received 2 June 2018 composites through stir casting route. The manufactured composites were effectively
Accepted 4 December 2018 characterized using various techniques such as X-ray diffraction, and advanced electron
Available online microscopes. The mechanical properties by the flexural strength and hardness results had
performed and investigated elaborately. Further, the tribological properties in terms of the
Keywords: wear resistance and the coefficient of friction was also done and demonstrated clearly. The
AA 7075 Al alloy dispersion of TiC ceramic particles and its embedding over the ductile Al 7075 matrix was
Metal matrix composite successfully obtained which exhibited excellent mechanical and surface behaviour with the
Characterization function of TiC particles when compared to monolithic Al 7075 alloy. These results were due
Mechanical properties to the particulate strengthening of hard TiC ceramic particle over the soft ductile phase. In
Wear addition, X-ray diffraction results ensured the manufacturing of Al 7075-x wt.% TiC metal
matrix composites successfully and no other inter-metallic phases were observed.
© 2018 Politechnika Wrocławska. Published by Elsevier B.V. All rights reserved.
* Corresponding author.
E-mail addresses: [email protected] (K.R. Ramkumar), [email protected], [email protected] (S. Sivasankaran),
[email protected] (F.A. Al-Mufadi), [email protected]
(S. Siddharth), [email protected] (R. Raghu).
https://doi.org/10.1016/j.acme.2018.12.003
1644-9665/© 2018 Politechnika Wrocławska. Published by Elsevier B.V. All rights reserved.
archives of civil and mechanical engineering 19 (2019) 428–438 429
Fig. 1 – (a) Schematic of stir casting of AA 7075–TiC composite preparation and (b) photograph of stir casting furnace.
Fig. 2 – Schematic of time steps involved during manufacturing of AA 7075 alloy and AA 7075 + wt.% TiC composites.
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then the samples were washed in acetone. The counterpart was expected to the distortion of a-Al lattice produced by the
disc made of high carbon high chromium steel with the outer incorporation of TiC ceramic particles. The manufactured
diameter of 70 mm with 10 mm thickness was used. The input composites (all samples) exhibited well crystalline peaks and
parameters used were: the load of 40 N, the sliding velocity of no other intermetallic phases were observed in XRD pattern,
1.5 m/s, the sliding distance of 500 m, and the disc speed of which demonstrated explicitly that there was no impurity.
240 m. The wear test was conducted at room temperature and Further, these results had explained that there was no reaction
the wear rate was calculated by weight loss basis which was between the a-Al matrix and cubic TiC phases [18,19].
measured using the digital weighing balance of Sartorius
CP423S with 1 mg precision. Finally, the SEM investigation was 3.2. Microstructures of AA7075/TiC AMCs
carried out on the worn samples to examine the various wear
mechanism and worn surface morphology. Fig. 4 shows the SEM images of AA 7075 reinforced with the
different weight percentage of TiC particles in which the a-Al
phase and the second phase particles were clearly seen. Some
3. Results and discussions casting defects, namely, the porosity, the scratches, and the
asperities were also observed in the unreinforced monolithic
3.1. XRD of AA7075/TiC AMCs alloy (Fig. 4(a), [20]). However, the intentionally added
reinforcements particles were distributed uniformly/homo-
Fig. 3 shows the X-ray diffraction pattern obtained for AA 7075 geneously over the matrix (Fig. 4(b)–(d)). These homogeneous
(JCPDS reference number 98-008-4180) alloy reinforced with distributions of TiC particles are necessary to enhance the
different weight percentage of TiC (JCPDS reference number 96- mechanical properties of materials. Further, Fig. 4(b)–(d) had
901-2565) ex situ particles (0, 2.5, 5 and 7.5 wt.%). It was clearly shown the proper interface between the TiC particles
observed that the intensity of peak corresponding to cubic TiC and the a-Al matrix which had indicated the good bonding of
phase had started to increase with the increase of weight second phase particles in the matrix. This could be expected to
percentage of TiC particles in the AMCs and simultaneously the enhance the load bearing capacity of a-Al matrix. In addition,
matrix peak (a-Al) had started to decrease [17]. Further, it was the observed clear interface between the TiC particles and a-Al
noticed that the peak position of a-Al was incoherent which matrix could be expected to increase the thermal stability. In
Fig. 4 – SEM images of Al 7075–composites of (a) Al 7075–0 wt.% TiC, (b) Al 7075–2.5 wt.% TiC, (c) Al 7075–5 wt.% TiC, (d) Al
7075–7.5 wt.% TiC composite and (e) EDX of (d).
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Fig. 5 – TEM micrographs of Al 7075–7.5% TiC composites: (a), (b) particulates and (c), (d) dislocation density.
general, the undesirable intermetallic compounds would form composites. Based on the grain size colour orientation map,
if there is no proper interface between the ceramic particles it was very clear that the AA 7075 matrix grains were refined
and matrix which lead to having the thermodynamically with the function of TiC ceramic particles. In general, the
unstable ceramic particles in the liquid matrix melt [21]. The presence of strain fields with more amounts of dislocations
energy dispersive diffraction (EDAX) pattern for AA 7075– is the major benefits to enhance the mechanical properties
7.5 wt.% TiC was also shown in Fig. 4(e) which confirmed the which could be achieved by the grain refinement process.
presence of both a-Al and TiC particles and no intermetallic Based on EBSD colour map, the grain size of a-Al matrix was
compounds [17,19]. determined and the grain size variation with the function of
However, the proper interface between the ceramic particles TiC particles is shown in Fig. 7. The observed average grain
and matrix phase with the good bonding of TiC particles in the size of a-Al matrix had started to decrease by incorporating
matrix was achieved in the present research work. In order to the TiC particles due to the pinning effect of TiC particles in
confirm the proper interface between TiC and a-Al matrix, TEM the matrix [23–25]. The calculated average grain size of AA
investigation on AA 7075–7.5 TiC AMC was carried out which is 7075 alloy, AA 7075–2.5 wt.% TiC, AA 7075–5.0 wt.% TiC, and
shown in Fig. 5. The TEM images of Fig. 5 revealed the TiC particle AA 7075–7.5 wt.% TiC AMCs were 155 4 mm, 121 3, 89
morphology, dislocations and interfacial properties in a-Al 4.5 and 65 2.5 mm, respectively (Fig. 7). Further, the
matrix phase. The measured TiC particle size was around crystallographic characteristics in terms of grain boundaries
250 nm (ultra-fine level) which was calculated from the average orientation angles, namely, low angle grain boundary
of 125 TiC particles obtained from several TEM images. Further, (LAGBs, 0–158), high angle grain boundaries (HAGBs, >158)
proper interfacial characteristics could be observed clearly based can also be used to examine the behaviour of materials. Fig. 8
on Fig. 5(a) and (b). In addition, there was no reaction layer shows the grain boundaries representations, misorientation
around the TiC particles due to which the TiC particles could not angle, and the corresponding pole figure for AA 7075 alloy
able to change its shape from around spherical shape to needle- and AA 7075 reinforced with 7.5 wt.% TiC composite. In Fig. 8
like shape. These results confirmed that the TiC particles had (a) and (d), the red colour grain boundaries were indicated
attained the stability during high-temperature casting processes. the angle from 08 to 58, the green colour grain boundaries
Moreover, more amounts of dislocations were also observed were indicated the angle from 58 to 158, and the blue colour
(Fig. 5(c) and (d)) which was due to the difference in the value of grain boundaries were indicated the angle of more than 158.
the coefficient of thermal expansion between the matrix phase From Fig. 8, it was very clear that the AA 7075–7.5 wt.% TiC
and TiC ceramic particles. In general, the a-Al matrix would composites was produced more HAGBs (78.8%) whereas the
expand and contract at a faster rate when compared to the TiC AA 7075 alloy was exhibited the HAGBs of 41.8% only. These
ceramic particles which were due to differences in the value of results explained that more grain refinement was occurred
the coefficient of thermal expansion. Due to this, a considerable in the composite. This grain refinement was expected to
amount of dislocations had formed after solidification which make the changes in the solidification of matrix melt with
produced more amount of strain fields [22]. the function of TiC particles. The introduction of TiC
Fig. 6 shows the grain size map obtained from EBSD for AA particles in a-Al matrix would lead to diminishing the a-
7075 alloy reinforced with different weight percentage of TiC Al grain growth [23,24]. This diminishing rate of grain grow
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Fig. 6 – Grain size colour orientation map obtained by EBSD for (a) AA 7075 alloy, (b) AA 7075–2.5 wt.% TiC, (c) AA 7075–5 wt.%
TiC and (d) AA 7075–7.5 wt.% TiC.
Fig. 7 – Effect of TiC content on the average grain size (mm) and the Rockwell hardness number (HRC) of Al 7075–x wt.% TiC
composites (x = 0, 2.5, 5.0 and 7.5 wt.%).
Fig. 8 – EBSD results of AA 7075 alloy: (a) LAGBs and HAGBs representation, (b) misorientation angle and (c) pole figure; EBSD
results of AA 7075–7.5 wt.% TiC composite: (d) LAGBs and HAGBs representation, (e) misorientation angle and (f) pole figure.
Based on the rule of mixture, the presence of hard TiC particle matrix (Fig. 6) had expected to assist the effective load carrying
would impart hard nature in the composites and hence the capacity of the matrix. In addition, the incorporation and
AMCs possessed more bending stress. Further, the effective getting of uniform distribution of TiC particles (Fig. 4) in the
interfacial bonds (Fig. 4) between the a-Al matrix and TiC matrix would enhance the strength in the composites due to
ceramic particles, and the grain refinement occurred in the Orowan strengthening mechanism. Moreover, the associated
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Fig. 9 – Bending stress–strain curves of Al 7075–x wt.% TiC The variation of wear rate, wear resistance and the coefficient
composites (x = 0, 2.5, 5.0 and 7.5 wt.%). of friction of AA 7075 alloy reinforced with the different weight
percentage of TiC particles is shown in Fig. 11. From Fig. 11(a), it
was observed that the wear rate had started to decrease with
the increase of the hard TiC ceramic particles in the a-Al
strain fields with the function of TiC particles (Fig. 5(b) and (c))
matrix. These results were attributed to the improvement of
in a-Al matrix had promoted more strength and hence the
hardness, outstanding interfacial bonding between the matrix
mechanical properties had improved in the present research
and ceramic particles, embedding of hard TiC particles, and
work. Baradeswaran and Elaya Perumal [27] had achieved the
grain refinement in the structure [25,29]. The increase in wear
improved bending strength of 435 MPa for AA 7075 alloy rein-
resistance with the incorporation of TiC second phase
forced with Al2O3 and Gr hybrid composite.
particles in a-Al matrix is also shown in Fig. 11(a). The
The fractured surfaces after bending under SEM images are addition of TiC particles in the matrix was expected to have a
shown in Fig. 10. From Fig. 10(a), it was clearly observed that homogeneous cast structure that might have reduced the
lower amount of dimples, the large size of cleavage fracture isolation of matrix. Further, the differences in the value of the
Fig. 10 – Fracture surface morphology of SEM images of Al 7075–composites of (a) Al 7075–0 wt.% TiC, (b) Al 7075–2.5 wt.% TiC,
(c) Al 7075–5 wt.% TiC and (d) Al 7075–7.5 wt.% TiC composite.
436 archives of civil and mechanical engineering 19 (2019) 428–438
Fig. 11 – Wear behaviour of Al 7075–x wt.% TiC (x = 0, 2.5, 5 and 7.5) composites: (a) variation of wear rate, and wear resistance
and (b) variation of coefficient of friction.
Fig. 12 – Worn surface morphology SEM images of Al 7075–composites of (a) Al 7075–0 wt.% TiC, (b) Al 7075–2.5 wt.% TiC, (c) Al
7075–5 wt.% TiC, (d) Al 7075–7.5 wt.% TiC composite and (e) EDX of (d) showing the Fe elements present in the material.
coefficient of thermal expansion between the TiC particle and had the lower value of wear resistance (Fig. 11(a)). The severe
a-Al matrix had expected to develop more amount of strain wear occurred in unreinforced alloy was attributed to the
fields consequently it led to enhance the dislocation density. presence of coarse grain matrix which had poor resistance
Due to this, the wear rate had started to decrease with the against deformation. However, the observed coefficient of
function of TiC particles. The variation of coefficient of friction friction value had started to decrease with the incorporation of
with the function of TiC particle is also shown in Fig. 11(b) in TiC particles (Fig. 11(b)) which was due to more in strength,
which the value of the coefficient of friction had started to uniform distribution of TiC particles, grain refinement, well
decrease considerably when the amount of TiC particles bonding, and embedding of TiC particles (Figs. 4–6 and 8). In
increased. The unreinforced monolithic AA 7075 alloy had general, the a-Al matrix embedded with hard TiC particles
possessed more value of the coefficient of friction and hence, it would offer more resistance against wear as the hard TiC
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particle would never allow the matrix to shear deformation. The absence of voids, cracks and other defects near the
Due to this, it was expected that the contact had occurred matrix and reinforcement interface provided the way for the
between the reinforcement particles and the steel counterface occurrence of effective load transfer from Al 7075 matrix to
in which the hard TiC particle would act as third body abrasion TiC reinforcement, which results in the enhancement of
[27,30]. This could minimize the coefficient of friction and flexural strength.
hence, the coefficient of friction had started to decrease with The increasing of reinforcement in the matrix had exhibited
the function of TiC particles (Fig. 11(b)). improved wear resistance due to increase in strength in the
The worn surface morphology observed from SEM of AA matrix, dispersion strengthening, and effective bonding.
7075–x wt.% TiC (x = 0, 2.5, 5 and 7.5) AMCs is shown in Figs. 12
(a)–(d). The abrasion and delamination mechanisms are the
common two wear mechanisms which would occur during the
Data availability statement
sliding wear test [23,24]. From Fig. 12(a) and (b), it was
obviously explained that severe delamination, more grooves,
rigorous surface failure, matrix peeling, more scratches, and The experimental datasets obtained from this research work
more ploughing had occurred in AA 7075 monolithic alloy and and then the analyzed results during the current study are
AA 7075–2.5 wt.% TiC AMCs. Further, the adhesive wear available from the corresponding author on reasonable
mechanism was expected to be the dominant one as these request.
samples was poor in strength and lower value of hardness.
Some wear debris with white particles was also observed
Authors' contributions
which was expected to oxidization. The formed debris was
attributed to poor in adhesive. However, fewer defects had
observed in AA 7075–5 wt.% TiC AMCs and AA 7075–7.5 wt.% Dr. S. Sivasankaran has framed the idea of this work and
TiC AMCs. Further, wear tracks with good tribo-film had also designed the experiments. Mr. K.R. Ramkumar and Mr. S.
observed in these AMCs (5 and 7.5 wt.% TiC) samples. Due to Siddharth have carried out the experimental part of this work.
this, the value of the coefficient of friction had started to Mr. R. Raghu has done the characterization studies using SEM
decrease with the function of reinforcement consequently the and TEM. Dr. Fahad Al-Mufadi has contributed to materials
good tribo film could decrease the adhesive wear. In addition, and tools. Dr. S. Sivasankaran has written this paper and
the higher reinforced sample had exhibited less wear track, finally Dr. Fahad Al-Mufadi has fine tuned the article.
fewer damages, and no oxidization layer. This was expected to
possess higher amount of resistances, uniform distribution of
reinforcements, more in strength, and effective interfacial
strength between TiC particles [31] and a-Al matrix. Based on Acknowledgments
these results, it could be concluded that admirable improved
tribological properties could be achieved in the manufactured On behalf of all teamwork of this research, the corresponding
AMCs and hence, the parts made of these materials are author wishes to thank the Qassim University for all the
expected to run in long life which is the major expectations in funding and support required to carry out this research.
the aerospace industries.
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