Abstract
In the present work, Al–TiB2 composites were casted using in situ and ex situ method of fabrication. The effect of processing temperature on the formation of titanium diboride particles was studied, and comparative evaluation of in situ and ex situ method was carried out. Characterization of composites was carried out to study the effect of various process parameters on the mechanical properties. The microstructure of in situ composites shows a homogeneous distribution of titanium diboride particles without agglomeration as compared to ex situ composites. SEM micrographs of in situ composites show distinct and reaction-free boundaries between reinforcement and matrix material as compared to the ex situ composites. In addition, average UTS of in situ AlSi5Cu3/3%TiB2 composite and ex situ AlSi5Cu3/3%TiB2 composite increased by 80.13% and 39.72% as compared to pure AlSi5Cu3, respectively. The average hardness of in situ AlSi5Cu3/3%TiB2 composite and ex situ AlSi5Cu3/3%TiB2 composite casted in metal mold increased by 45% and 31.66%, respectively, as compared to pure AlSi5Cu3.
Similar content being viewed by others
Change history
27 November 2020
A Correction to this paper has been published: https://doi.org/10.1007/s40962-020-00554-8
References
M.K. Akbari, H.R. Baharvandi, O. Mirzaee, Nano-sized aluminum oxide reinforced commercial casting A356 alloy matrix: evaluation of hardness, wear resistance and compressive strength focusing on particle distribution in aluminum matrix. Compos. B Eng. 52, 262–268 (2013)
ASM International. Handbook Committee, Properties and Selection: Nonferrous Alloys and Special-Purpose Materials, vol. 2 (ASM International, Philadelphia, 1990)
V.S. Ayar, M.P. Sutaria, Development and characterization of in situ AlSi5Cu3/TiB2 composites. Int. J. Metalcast. 14, 59–68 (2020). https://doi.org/10.1007/s40962-019-00328-x
V.S. Ayar, T.R. Mehta, M.P. Sutaria, Enhancement of mechanical properties of AlSi5Cu3 aluminum alloy using TiB2 reinforcements. IOP Conf. Ser. Mater. Sci. Eng. 455, 012127 (2018)
N. Chawla, K.K. Chawla, Composite Materials: Science and Engineering (Springer, Berlin, 2012)
Z.Y. Chen, Y.Y. Chen, Q. Shu, G.Y. An, D. Li, D.S. Xu, Y.Y. Liu, Solidification and interfacial structure of in situ Al–4.5Cu/TiB2 composite. J. Mater. Sci. 35, 5605–5608 (2000)
Z. Chen, T. Wang, Y. Zheng, Y. Zhao, H. Kang, L. Gao, Development of TiB2 reinforced aluminum foundry alloy based in situ composites—part I: an improved halide salt route to fabricate Al–5 wt% TiB2 master composite. Mater. Sci. Eng. A 605, 301–309 (2014)
A.M. Davidson, D. Regener, A comparison of aluminium-based metal-matrix composites reinforced with coated and uncoated particulate silicon carbide. Compos. Sci. Technol. 60, 865–869 (2000)
P. Davies, J.L.F. Kellie, D.P. Parton, J.V. Wood, Metal Matrix Alloys. U.S. Patent No. 6,228,185. U.S. Patent and Trademark Office, Washington, DC (2001)
H.P. Degischer, Innovative Light Metals: Metal Matrix Composites and Foamed Aluminium. Mater. Des. 18, 221–226 (1997)
G.I. Eskin, D.G. Eskin, Production of natural and synthesized aluminum-based composite materials with the aid of ultrasonic (cavitation) treatment of the melt. Ultrason. Sonochem. 10, 297–301 (2003)
C.F. Feng, L. Froyen, In situ synthesis of Al2O3 and TiB2 particulate mixture reinforced aluminium matrix composites. Scr. Mater. 36, 467–473 (1997)
Y. Han, X. Liu, X. Bian, In situ TiB2 particulate reinforced near eutectic Al–Si alloy composites. Compos. A Appl. Sci. Manuf. 33, 439–444 (2002)
J. Hashim, L. Looney, M.S.J. Hashmi, Metal matrix composites: production by the stir casting method. J. Mater. Process. Technol. 92–93, 1–7 (1999)
I.A. Ibrahim, F.A. Mohamed, E.J. Lavernia, Particulate reinforced metal matrix composites—a review. J. Mater. Sci. 26, 1137–1156 (1991)
X. Kai, K. Tian, C. Wang, L. Jiao, G. Chen, Y. Zhao, Effects of ultrasonic vibration on the microstructure and tensile properties of the nano ZrB2/2024Al composites synthesized by direct melt reaction. J. Alloys Compd. 668, 121–127 (2016)
A.R. Kennedy, S.M. Wyatt, The effect of processing on the mechanical properties and interfacial strength of aluminium/TiC MMCs. Compos. Sci. Technol. 60, 307–314 (2000)
S. Kumar, M. Chakraborty, V.S. Sarma, B.S. Murty, Tensile and wear behaviour of in situ Al–7Si/TiB2 particulate composites. Wear 265, 134–142 (2008)
S. Kumar, V.S. Sarma, B.S. Murty, Influence of in situ formed TiB2 particles on the abrasive wear behaviour of Al–4Cu alloy. Mater. Sci. Eng. A 465, 160–164 (2007)
S. Kumar, V.S. Sarma, B.S. Murty, A statistical analysis on erosion wear behaviour of A356 alloy reinforced with in situ formed TiB2 particles. Mater. Sci. Eng. A 476, 333–340 (2008)
D.J. Lloyd, S.K. Das, C.P. Ballard, F. Marikar, High Performance Composites for the 1990s (TMS, Warrendable, PA, 1990)
L. Lu, M.O. Lai, F.L. Chen, Al–4 wt% Cu composite reinforced with in situ TiB2 particles. Acta Mater. 45, 4297–4309 (1997)
L. Lu, M.O. Lai, Y. Su, H.L. Teo, C.F. Feng, In situ TiB2 reinforced Al alloy composites. Scr. Mater. 45, 1017–1023 (2001)
A. Mandal, M. Chakraborty, B.S. Murty, Ageing behaviour of A356 alloy reinforced with in situ formed TiB2 particles. Mater. Sci. Eng. A 489, 220–226 (2008)
A. Mazahery, M.O. Shabani, Study on microstructure and abrasive wear behavior of sintered Al matrix composites. Ceram. Int. 38, 4263–4269 (2012)
J.J. Moses, S.J. Sekhar, Investigation on the tensile strength and microhardness of AA6061/TiC composites by stir casting. Trans. Indian Inst. Met. 70, 1035–1046 (2017)
S. Natarajan, R. Narayanasamy, S.K. Babu, G. Dinesh, B.A. Kumar, K. Sivaprasad, Sliding wear behaviour of Al 6063/TiB2 in situ composites at elevated temperatures. Mater. Des. 30, 2521–2531 (2009)
H. Okamoto, L. Kacprzak, P.R. Subramanian (eds.), Binary Alloy Phase Diagrams (ASM international, Materials Park, OH, 1996)
S. Poria, P. Sahoo, G. Sutradhar, Tribological characterization of stir-cast aluminium-TiB2 metal matrix composites. Silicon 8, 591–599 (2016)
S.B. Prabu, L. Karunamoorthy, S. Kathiresan, B. Mohan, Influence of stirring speed and stirring time on distribution of particles in cast metal matrix composite. J. Mater. Process. Technol. 171, 268–273 (2006)
S.L. Pramod, S.R. Bakshi, B.S. Murty, Aluminum-based cast in situ composites: a review. J. Mater. Eng. Perform. 24, 2185–2207 (2015)
S.L. Pramod, A.P. Rao, B.S. Murty, S.R. Bakshi, Effect of Sc addition on the microstructure and wear properties of A356 alloy and A356–TiB2 in situ composite. Mater. Des. 78, 85–94 (2015)
K.S. Prasad, B.S. Murty, P. Pramanik, P.G. Mukunda, M. Chakraborty, Reaction of fluoride salts with aluminum. Mater. Sci. Technol. 12, 766–770 (1996)
H. Puga, J.C. Teixeira, J. Barbosa, E. Seabra, S. Ribeiro, M. Prokic, The combined effect of melt stirring and ultrasonic agitation on the degassing efficiency of AlSi9Cu3 alloy. Mater. Lett. 63, 2089–2092 (2009)
H.M. Rajan, S. Ramabalan, I. Dinaharan, S.J. Vijay, Synthesis and characterization of in situ formed titanium diboride particulate reinforced AA7075 aluminum alloy cast composites. Mater. Des. 44, 438–445 (2013)
H.M. Rajan, S. Ramabalan, I. Dinaharan, S.J. Vijay, Effect of TiB2 content and temperature on sliding wear behavior of AA7075/TiB2 in situ aluminum cast composites. Arch. Civ. Mech. Eng. 14, 72–79 (2014)
C.S. Ramesh, S. Pramod, R. Keshavamurthy, A study on microstructure and mechanical properties of Al 6061–TiB2 in situ composites. Mater. Sci. Eng. A 528, 4125–4132 (2011)
A.M. Samuel, H.W. Doty, S. Valtierra, F.H. Samuel, A metallographic study of grain refining of Sr-modified 356 alloy. Int. J. Metalcast. 11, 305–320 (2017). https://doi.org/10.1007/s40962-016-0075-x
R. Shobha, K.R. Suresh, H.B. Niranjan, K.G. Satyanarayana, Achieving enhanced mechanical properties and analysis of chemical kinetics of the in situ reaction in an Al–TiB2 in situ composite. Adv. Mater. Res. 129, 1385–1388 (2010)
S. Singh, I. Singh, A. Dvivedi, Design and development of novel cost effective casting route for production of metal matrix composites (MMCs). Int. J. Cast Met. Res. 30, 356–364 (2017)
M.D. Skibo, D.M. Schuster, Process for preparation of composite materials containing nonmetallic particles in a metallic matrix and composite materials made thereby. United States Patents, Patent No. 4,786,467 (1988)
A.K. Surappa, P.K. Rohatgi, Preparation and properties of cast aluminium ceramic particle composites. J. Mater. Sci. 16, 983–993 (1981)
H. Su, W. Gao, H. Zhang, H. Liu, J. Lu, Z. Lu, Optimization of stirring parameters through numerical simulation for the preparation of aluminum matrix composite by stir casting process. J. Manuf. Sci. Eng. 132, 061007 (2010)
K.L. Tee, L. Lu, M.O. Lai, Synthesis of in situ Al–TiB2 composites using stir cast route. Compos. Struct. 47, 589–593 (1999)
S.C. Tjong, Z.Y. Ma, Microstructural and mechanical characteristics of in situ metal matrix composites. Mater. Sci. Eng. R 29, 49–113 (2000)
B. Yang, Y.Q. Wang, B.L. Zhou, The mechanism of formation of TiB2 particulates prepared by in situ reaction in molten aluminum. Metall. Mater. Trans. B 29, 635–640 (1998)
N.L. Yue, L. Lu, M.O. Lai, Application of thermodynamic calculation in the in situ process of Al/TiB2. Compos. Struct. 47, 691–694 (1999)
J. Zhang, Z. Fan, Y.-Q. Wang, B.-L. Zhou, Microstructure and mechanical properties of in situ Al–Mg2Si composites. Mater. Sci. Technol. 16, 913–918 (2000)
Y. Zhang, N. Ma, H. Wang, Y. Le, X. Li, Damping capacity of in situ TiB2 particulates reinforced aluminium composites with Ti addition. Mater. Des. 28, 628–632 (2007)
Z. Zhang, D.L. Chen, Contribution of Orowan strengthening effect in particulate-reinforced metal matrix nanocomposites. Mater. Sci. Eng. A 483, 148–152 (2008)
Acknowledgements
The authors gratefully acknowledge the support from Department of Science and Technology (DST), New Delhi, sponsored SMART Foundry Project (DST/TSG/AMT/2015/332 dated 17/08/2016).
Author information
Authors and Affiliations
Corresponding author
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
The original online version of this article was revised: AlSi5Cu3 was corrected to AlSi5Cu3 throughout the text.
Rights and permissions
About this article
Cite this article
Ayar, V.S., Sutaria, M.P. Comparative Evaluation of Ex Situ and In Situ Method of Fabricating Aluminum/TiB2 Composites. Inter Metalcast 15, 1047–1056 (2021). https://doi.org/10.1007/s40962-020-00539-7
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s40962-020-00539-7