Study of 6061-Al₂O_3p composites produced by reciprocating extrusion

Abstract

A reciprocating extrusion process was developed to consolidate 6061-Al₂O_3p composites from mixed powders. The 6061 alloy powder was first dehydrated in a vacuum chamber at 450 °C and then mixed with 12.5 µm Al₂O₃ powder in various volume fractions: 0, 5, 10, 20, and 30 pct. The mixed powders were hot pressed at 300 °C under a pressure of 300 MPa and finally extruded reciprocatingly 14 times at 460 °C. The results show that the composites were fully densified, with no sign of pores or oxide layers observable in the optical microscope. The Al₂O₃ particles were distributed uniformly in the matrix. As compared with 6061 alloys, the composites demonstrated a smaller precipitation hardening and elongation, but exhibited a higher Young’s modulus and a larger work hardening capacity. The degradation of precipitation hardening was due to the loss of Mg, which reacts with Al₂O₃ to form MgAl₂O₄. The large work-hardening capacity is attributable to the incompatibility between Al₂O₃ and the matrix, which possibly generates more dislocations to harden the matrix. The composites had much higher friction coefficients and greater wear resistances than the 6061 alloy against steel disc surface. The friction coefficient of the 6061-30 vol pct Al₂O_3p composite was double that of the 6061 alloy and the wear resistance was 100-fold. As compared with similar composites reported previously, these composites possessed much higher elongation at the same strength level. A 30 vol pct Al₂O_3p still displayed an elongation of 9.8 pct in the T6 condition. All of these improvements are attributed to the merits, including full densification of the bulk, uniform dispersion of the Al₂O₃ particles in the matrix, and strong binding between the Al₂O₃ particles and the matrix resulting from reciprocating extrusion.