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Powder processing and properties of zircon-reinforced Al-13.5Si-2.5Mg alloy composites

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Abstract

Zircon, ZrSiO4, is a thermally stable mineral requiring expensive and energy-intensive process to reduce. Owing to its abundance, high hardness, excellent abrasion/wear resistance, and low coefficient of thermal expansion, a low-cost alternative use of the mineral for medium-strength tribology was investigated. The present study has developed a conventional low-cost, double-compaction powder metallurgy route in the synthesis of Al-13.5Si-2.5Mg alloy reinforced with zircon. The mechanical and physical properties were determined following the development of optimum conditions of cold pressing and reactionsintering. Reinforcing the hypereutectic Al-Si alloy with 15 vol% zircon particles (size < 200 µm) and cold pressing at 350 MPa to near-net shape, followed by liquid-phase reaction sintering at 615 °C in vacuum for 20 min, improved the ultimate tensile strength, 0.2 % yield strength, and hardness of the alloy by 4,12.8, and 88%, respectively. At values of more than 9 vol% zircon, percent elongation and the dimensional changes of the sintered composites remained virtually unchanged. At a critical volume fraction of zircon, between 0.03 and 0.05, a sharp rise in hardness was observed. Microstructural and mechanical property analysis showed that the improvement in the mechanical properties is attributable largely to the load-bearing ability and intrinsic hardness of zircon, rather than to particulate dispersion effects. A good distribution of the dispersed zircon particulates in the matrix alloy was achieved.

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Authors and Affiliations

  1. Dept. of Metallurgical and Materials Engineering, The University of Alabama, P.O. Box 870202, 35487, Tuscaloosa, AL, USA

    J. U. Ejiofo & R. G. Reddy

  2. Dept. of Metallurgical and Materials Engineering, Enugu State University of Technology, 01660, P.M.B, Enugu, Nigeria

    B. A. Okorie

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  1. J. U. Ejiofo
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  2. B. A. Okorie
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  3. R. G. Reddy
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Ejiofo, J.U., Okorie, B.A. & Reddy, R.G. Powder processing and properties of zircon-reinforced Al-13.5Si-2.5Mg alloy composites. J. of Materi Eng and Perform 6, 326–334 (1997). https://doi.org/10.1007/s11665-997-0097-x

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