Al_2O_3·SiO_（2sf）/Al复合材料基体成份优化及耐磨性能研究
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摘要
本文采用挤压铸造的方法制备了Al_2O_3·SiO_(2sf)/Al复合材料,选用纯Al、Al-Cu、Al-Cu-Mg合金做为基体,并通过调整合金成份得到性能良好、成本低廉的复合材料,为寻求一种可供民用的短纤维增强铝基复合材料提供理论依据。
采用SEM、TEM、DEX和XRD对Al_2O_3·SiO_(2sf)/Al合金复合材料中的微观组织及界面结构进行分析,研究表明Al_2O_3·SiO_(2sf)/Al复合材料制备过程中金属铝液与原始纤维表面涂覆的SiO2非晶层发生反应,形成固溶在基体中硅相或在基体中以单质Si的形式析出。Cu元素加入后在纤维界面产生偏聚,有效的抑制和阻止这个界面反应的进行。当Cu含量增加到5%后,界面反应基本不再发生,基体中的溶质原子也由Si相转变为Cu相,并在局部区域析出少量CuAl2相。利用X射线标定萃取后的Al_2O_3·SiO_(2sf)/Al-Cu和Al_2O_3·SiO_(2sf)/(2024Al+Mg)复合材料的物相,发现复合材料中含有CuAl2O4尖晶石和MgAl2O4尖晶石结构,并利用反应物吉布斯自由能的变化量推断其反应历程和可能性,确定出CuAl2O4不是界面反应的产物,而是由CuAl2氧化生成;MgAl2O4是在挤压铸造时产生的纤维和基体之间的界面反应物。深入研究Al_2O_3·SiO_(2sf)/Al-Cu和Al_2O_3·SiO_(2sf)/(2024Al+Mg)复合材料及其基体合金的时效硬化析出行为。研究结果表明,随着Cu含量增加,峰时效时间提前,硬度提高,190oC时效时作用最明显。随着Mg含量的增加,峰时效时间延后,峰时效温度范围变宽,185oC时效时作用最明显。硬度测试结果和组织观察表明:Al_2O_3·SiO_(2sf)/(2024Al+1%Mg)的析出相细小、呈针状,对基体的强化效果最好,塑性也最好;Al_2O_3·SiO_(2sf)/(2024Al+2%Mg)析出相呈块状,尺寸略有长大,强度比前者略有下降;Al_2O_3·SiO_(2sf)/(2024Al+3%Mg)时析出相粗化严重,导致强度进一步降低。
研究表明,纯Al基体中添加Cu元素和Mg元素有利于复合材料热膨胀系数的降低,而且随着Cu或Mg含量增加,热膨胀系数呈现逐渐降低的趋势;在2024基体合金的基础上添加Mg元素,得到的复合材料热膨胀曲线更加平缓。加热温度在100~300oC之间时,Al_2O_3·SiO_(2sf)/Al,Al_2O_3·SiO_(2sf)/Al-Cu,Al_2O_3·SiO_(2sf)/(2024Al+Mg)三个系列复合材料的热膨胀系数都随着温度的提高缓慢增大,并呈线性变化规律,温度高于300oC之后,Al_2O_3·SiO_(2sf)/ (2024Al+Mg)复合材料的热膨胀系数随着温度的提高表现为急剧增大,而Al_2O_3·SiO_(2sf)/ (2024Al+3%Mg)复合材料的热膨胀系数相对平稳增大。
摩擦磨损实验表明,在磨损过程中Al_2O_3·SiO_2纤维增强相牢固地镶嵌在基体里并形成支架,从而在磨损过程中不易脱落;当材料表层中较软的基体被磨掉后,裸露出来的增强体纤维和对磨件接触摩擦,磨损接触面积减少,纤维既承担了部分载荷又减少了局部应力,从而保护基体而提高了复合材料耐磨性。Al_2O_3·SiO_(2sf)/Al合金复合材料的磨损机制主要为粘着磨损,Al_2O_3·SiO_(2sf)/Al-Cu合金复合材料的磨损机制为粘着磨损为主并伴有磨粒磨损;Al_2O_3·SiO_(2sf)/(2024Al+Mg)合金复合材料为轻微粘着磨损与磨粒磨损机制为主。复合材料的表面损失表现为破碎磨屑、剥层撕裂和流变滑移三种形式。
实验结果表明,滑动距离相同时,低转速下, Al_2O_3·SiO_(2sf)/Al合金复合材料的摩擦系数随着载荷的加大呈下降的趋势;在相对较高的转速下Al_2O_3·SiO_(2sf)/Al复合材料的摩擦系数随着载荷的加大却呈上升的趋势。多元合金元素的加入使得复合材料材料无论在高载荷还是在高转速条件下都能得到较小的摩擦系数,并能很好地保持摩擦系数的稳定性,体现了设计后复合材料的优良的耐磨性能。
The Al_2O_3·SiO_(2sf)/Al composites were fabricated by squeeze casting method. The Al, Al-Cu, and Al-Cu-Mg alloys were selected as the matrix, respectively, which were adjusted so as to get composites with excellent property and low cost. The research provided a theoretical base for finding a kind of short fiber reinforcement Al matrix composite material for civil use.
The microstructure and interface of Al_2O_3·SiO_(2sf)/Al composites are investigated by SEM, TEM and DEX. The results showed that during the manufacturing process of Al_2O_3·SiO_(2sf)/Al composites, there was a chemical reaction between the liquid Al and the SiO2 amorphous layer on the fiber surface. Therefore, the silicon dissolved into matrix alloy or precipitated as single crystal silicon phase. The aggregation of Cu element which generated at the interface of the fiber could effectively prevent or inhibit the reaction. When the Cu content increased to 5%, the reaction at the interface basically did not occur, the solute atoms in the matrix changed from silicon to Cu. In addition, small amount of CuAl2 phase precipitated at the local area of interface. X-ray results showed that CuAl2O4 spinel and MgAl2O4 spinel were formed in the Al_2O_3·SiO_(2sf)/Al-Cu and Al_2O_3·SiO_(2sf)/(2024Al+Mg) composites. Gibbs energy calculation of possible reactions in Al_2O_3·SiO_(2sf)/Al-Cu and Al_2O_3·SiO_(2sf)/ (2024Al+Mg) composites shows that CuAl2O4 is obtained through oxidation of CuAl2, not the reaction product of the interface, and that MgAl2O4 was the reaction product between fiber and matrix alloy during extrusion cladding.
The age hardening precipitation behavior of Al_2O_3·SiO_(2sf)/Al-Cu and Al_2O_3·SiO_(2sf)/(2024Al+Mg) composites was studied. Results showed that with the increasing of Cu content, the hardness was increased, and the peak aging time was shortened. The effect was the most obvious when aging at temperature 190oC. With the increasing of Mg content the peak aging time was postponed and the temperature range of peak aging was enlarged. The most obvious effect of aging treatment was at 185 oC. The results of hardness test and microstructure observation showed that the precipitation of Al_2O_3·SiO_(2sf)/(2024Al+1%Mg) was fine and acicular, which provided with the best effect of strengthening and plasticity. Some bulk precipitation, which the size was still small, was found in the Al_2O_3·SiO_(2sf)/(2024Al+2%Mg) composite and a slight decrease of hardness is obtained. For Al_2O_3·SiO_(2sf)/(2024Al+3%Mg), the precipitation grows larger which leads to further decrease of hardness.
Addition of Cu and Mg elements were both benefit to decrease the thermal expansion coefficients (CTEs) of the Al_2O_3·SiO_(2sf)/Al composites. The CTEs value of composites decreased with the Cu or Mg increasing. With the addition of Mg in the 2024 matrix alloy, the CTE curve of the composite was flat and the thermal expansion property of the Al_2O_3·SiO_2/(2024Al+3%Mg) composite material was optimum. During the heating temperature of 100~300oC the CTE values of the Al_2O_3·SiO_(2sf)/(2024Al+Mg) composites increased linearly and slowly with the temperature increasing. When the temperature is above 300oC the CTE value of Al_2O_3·SiO_(2sf)/(2024Al+Mg) composites increased sharply with the temperature increasing. While the thermal expansion was coefficient of Al_2O_3·SiO_(2sf)/(2024Al+3%Mg) composite increased smoothly.
Research work on the wear process showed that Al_2O_3·SiO_2 short fiber was firmly fixed in the matrix and formed the framework. The fiber in composites would be hardly pulled out during the wear processing. When the soft matrix material in the composite worn off, the bare area of Al_2O_3·SiO_2 fiber frictionated the opposite grinding material, The contact area was reduced and the fiber either took partial load or reduced local stress, protecting the comparatively soft matrix and improved the wear resistance of the composites. The wear mechanism of Al_2O_3·SiO_(2sf)/pure Al composite was mainly adherence abrasion. The wear mechanism of Al_2O_3·SiO_(2sf)/Al-Cu composite was mainly appeared to be adhesive wear, accompanied by abrasive wear. For the Al_2O_3·SiO_(2sf)/(2024Al+Mg) composite, the mechanism mainly was adhesive wear and grain wear mechanism.
At the same time, the loss of the material on the surface of the matrix alloy appeared to be grinding debris, peeling-off type and flow slip.
The result showed that the friction coefficient of the Al_2O_3·SiO_(2sf)/Al composites decreased with the load increasing under low spinning speed and same sliding distance, but the friction coefficient of the Al_2O_3·SiO_(2sf)/Al composites increased with the load increasing under high spinning speed. The addition of multi-components made it possible to obtain smaller friction coefficient under both high load and high speed. In addition, the stability of the friction coefficient showed the excellent wear resistance of the Al_2O_3·SiO_(2sf)/(2024Al+1%Mg) after design.
采用SEM、TEM、DEX和XRD对Al_2O_3·SiO_(2sf)/Al合金复合材料中的微观组织及界面结构进行分析,研究表明Al_2O_3·SiO_(2sf)/Al复合材料制备过程中金属铝液与原始纤维表面涂覆的SiO2非晶层发生反应,形成固溶在基体中硅相或在基体中以单质Si的形式析出。Cu元素加入后在纤维界面产生偏聚,有效的抑制和阻止这个界面反应的进行。当Cu含量增加到5%后,界面反应基本不再发生,基体中的溶质原子也由Si相转变为Cu相,并在局部区域析出少量CuAl2相。利用X射线标定萃取后的Al_2O_3·SiO_(2sf)/Al-Cu和Al_2O_3·SiO_(2sf)/(2024Al+Mg)复合材料的物相,发现复合材料中含有CuAl2O4尖晶石和MgAl2O4尖晶石结构,并利用反应物吉布斯自由能的变化量推断其反应历程和可能性,确定出CuAl2O4不是界面反应的产物,而是由CuAl2氧化生成;MgAl2O4是在挤压铸造时产生的纤维和基体之间的界面反应物。深入研究Al_2O_3·SiO_(2sf)/Al-Cu和Al_2O_3·SiO_(2sf)/(2024Al+Mg)复合材料及其基体合金的时效硬化析出行为。研究结果表明,随着Cu含量增加,峰时效时间提前,硬度提高,190oC时效时作用最明显。随着Mg含量的增加,峰时效时间延后,峰时效温度范围变宽,185oC时效时作用最明显。硬度测试结果和组织观察表明:Al_2O_3·SiO_(2sf)/(2024Al+1%Mg)的析出相细小、呈针状,对基体的强化效果最好,塑性也最好;Al_2O_3·SiO_(2sf)/(2024Al+2%Mg)析出相呈块状,尺寸略有长大,强度比前者略有下降;Al_2O_3·SiO_(2sf)/(2024Al+3%Mg)时析出相粗化严重,导致强度进一步降低。
研究表明,纯Al基体中添加Cu元素和Mg元素有利于复合材料热膨胀系数的降低,而且随着Cu或Mg含量增加,热膨胀系数呈现逐渐降低的趋势;在2024基体合金的基础上添加Mg元素,得到的复合材料热膨胀曲线更加平缓。加热温度在100~300oC之间时,Al_2O_3·SiO_(2sf)/Al,Al_2O_3·SiO_(2sf)/Al-Cu,Al_2O_3·SiO_(2sf)/(2024Al+Mg)三个系列复合材料的热膨胀系数都随着温度的提高缓慢增大,并呈线性变化规律,温度高于300oC之后,Al_2O_3·SiO_(2sf)/ (2024Al+Mg)复合材料的热膨胀系数随着温度的提高表现为急剧增大,而Al_2O_3·SiO_(2sf)/ (2024Al+3%Mg)复合材料的热膨胀系数相对平稳增大。
摩擦磨损实验表明,在磨损过程中Al_2O_3·SiO_2纤维增强相牢固地镶嵌在基体里并形成支架,从而在磨损过程中不易脱落;当材料表层中较软的基体被磨掉后,裸露出来的增强体纤维和对磨件接触摩擦,磨损接触面积减少,纤维既承担了部分载荷又减少了局部应力,从而保护基体而提高了复合材料耐磨性。Al_2O_3·SiO_(2sf)/Al合金复合材料的磨损机制主要为粘着磨损,Al_2O_3·SiO_(2sf)/Al-Cu合金复合材料的磨损机制为粘着磨损为主并伴有磨粒磨损;Al_2O_3·SiO_(2sf)/(2024Al+Mg)合金复合材料为轻微粘着磨损与磨粒磨损机制为主。复合材料的表面损失表现为破碎磨屑、剥层撕裂和流变滑移三种形式。
实验结果表明,滑动距离相同时,低转速下, Al_2O_3·SiO_(2sf)/Al合金复合材料的摩擦系数随着载荷的加大呈下降的趋势;在相对较高的转速下Al_2O_3·SiO_(2sf)/Al复合材料的摩擦系数随着载荷的加大却呈上升的趋势。多元合金元素的加入使得复合材料材料无论在高载荷还是在高转速条件下都能得到较小的摩擦系数,并能很好地保持摩擦系数的稳定性,体现了设计后复合材料的优良的耐磨性能。
The Al_2O_3·SiO_(2sf)/Al composites were fabricated by squeeze casting method. The Al, Al-Cu, and Al-Cu-Mg alloys were selected as the matrix, respectively, which were adjusted so as to get composites with excellent property and low cost. The research provided a theoretical base for finding a kind of short fiber reinforcement Al matrix composite material for civil use.
The microstructure and interface of Al_2O_3·SiO_(2sf)/Al composites are investigated by SEM, TEM and DEX. The results showed that during the manufacturing process of Al_2O_3·SiO_(2sf)/Al composites, there was a chemical reaction between the liquid Al and the SiO2 amorphous layer on the fiber surface. Therefore, the silicon dissolved into matrix alloy or precipitated as single crystal silicon phase. The aggregation of Cu element which generated at the interface of the fiber could effectively prevent or inhibit the reaction. When the Cu content increased to 5%, the reaction at the interface basically did not occur, the solute atoms in the matrix changed from silicon to Cu. In addition, small amount of CuAl2 phase precipitated at the local area of interface. X-ray results showed that CuAl2O4 spinel and MgAl2O4 spinel were formed in the Al_2O_3·SiO_(2sf)/Al-Cu and Al_2O_3·SiO_(2sf)/(2024Al+Mg) composites. Gibbs energy calculation of possible reactions in Al_2O_3·SiO_(2sf)/Al-Cu and Al_2O_3·SiO_(2sf)/ (2024Al+Mg) composites shows that CuAl2O4 is obtained through oxidation of CuAl2, not the reaction product of the interface, and that MgAl2O4 was the reaction product between fiber and matrix alloy during extrusion cladding.
The age hardening precipitation behavior of Al_2O_3·SiO_(2sf)/Al-Cu and Al_2O_3·SiO_(2sf)/(2024Al+Mg) composites was studied. Results showed that with the increasing of Cu content, the hardness was increased, and the peak aging time was shortened. The effect was the most obvious when aging at temperature 190oC. With the increasing of Mg content the peak aging time was postponed and the temperature range of peak aging was enlarged. The most obvious effect of aging treatment was at 185 oC. The results of hardness test and microstructure observation showed that the precipitation of Al_2O_3·SiO_(2sf)/(2024Al+1%Mg) was fine and acicular, which provided with the best effect of strengthening and plasticity. Some bulk precipitation, which the size was still small, was found in the Al_2O_3·SiO_(2sf)/(2024Al+2%Mg) composite and a slight decrease of hardness is obtained. For Al_2O_3·SiO_(2sf)/(2024Al+3%Mg), the precipitation grows larger which leads to further decrease of hardness.
Addition of Cu and Mg elements were both benefit to decrease the thermal expansion coefficients (CTEs) of the Al_2O_3·SiO_(2sf)/Al composites. The CTEs value of composites decreased with the Cu or Mg increasing. With the addition of Mg in the 2024 matrix alloy, the CTE curve of the composite was flat and the thermal expansion property of the Al_2O_3·SiO_2/(2024Al+3%Mg) composite material was optimum. During the heating temperature of 100~300oC the CTE values of the Al_2O_3·SiO_(2sf)/(2024Al+Mg) composites increased linearly and slowly with the temperature increasing. When the temperature is above 300oC the CTE value of Al_2O_3·SiO_(2sf)/(2024Al+Mg) composites increased sharply with the temperature increasing. While the thermal expansion was coefficient of Al_2O_3·SiO_(2sf)/(2024Al+3%Mg) composite increased smoothly.
Research work on the wear process showed that Al_2O_3·SiO_2 short fiber was firmly fixed in the matrix and formed the framework. The fiber in composites would be hardly pulled out during the wear processing. When the soft matrix material in the composite worn off, the bare area of Al_2O_3·SiO_2 fiber frictionated the opposite grinding material, The contact area was reduced and the fiber either took partial load or reduced local stress, protecting the comparatively soft matrix and improved the wear resistance of the composites. The wear mechanism of Al_2O_3·SiO_(2sf)/pure Al composite was mainly adherence abrasion. The wear mechanism of Al_2O_3·SiO_(2sf)/Al-Cu composite was mainly appeared to be adhesive wear, accompanied by abrasive wear. For the Al_2O_3·SiO_(2sf)/(2024Al+Mg) composite, the mechanism mainly was adhesive wear and grain wear mechanism.
At the same time, the loss of the material on the surface of the matrix alloy appeared to be grinding debris, peeling-off type and flow slip.
The result showed that the friction coefficient of the Al_2O_3·SiO_(2sf)/Al composites decreased with the load increasing under low spinning speed and same sliding distance, but the friction coefficient of the Al_2O_3·SiO_(2sf)/Al composites increased with the load increasing under high spinning speed. The addition of multi-components made it possible to obtain smaller friction coefficient under both high load and high speed. In addition, the stability of the friction coefficient showed the excellent wear resistance of the Al_2O_3·SiO_(2sf)/(2024Al+1%Mg) after design.
引文
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