反应合成Al_2O_3颗粒增强铝基复合材料的研究
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摘要
颗粒增强铝基复合材料因具有密度低、比强度与比模量高、耐磨及耐高温等优点,在航空航天、电子和汽车制造等行业中具有广阔的应用前景。其制造方法一般分为外加法与内生法。外加法制备工艺简单,但颗粒表面容易污染,而内生法增强颗粒是在基体内部原位反应生成,颗粒细小,表面洁净,与基体结合良好。
本课题分别采用粉末冶金、熔体原位反应合成方法,在Al-SiO_2体系制备了Al_2O_3颗粒增强铝基复合材料。利用光学显微镜(OM)、扫描电镜(SEM)、X射线衍射仪(XRD)、差热扫描量热分析仪(DSC)等现代分析手段分析了复合材料的凝固组织,并探讨了Al-SiO_2体系的反应动力学以及影响颗粒大小和分布的因素,研究了复合材料的硬度和拉伸性能,分析了复合材料的断裂行为。
对Al-SiO_2体系反应的研究表明:根据热力学计算,Al-SiO_2体系的反应是自发进行的放热反应。只要加热到一定温度,就会引发反应,而反应放出的反应热将会导致体系温度上升,更有利于反应的进行。在660℃时,SiO_2与Al开始反应,生成Al_2O_3和Si,但反应未完全。直到920℃-950℃时反应完全,最终反应合成以Al-Si合金为基体,Al_2O_3颗粒为增强体的复合材料。对SiO_2颗粒进行球磨预处理可使粉体颗粒变得细小,平均粒径为1μm,从而改善SiO_2与Al的润湿性,降低反应的温度。Al-SiO_2体系的反应动力学过程可以分为浸渗阶段、反应和扩散阶段、完全反应阶段和弥散阶段。
Al-SiO_2体系熔体直接反应制备复合材料的最佳工艺参数为:反应温度850℃、反应时间30min,SiO_2在室温时放置在铝锭中间然后一起加热至850℃。X射线衍射和扫描电镜分析表明:Al-SiO_2体系原位反应生成的颗粒增强相为Al_2O_3颗粒,且颗粒尺寸细小,均匀分布于基体中。在反应过程中,对熔体施加高能超声,可提高Al_2O_3颗粒的体积分数,并使颗粒更细小、分布更均匀。
力学性能测试表明:反应合成的Al_2O_3/Al复合材料,与纯铝相比硬度有较大的提高,抗拉强度略有提高,伸长率则略有下降。SiO_2加入量为铝熔体的10wt%时,Al_2O_3/Al复合材料的硬度为62.6HV,较纯铝提高102.6%;抗拉强度为112.3MPa,较纯铝提高22.1%;伸长率为10.1%,较纯铝下降1.9%。
Particle reinforced metal matrix composites possess several advantages such as low density,high specific strength and stiffness,good wear-resistance and thermal stability.These composites can be applied to aerial and aerospace industries, electronic industry,automotive industry,etc.According to the source difference of reinforcements,the fabrication methods of metal matrix composites can be divided into traditional and in situ ones.The advantage of the traditional method is the simple process,but the particles will be polluted easily.As the reinforcement is formed from the metal matrix,in situ composites has advantages such as fine reinforcement paticles,clean reinforcement surface,and well-bonded interface between the reinforcement and the matrix.
In this paper,Al_2O_3 particle reinforced aluminum matrix composites have been prepared by powder metallurgy and diect melt reaction methods,respectively.The solidification microstructure,reaction kinetics and factors influencing the particulate size and distribution have been investigated by modem analysis equipments such as optical microscope(OM),scanning electron microscope(SEM),X-ray diffractometor (XRD),differential scanning calorimeter(DSC)and so on.The mechanical properties of composites are tested and the fracture behavior has been analyzed.
It is indicated that the exothermic chemical reaction in Al-SiO_2 system can proceed in aluminum melt spontaneously.If the reactants are heated to certain temperature,the chemical reaction will be triggered.The heat released from the reaction can lead a temperature rising and accelerate the reaction.The chemical reaction can start as the temperature is 660℃and the products are Al_2O_3 and Si. However,the reaction is not complete until 920℃to 950℃.It is proposed that the reaction process consists of infiltration,reaction and diffusion,reaction terminal,and particle dispersion.It is shown that the size of SiO_2 powders after ball milling is much smaller,which is about 1μm.Smaller size of SiO_2 powder can improve the wettability between SiO_2 and aluminum melt and decrease the reaction temperature.
The optimum parameters of composite fabrication in Al-SiO_2 system are that the reaction temperature is 850℃and the reacton time is 30 minutes.The prefered adding method of SiO_2 powders is to put them between aluminum ingots and heat to 850℃with aluminum directly.XRD and SEM analysis indicates that the reaction synthesized particles are Al_2O_3.These particles are finer and well-distributed in the aluminum matrix.Ultrasonic treatment during the in-situ synthesis process can increase the volume fraction of in-situ particles,and make them smaller and better distributed in the matrix.
The hardness and tensile strength of Al_2O_3/Al composites are higher than those of the corresponding matrix alloy,while the elongation of the composite is lower,than that of the matrix alloy.When the SiO_2 addition content is 10wt%,the hardness of composites is 62.6HV,102.6%more than that of pure aluminum.The tensile strength of the composite is 112.3MPa,22.1%more than that of pure aluminum.The elongation of the composite is 10.1%,1.9%less than that of pure aluminum.
本课题分别采用粉末冶金、熔体原位反应合成方法,在Al-SiO_2体系制备了Al_2O_3颗粒增强铝基复合材料。利用光学显微镜(OM)、扫描电镜(SEM)、X射线衍射仪(XRD)、差热扫描量热分析仪(DSC)等现代分析手段分析了复合材料的凝固组织,并探讨了Al-SiO_2体系的反应动力学以及影响颗粒大小和分布的因素,研究了复合材料的硬度和拉伸性能,分析了复合材料的断裂行为。
对Al-SiO_2体系反应的研究表明:根据热力学计算,Al-SiO_2体系的反应是自发进行的放热反应。只要加热到一定温度,就会引发反应,而反应放出的反应热将会导致体系温度上升,更有利于反应的进行。在660℃时,SiO_2与Al开始反应,生成Al_2O_3和Si,但反应未完全。直到920℃-950℃时反应完全,最终反应合成以Al-Si合金为基体,Al_2O_3颗粒为增强体的复合材料。对SiO_2颗粒进行球磨预处理可使粉体颗粒变得细小,平均粒径为1μm,从而改善SiO_2与Al的润湿性,降低反应的温度。Al-SiO_2体系的反应动力学过程可以分为浸渗阶段、反应和扩散阶段、完全反应阶段和弥散阶段。
Al-SiO_2体系熔体直接反应制备复合材料的最佳工艺参数为:反应温度850℃、反应时间30min,SiO_2在室温时放置在铝锭中间然后一起加热至850℃。X射线衍射和扫描电镜分析表明:Al-SiO_2体系原位反应生成的颗粒增强相为Al_2O_3颗粒,且颗粒尺寸细小,均匀分布于基体中。在反应过程中,对熔体施加高能超声,可提高Al_2O_3颗粒的体积分数,并使颗粒更细小、分布更均匀。
力学性能测试表明:反应合成的Al_2O_3/Al复合材料,与纯铝相比硬度有较大的提高,抗拉强度略有提高,伸长率则略有下降。SiO_2加入量为铝熔体的10wt%时,Al_2O_3/Al复合材料的硬度为62.6HV,较纯铝提高102.6%;抗拉强度为112.3MPa,较纯铝提高22.1%;伸长率为10.1%,较纯铝下降1.9%。
Particle reinforced metal matrix composites possess several advantages such as low density,high specific strength and stiffness,good wear-resistance and thermal stability.These composites can be applied to aerial and aerospace industries, electronic industry,automotive industry,etc.According to the source difference of reinforcements,the fabrication methods of metal matrix composites can be divided into traditional and in situ ones.The advantage of the traditional method is the simple process,but the particles will be polluted easily.As the reinforcement is formed from the metal matrix,in situ composites has advantages such as fine reinforcement paticles,clean reinforcement surface,and well-bonded interface between the reinforcement and the matrix.
In this paper,Al_2O_3 particle reinforced aluminum matrix composites have been prepared by powder metallurgy and diect melt reaction methods,respectively.The solidification microstructure,reaction kinetics and factors influencing the particulate size and distribution have been investigated by modem analysis equipments such as optical microscope(OM),scanning electron microscope(SEM),X-ray diffractometor (XRD),differential scanning calorimeter(DSC)and so on.The mechanical properties of composites are tested and the fracture behavior has been analyzed.
It is indicated that the exothermic chemical reaction in Al-SiO_2 system can proceed in aluminum melt spontaneously.If the reactants are heated to certain temperature,the chemical reaction will be triggered.The heat released from the reaction can lead a temperature rising and accelerate the reaction.The chemical reaction can start as the temperature is 660℃and the products are Al_2O_3 and Si. However,the reaction is not complete until 920℃to 950℃.It is proposed that the reaction process consists of infiltration,reaction and diffusion,reaction terminal,and particle dispersion.It is shown that the size of SiO_2 powders after ball milling is much smaller,which is about 1μm.Smaller size of SiO_2 powder can improve the wettability between SiO_2 and aluminum melt and decrease the reaction temperature.
The optimum parameters of composite fabrication in Al-SiO_2 system are that the reaction temperature is 850℃and the reacton time is 30 minutes.The prefered adding method of SiO_2 powders is to put them between aluminum ingots and heat to 850℃with aluminum directly.XRD and SEM analysis indicates that the reaction synthesized particles are Al_2O_3.These particles are finer and well-distributed in the aluminum matrix.Ultrasonic treatment during the in-situ synthesis process can increase the volume fraction of in-situ particles,and make them smaller and better distributed in the matrix.
The hardness and tensile strength of Al_2O_3/Al composites are higher than those of the corresponding matrix alloy,while the elongation of the composite is lower,than that of the matrix alloy.When the SiO_2 addition content is 10wt%,the hardness of composites is 62.6HV,102.6%more than that of pure aluminum.The tensile strength of the composite is 112.3MPa,22.1%more than that of pure aluminum.The elongation of the composite is 10.1%,1.9%less than that of pure aluminum.
引文
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