Dry Sliding Wear Studies on Sillimanite and B4C Reinforced Aluminium Hybrid Composites Fabricated by Vacuum Assisted Stir Casting Process

This paper presents the results of studies to understand the influence of hybridisation on mechanical and tribological behaviour as well as dry sliding wear of aluminium metal matrix composites. Sillimanite and boron carbide (B₄C) were used as primary and secondary reinforcements and pure aluminium was used as the matrix material. The composite was fabricated by using a vacuum assisted stir casting process. Different research instruments were used, including a scanning electron microscope with EDX spectrometer, a surface measurement device, a thermal image analyser, as well as a tribotester. The results show that tensile, impact strength and hardness of the hybridised composites are superior (a step ahead) than unreinforced and primary composites. The wear behaviour of the fabricated specimens was tested for the dry sliding wear behaviour under the load range of 10–50 N with the steps of 20 N for the sliding velocities 0.75, 1.5 and 2.25 m/s over a distance of 1000 m. The wear rate increased with load and decreased as the wt.% of reinforcement increased. The wear rate of the composite with 10 wt.% Al₂SiO₅ was approximately 44% lower than that of the composite with 5 wt.% Al₂SiO₅. The same dependence was noted for hybrid composite (5 wt.% Al₂SiO₅ + 5 wt.% B₄C)—the wear rate was approximately 50.8% lower than that of the composite with 5 wt.% Al₂SiO₅ under the same test condition. The friction coefficient decreased as the weight percentage of the reinforcement (Al₂SiO₅ and B₄C) increased due to the uniform distribution of the reinforcement on the surface of the composites. The main wear mechanism of the studied materials was abrasion wear. The wear mechanism of the composite had tribochemical type. It involved the oxidation and transfer of the material, which formed protective tribolayers ensuring an additional sliding process. The mechanism that played the main role in the wear process of the composites was a combination of abrasive, adhesive and oxidative wear.     

Influence of Graphene Type and Content on Friction and Wear of Silicon Carbide/Graphene Nanocomposites in Aqueous Environment

Two different types of graphene materials were used as functional nanofillers for the mechanical and tribological improvement of silicon carbide/graphene nanocomposites. On the one hand is thermally reduced graphite oxide (TRGO) reduced at three different temperatures, and on the other hand is graphene made of three different organic precursors, which were directly coated on silicon carbide (SiC) platelets (GSiC). Additionally, benchmark materials were also used as carbon fillers. The SiC/graphene nanocomposites with 2 wt% filler content were manufactured by pressureless sintering (PLS). Some composites were produced with higher graphene contents of 4% and 8% and sintered by spark plasma sintering (SPS). Microstructural analyses were conducted using scanning electron microscopy (SEM) and transmission electron microscopy (TEM). Underwater lubrication, the SP sintered TRGO and GSiC materials with high graphene content have shown the most promising tribological performance. Furthermore, the reduced size of the homogeneously distributed nanoparticles promotes the formation of surface states, which improve the friction and wear properties.     

Effect of Zirconium Diboride and Titanium Diboride on the Structure and Properties of 316L Steel-Based Composites

The effect of zirconium diboride (ZrB₂) and titanium diboride (TiB₂) on the microstructure as well as the physical, mechanical, and tribological properties of composites based on 316 L steel is presented. Each reinforcing phase was added to the base alloy in the amount of 5 wt% and 10 wt%. The composites were fabricated by the SPS process (Spark Plasma Sintering). The results show that the weight fraction of the reinforcing phase affects the physical, mechanical, and tribological properties of the sintered composites. The sintered materials were characterized by a very high level of density. The addition of TiB₂ has proved to be effective in increasing the hardness and compressive strength of the composites. The hardness of the composites with the addition of 10% TiB₂ increased by 100% compared to the hardness of sintered 316L steel. It was found that introducing ZrB₂ to the steel matrix significantly improved the wear resistance of the composites. The results showed that compared to 316L steel with the wear rate of 519 × 10⁻⁶ mm³/Nm, the wear rate of the composites containing 10% ZrB₂ decreased more than twice, i.e., to 243 × 10⁻⁶ mm³/Nm.     

Preparation of B4Cp/Al Composites via Selective Laser Melting and Their Tribological Properties

B₄C-particle-reinforced Al (B₄C_p/Al) composites are widely used in various areas, e.g., armors, electronic packaging and fuel storage, owing to their several outstanding properties including high specific rigidity, excellent wear resistance and light weight. Selective laser melting (SLM) is favored in manufacturing complex components because of its high raw material utilization rate and high efficiency. In this work, a B₄C_p/Al composite was successfully synthesized by SLM, and the effects of one of the most important parameters, scanning speed (100–700 mm/s), on the phase composition, density, microhardness and tribological properties of the samples were investigated. The microhardness, relative density and dry-sliding wear resistance of as-prepared B₄C_p/Al composites were improved with the decrease in scanning speed, and the sample fabricated at a scanning speed of 100 mm/s exhibited a relative density as high as about 97.1%, and a maximum microhardness of ~180 HV_0.1 (approximately six times more than that of the SLM-formed pure Al sample, 31 HV_0.1), a minimum wear rate of 4.2 × 10⁻⁵ mm³·N⁻¹·m⁻¹ and a corresponding friction coefficient of 0.41. In addition, abrasive wear, adhesive wear and oxidation wear were found to be behind the overall wear behavior of as-prepared B₄C_p/Al composites.     

Mechanical and Microstructural Characterization of Friction Stir Welded SiC and B4C Reinforced Aluminium Alloy AA6061 Metal Matrix Composites

This study focuses on the properties and process parameters dictating behavioural aspects of friction stir welded Aluminium Alloy AA6061 metal matrix composites reinforced with varying percentages of SiC and B₄C. The joint properties in terms of mechanical strength, microstructural integrity and quality were examined. The weld reveals grain refinement and uniform distribution of reinforced particles in the joint region leading to improved strength compared to other joints of varying base material compositions. The tensile properties of the friction stir welded Al-MMCs improved after reinforcement with SiC and B₄C. The maximum ultimate tensile stress was around 172.8 ± 1.9 MPa for composite with 10% SiC and 3% B₄C reinforcement. The percentage elongation decreased as the percentage of SiC decreases and B₄C increases. The hardness of the Al-MMCs improved considerably by adding reinforcement and subsequent thermal action during the FSW process, indicating an optimal increase as it eliminates brittleness. It was seen that higher SiC content contributes to higher strength, improved wear properties and hardness. The wear rate was as high as 12 ± 0.9 g/s for 10% SiC reinforcement and 30 N load. The wear rate reduced for lower values of load and increased with B₄C reinforcement. The microstructural examination at the joints reveals the flow of plasticized metal from advancing to the retreating side. The formation of onion rings in the weld zone was due to the cylindrical FSW rotating tool material impression during the stirring action. Alterations in chemical properties are negligible, thereby retaining the original characteristics of the materials post welding. No major cracks or pores were observed during the non-destructive testing process that established good quality of the weld. The results are indicated improvement in mechanical and microstructural properties of the weld.     

Influence of Elemental Carbon (EC) Coating Covering nc-(Ti,Mo)C Particles on the Microstructure and Properties of Titanium Matrix Composites Prepared by Reactive Spark Plasma Sintering

This paper describes the microstructure and properties of titanium-based composites obtained as a result of a reactive spark plasma sintering of a mixture of titanium and nanostructured (Ti,Mo)C-type carbide in a carbon shell. Composites with different ceramic addition mass percentage (10 and 20 wt %) were produced. Effect of content of elemental carbon covering nc-(Ti,Mo)C reinforcing phase particles on the microstructure, mechanical, tribological, and corrosion properties of the titanium-based composites was investigated. The microstructural evolution, mechanical properties, and tribological behavior of the Ti + (Ti,Mo)C/C composites were evaluated using X-ray diffraction (XRD), scanning electron microscopy (SEM), energy dispersive X-ray spectroscopy (EDX), electron backscatter diffraction analysis (EBSD), X-ray photoelectron spectroscopy (XPS), 3D confocal laser scanning microscopy, nanoindentation, and ball-on-disk wear test. Moreover, corrosion resistance in a 3.5 wt % NaCl solution at RT were also investigated. It was found that the carbon content affected the tested properties. With the increase of carbon content from ca. 3 to 40 wt % in the (Ti,Mo)C/C reinforcing phase, an increase in the Young’s modulus, hardness, and fracture toughness of spark plasma sintered composites was observed. The results of abrasive and corrosive resistance tests were presented and compared with experimental data obtained for cp-Ti and Ti-6Al-4V alloy without the reinforcing phase. Moreover, it was found that an increase in the percentage of carbon increased the resistance to abrasive wear and to electrochemical corrosion of composites, measured by the relatively lower values of the friction coefficient and volume of wear and higher values of resistance polarization. This resistance results from the fact that a stable of TiO₂ layer doped with MoO₃ is formed on the surface of the composites. The results of experimental studies on the composites were compared with those obtained for cp-Ti and Ti-6Al-4V alloy without the reinforcing phase.     

On Investigating the Microstructural,Mechanical, and Tribological Properties of Hybrid FeGr1/SiC/Gr Metal Matrix Composites

In recent years, studies of different properties of hybrid metal matrix composites, as well as very detailed issues, have been published. In this article, ready-made iron, graphite, and silicon carbide powders were used to produce the base material and composites. An analysis of some microstructural and mechanical properties, as well as the tribological behavior of metal matrix composites (MMCs), based on FeGr1 sintered material with the single and hybrid addition of a silicon carbide and graphite was undertaken. During the study, the flexural and compressive strength of MMCs were analyzed and changes of the momentary coefficient of friction, the temperature of friction, as well as wear rates of the MMCs tested were monitored. Based on the results, it was revealed that wear rates decreased 12-fold in comparison to the base material when SiC or SiC + Gr were added. Further research into MMCs with ceramic particle additives is proposed.     

Effects of TiB2 Particles on the Microstructure Evolution and Mechanical Properties of B4C/TiB2 Ceramic Composite

B₄C/TiB₂ ceramic composites reinforced with three size scales (average particle size: 7 μm, 500 nm, and 50 nm) of TiB₂ were prepared by using a pressureless sintering furnace at 2100 °C under Ar atmosphere for 60 min. The results demonstrated that during the sintering process, TiB₂ located on the boundaries between different B₄C grains could inhibit the grain growth which improved the mass transport mechanism and sintering driving force. A semi-coherent interface between B₄C and SiC was found, which is supposed to help to reduce the interface energy and obtain good mechanical properties of the B₄C/TiB₂ ceramic composite. On sample cooling from sintering temperature to room temperature, the residual tensile stress fields formed at the TiB₂ interfaces owning to the thermo-elastico properties mismatched, which might have contributed to increase the ability of the sample to resist crack propagation. The results showed that the relative density, Vickers hardness, and fracture toughness of the composite with 20 wt.% submicron and 10 wt.% nano-TiB₂ were significantly improved, which were 98.6%, 30.2 GPa, and 5.47 MPa·m^1/2, respectively.     

Influence of Different Aqueous Media on the Corrosion Behavior of B4C-Modified Lightweight Al-Mg-Si Matrix Composites

In this study, we have investigated the electrochemical corrosion behavior of boron carbide (B₄C) ceramic-reinforced Al-Mg-Si matrix composites in various aqueous environments (NaOH, NaCl, HCl, and H₂SO₄). The samples were produced by the powder metallurgy (P/M) route and the corrosion investigations were conducted by potentiodynamic polarization (PDP) and electrochemical impedance spectroscopy (EIS) methods. The morphology of the as-prepared and corroded samples was examined by scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS) studies. The investigations revealed that the corrosion resistance of Al-Mg-Si composites is highest in NaCl medium due to a less negative corrosion potential, higher charge transfer (R_ct) resistance, and lower double-layer capacitance (C_dl) as compared to other media. The SEM morphology suggests that B₄C ceramics enhance corrosion resistance by forming a protective barrier layer of OH- and Cl- deposits in the composite and unreinforced alloy, respectively.     

Ceramic Matrix Composites Obtained by the Reactive Sintering of Boron Carbide with Intermetallic Compounds from the Ti-Si System

In this study, we investigated the effect of adding two different intermetallics, Ti₅Si₃ and TiSi₂, for the preparation of TiB₂-SiC-B₄C composites. As part of the research, stoichiometric composites consisting only of two phases TiB₂ and SiC were obtained. The TiB₂-SiC-B₄C composites were prepared via pressureless sintering. The presence of the phases in the sintered composites was confirmed using X-ray diffraction and scanning electron microscopy. The SEM-EDS examination revealed that the TiB₂ and SiC phases were formed during the composite process synthesis and were distributed homogeneously in the B₄C matrix. The obtained results allowed us to usually exceed 2000 °C and the use of specialized equipment for firing, that is, vacuum or protective atmosphere furnaces as well as control and measurement equipment. Such an approach generates high costs that are decisive for the economics of the technological processes. In the case of our compositions, it is possible to lower the temperature to 1650 °C. The TiB₂-SiC-B₄C composites were classified as UHTCs.     

Electrochemical Behavior of Al-B4C Metal Matrix Composites in NaCl Solution

Aluminum based metal matrix composites (MMCs) have received considerable attention in the automotive, aerospace and nuclear industries. One of the main challenges using Al-based MMCs is the influence of the reinforcement particles on the corrosion resistance. In the present study, the corrosion behavior of Al-B₄C MMCs in a 3.5 wt.% NaCl solution were investigated using potentiodynamic polarization (PDP) and electrochemical impedance spectroscopy (EIS) techniques. Results indicated that the corrosion resistance of the composites decreased when increasing the B₄C volume fraction. Al-B₄C composite was susceptible to pitting corrosion and two types of pits were observed on the composite surface. The corrosion mechanism of the composite in the NaCl solution was primarily controlled by oxygen diffusion in the solution. In addition, the galvanic couples that formed between Al matrix and B₄C particles could also be responsible for the lower corrosion resistance of the composites.     

Multi Ceramic Particles Inclusion in the Aluminium Matrix and Wear Characterization through Experimental and Response Surface-Artificial Neural Networks

Lightweight composite materials have recently been recognized as appropriate materials have been adopted in many industrial applications because of their versatility. The present research recognizes the inclusion of ceramics such as Gr and B₄C in manufacturing AMMCs through stir casting. Prepared composites were tested for hardness and wear behaviour. The tests’ findings revealed that the reinforced matrix was harder (60%) than the un-reinforced alloy because of the increased ceramic phase. The rising content of B₄C and Gr particles led to continuous improvements in wear resistance. The microstructure and worn surface were observed through SEM (Scanning electron microscope) and revealed the formation of mechanically mixed layers of both B₄C and Gr, which served as the effective insulation surface and protected the test sample surface from the steel disc. With the rise in the content of B₄C and Gr, the weight loss declined, and significant wear resistance was achieved at 15 wt.% B₄C and 10 wt.% Gr. A response surface analysis for the weight loss was carried out to obtain the optimal objective function. Artificial neural network methodology was adopted to identify the significance of the experimental results and the importance of the wear parameters. The error between the experimental and ANN results was found to be within 1%.     

Preparation and Tribological Properties of Modified MoS2/SiC/Epoxy Composites

In order to improve the tribological properties of epoxy (EP), EP composites were prepared by filling different proportions of silicon carbide (SiC) particles and molybdenum disulfide (MoS₂) powder. SiC and MoS₂ particle surfaces were modified by the silane coupling agent KH560 to improve dispersion and avoid agglomeration of the inorganic particles in the EP resin matrix. The effect of different proportions of modified MoS₂ content on the tribological properties of SiC/EP composites, and the wear mechanism of the worn surface, were investigated when the filler content was fixed at 55 wt.%. The results indicate that the friction and wear properties of modified MoS₂/SiC/EP composites are better than SiC/EP composites without modified MoS₂. When the modified MoS₂ content is 4 wt.%, the average friction coefficient and volume wear rate of the modified MoS₂/SiC/EP composite are 0.447 and 14.39 × 10⁻⁵ mm³/N·m, respectively, which is reduced by 10.06% and 52.13% in comparison with that of the 55 wt.% SiC/EP composite. Furthermore, the average friction coefficient of a composite containing 4 wt.% MoS₂ is 16.14% lower, and the volume wear rate is 92.84% lower than that of pure EP.     

Modelling and Characterisation of Residual Stress of SiC-Ti3C2Tx MXene Composites Sintered via Spark Plasma Sintering Method

This article presents an attempt to determine the effect of the MXene phase addition and its decomposition during sintering with the use of the spark plasma sintering method on mechanical properties and residual stress of silicon carbide based composites. For this purpose, the unreinforced silicon carbide sinter and the silicon carbide composite with the addition of 2 wt.% of Ti₃C₂T_x were tested. The results showed a significant increase of fracture toughness and hardness for composite, respectively 36% and 13%. The numerical study involving this novel method of modelling shows the presence of a complex state of stress in the material, which is related to the anisotropic properties of graphitic carbon structures formed during sintering. An attempt to determine the actual values of residual stress in the tested materials using Raman spectroscopy was also made. These tests showed a good correlation with the constructed numerical model and confirmed the presence of a complex state of residual stress.     

Effect of Carbon Content on Mechanical Properties of Boron Carbide Ceramics Composites Prepared by Reaction Sintering

In this study, different reaction-bonded boron carbide (RBBC) composites with a free carbon addition from 0 to 15 wt% were prepared, and the effect of the carbon content on the mechanical properties was discussed. With the free carbon addition increase from 0 to 15 wt%, the residual silicon content in the RBBC composite decreased first and then increased. Meanwhile, the strength of the RBBC composite improved first and then worsened. In the RBBC composite without free carbon, the B₄C grains are obviously dissolved, the grains become facet-shape, and the grain boundary becomes straight. The microstructure of the composite was tested by SEM, and the phase composition of the composite was tested by XRD. The RBBC composite with the addition of 10 wt% free carbon has the highest flexural strength (444 MPa) and elastic modulus (329 GPa). In the composite with a 10 wt% carbon addition, the phase distribution is uniform and the structure is compact.     

Fabrication of the Zirconium Diboride-Reinforced Composites by a Combination of Planetary Ball Milling,Turbula Mixing and Spark Plasma Sintering

The aim of this study was to carry out the consolidation of zirconium diboride-reinforced composites using the SPS technique. The effect of the adopted method of powder mixture preparation (mixing in Turbula or milling in a planetary mill) and of the reinforcing phase content and sintering temperature on the microstructure, physical properties, strength and tribological properties of sintered composites was investigated. Experimental data showed that the maximum relative density of 94–98% was obtained for the composites sintered at 1100 °C. Milling in a planetary mill was found to contribute to the homogeneous dispersion and reduced clustering of ZrB₂ particles in the steel matrix, improving in this way the properties of sintered steel + ZrB₂ composites. Morphological and microstructural changes caused by the milling process in a planetary mill increase the value of Young’s modulus and improve the hardness, strength and wear resistance of steel + ZrB₂ composites. Higher content of ZrB₂ in the steel matrix is also responsible for the improvement in Young’s modulus, hardness and abrasive wear resistance.     

Chemical Modification of B4C Films and B4C/Pd Layers Stored in Different Environments

B₄C/Pd multilayers with small d-spacing can easily degrade in the air, and the exact degradation process is not clear. In this work, we studied the chemical modification of B₄C films and B₄C/Pd double layers stored in four different environments: a dry nitrogen environment, the atmosphere, a dry oxygen-rich environment, and a wet nitrogen environment. The XANES spectra of the B₄C/Pd layers placed in a dry oxygen-rich environment showed the most significant decrease in the σ* states of the B–C bonds and an increase in the π* states of the B–O bonds compared with the other samples. X-ray photoelectron spectroscopy (XPS) measurements of the samples placed in a dry oxygen-rich environment showed more intensive B-O binding signals in the B₄C/Pd layers than in the single B₄C film. The results of the Fourier-transform infrared spectroscopy (FTIR) showed a similar decrease in the B–C bonds and an increase in the B–O bonds in the B₄C/Pd layers in contrast to the single B₄C film placed in a dry oxygen-rich environment. We concluded that the combination of palladium catalysis and the high content of oxygen in the environment promoted the oxidization of boron, deteriorated the B₄C composition.     

The Effect of B4C Powder on Properties of the WAAM 2319 Al Alloy

With ER2319 and B₄C powder as feedstocks and additives, respectively, a wire arc additive manufacturing (WAAM) system based on double-pulse melting electrode inert gas shielded welding (DP-MIG) was used to fabricate single-pass multilayer 2319 aluminum alloy. The results showed that, compared with additive manufacturing component without B₄C, the addition of which can effectively reduce the grain size (from 43 μm to 25 μm) of the tissue in the deposited layer area and improve its mechanical properties (from 231 MPa to 286 MPa). Meanwhile, the mechanical properties are better in the transverse than in the longitudinal direction. Moreover, the strengthening mechanism of B₄C on the mechanical properties of aluminum alloy additive manufacturing mainly includes dispersion strengthening from fine and uniform B₄C granular reinforcing phases and fine grain strengthening from the grain refinement of B₄C. These findings shed light on the B₄C induced grain refinement mechanism and improvement of WAAM 2319 Al alloy.     

Influence of Ti3C2Tx MXene and Surface-Modified Ti3C2Tx MXene Addition on Microstructure and Mechanical Properties of Silicon Carbide Composites Sintered via Spark Plasma Sintering Method

This article presents new findings related to the problem of the introduction of MXene phases into the silicon carbide matrix. The addition of MXene phases, as shown by the latest research, can significantly improve the mechanical properties of silicon carbide, including fracture toughness. Low fracture toughness is one of the main disadvantages that significantly limit its use. As a part of the experiment, two series of composites were produced with the addition of 2D-Ti₃C₂T_x MXene and 2D-Ti₃C₂T_x surface-modified MXene with the use of the sol-gel method with a mixture of Y₂O₃/Al₂O₃ oxides. The composites were obtained with the powder metallurgy technique and sintered with the Spark Plasma Sintering method at 1900 °C. The effect adding MXene phases had on the mechanical properties and microstructure of the produced sinters was investigated. Moreover, the influence of the performed surface modification on changes in the properties of the produced composites was determined. The analysis of the obtained results showed that during sintering, the MXene phases oxidize with the formation of carbon flakes playing the role of reinforcement. The influence of the Y₂O₃/Al₂O₃ layer on the structure of carbon flakes and the higher quality of the interface was also demonstrated. This was reflected in the higher mechanical properties of composites with the addition of modified Ti₃C₂T_x. Composites with 1 wt.% addition of Ti₃C₂T_x M are characterized with a fracture toughness of 5 MPa × m^0.5, which is over 50% higher than in the case of the reference sample and over 15% higher than for the composite with 2.5 wt.% addition of Ti₃C₂T_x, which showed the highest fracture toughness in this series.     

TiB2-Based Composites for Ultra-High-Temperature Devices,Fabricated by SHS,Combining Strong and Weak Exothermic Reactions

TiB₂-based ceramic matrix composites (CMCs) were fabricated using elemental powders of Ti, B and C. The self-propagating high temperature synthesis (SHS) was carried out for the highly exothermic “in situ” reaction of TiB₂ formation and the “tailing” synthesis of boron carbide characterized by weak exothermicity. Two series of samples were fabricated, one of them being prepared with additional milling of raw materials. The effects of TiB₂ vol fraction as well as grain size of reactant were investigated. The results revealed that combustion was not successful for a TiB₂:B₄C molar ratio of 0.96, which corresponds to 40 vol% of TiB₂ in the composite, however the SHS reaction was initiated and self-propagated for the intended TiB₂:B₄C molar ratio of 2.16 or above. Finally B₁₃C₂ was formed as the matrix phase in each composite. Significant importance of the grain size of the C precursor with regard to the reaction completeness, which affected the microstructure homogeneity and hardness of investigated composites, was proved in this study. The grain size of Ti powder did not influence the microstructure of TiB₂ grains. The best properties (HV = 25.5 GPa, average grain size of 9 μm and homogenous microstructure), were obtained for material containing 80 vol% of TiB₂, fabricated using a graphite precursor of 2 μm.