Developments in Processing of Functionally Gradient Metals and Metal-Ceramic Composites: A Review

doi:10.1007/s40195-014-0142-3

摘要/Abstract

Abstract:

Functionally gradient/graded materials (FGMs), an emerging new class of materials, are the outcome of the recent innovative concepts in materials technology. FGMs are in their early stages of evolution and expected to have a strong impact on the design and development of new components and structures with better performance. FGMs exhibit gradual transitions in the microstructure and/or the composition in a specific direction, the presence of which leads to variation in the functional performance within a part. The presence of gradual transitions in material composition in FGMs can reduce or eliminate the deleterious stress concentrations and result in a wide gradation of physical and/or chemical properties within the material. Functionally graded metal-ceramic composites are also getting the attention of the researchers. Among the fabrication routes for FGMs such as chemical vapour deposition, physical vapour deposition, the sol-gel technique, plasma spraying, molten metal infiltration, self propagating high temperature synthesis, spray forming, centrifugal casting, etc., the ones based on solidification route are preferred for FGMs because of their economics and capability to make large size products. The present paper discusses and compares various solidification processing techniques available for the fabrication of functionally gradient metals and metal-ceramic composites and lists their properties and possible applications. The other processing methods are briefly described.

Key words: Functionally gradient materials, Solidification, Aluminium, Centrifugal casting, Infiltration

. [J]. 金属学报英文版, 2014, 27(5): 825-838.

P. D. Rajan T., C. Pai B.. Developments in Processing of Functionally Gradient Metals and Metal-Ceramic Composites: A Review[J]. Acta Metallurgica Sinica (English Letters), 2014, 27(5): 825-838.

图/表 17

Fig. 1 Schematic illustration of an FGMCC with continuously graded microstructure

Fig. 2 a Graded SiC perform and aluminium-SiC infiltrated specimen, b-e microstructures of functionally graded Al(6061)-SiCp composite by squeeze infiltration

Fig. 3 Schematic diagram of horizontal centrifugal casting process for FGMCC

Fig. 4 Centrifugal casting of Al-graphite and Al-zircon composites [18, 19]

Table 1 Observations made on centrifugal casting of different aluminium metal matrix composites

Composite system	Observations
Al-SiC [22-24]	Graded distribution of SiC particles near the outer periphery of the casting
	Higher strength and modulus near outer periphery
	A smooth and gradual distribution of particles is observed when mixture of particle sizes is used
Al-graphite [18]	Higher volume fraction of graphite particles near the inner periphery of the casting
Al-Si	Primary Si particles are observed near the inner periphery of the hollow casting
Al-Al₃Ni [25, 26]	Primary Al₃Ni phases near the inner periphery of the casting
	Al-20% Ni forms the best graded distribution compared to Al-(10-40%) Ni
	Young’s modulus vary from 81 to 100 GPa across the 6-mm tube wall thickness from the inner to outer surface, reflecting 15.2 and 43.2 vol% Al₃Ni second phase
Al-Al₂Cu [27]	Graded structure of Al₂Cu is observed in Al-33 mass% Cu eutectic system
Al-Al₃Ti [28, 29]	Al₃Ti platelets are distributed gradually near the outer periphery of cylindrical casting
Al-AlB₂ [30]	AlB₂ particles with higher bulk density than liquid aluminium segregate towards the outer surface regions leading to higher wear resistance
Al-SiC-graphite	Graded distribution of SiC and graphite particles near the inner periphery of the casting. Few percentage of SiC is also observed near outer periphery
Al-(Al₃Ti + Al₃Ni) [31]	Hybrid Al-(Al₃Ti + Al₃Ni) show superior wear resistance than pure Al. The wear resistance at outer region of ring is higher compare to inner region

Fig. 5 Optical photomicrographs of Al(6061)-SiC FGM at different positions

Fig. 6 SiC Particle distribution in Al(6061)-SiC FGM

Fig. 7 Optical micrographs of Al-20% Si FGM fabricated by vertical centrifugal casting

Fig. 8 Optical micrographs of Al-Al3Ni in situ functionally graded composite formed from outer periphery of the casting Al-20% Ni

Fig. 9 Optical micrographs of Al-10 SiC-5 graphite functionally graded metal matrix composites by centrifugal casting from outer to inner periphery

Fig. 10 Microstructure of sequentially cast aluminium alloys showing the dewetting of the layers

Fig. 11 Microstructures of the sequential gravity Al319 and Al390 aluminium alloys with good bonding

Fig. 12 Microstructures of the sequential centrifugally cast Al319 and Al390 aluminium alloys

Fig. 13 Macrograph and properties of the brake rotor disc: a macrograph; b volume fraction of SiC distribution from outer to inner periphery by image analysis; c hardness profile; d tensile strength; e modulus of elasticity; f compression strength

Fig. 14 a Macrograph of as cast cylinder liner fabricated using Al390 aluminium alloy; b volume fraction of primary silicon from inner to outer periphery; c hardness profile of the cylinder liner from outer to inner periphery

Fig. 15 Functionally graded aluminium-matrix composite prototype components: a cylinder liners and gears; b brake rotor disc; c piston fabricated by centrifugal casting for engineering application at NIIST

Fig. 16 Functionally graded metal-ceramic brake pads developed by NIIST using squeeze infiltration

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