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Advances in Preparation Methods and Numerical Simulation of Composites: Formation and Properties

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A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Metal Matrix Composites".

Deadline for manuscript submissions: closed (10 June 2024) | Viewed by 15934

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Prof. Dr. Zhengyi Jiang

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Guest Editor

School of Mechanical, Materials, Mechatronic and Biomedical Engineering, University of Wollongong, Wollongong, NSW 2522, Australia
Interests: numerical simulation of metal forming; tribology in metal forming; multi-scale materials processing; advanced rolling technology; microforming; manufacturing of composites; contact mechanics; friction and wear in manufacturing; lubrication technology; development of novel lubricants
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Prof. Dr. Hongmei Zhang

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Guest Editor

School of Material and Metallurgy, University of Science and Technology Liaoning, Anshan 114051, China
Interests: rolling; micro forming; manufacturing of composites; tribology in materials manufacturing; contact mechanics; computational contact mechanics; numerical simulation of metal manufacturing; novel lubricants in rolling; oxidation in metal manufacturing
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Special Issue Information

Dear Colleagues,

Advanced composite materials are lightweight and high strength and have designable performance. Further advantages include their heat insulation, heat conduction, vibration reduction, high (low) temperature resistance, corrosion resistance, and wave transmission and absorption. The composites are widely used in aerospace, transportation, energy, and chemical industries, as well as in construction, textiles, sports, and medical treatment, and have played an important role in the development of modern science and technology and the renewal and upgrading of high-end equipment. The material is also one of the core contents of the modern low-carbon economy. Since monolithic materials are no longer state-of-the-art, composite materials represent an emerging future with many industrial applications, particularly where superior material properties are required.

This Special Issue on “Advances in Preparation Methods and Numerical Simulation of Composites: Formation and Properties” intends to cover original research and critical review articles on recent advances in all aspects of metal–metal, metal–nonmetal, and nonmetal–nonmetal composites.

In particular, the topics of interest include, but are not limited to the following:

Material composition design;
The design and manufacturing process;
Microstructure and properties;
Interfacial diffusion behavior;
Microstructure characterization of constituent phases;
Physical and chemical properties;
Modeling and simulation.

Prof. Dr. Zhengyi Jiang
Prof. Dr. Hongmei Zhang
Guest Editors

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Keywords

material composition design
the design and manufacturing process
microstructure and properties
interfacial diffusion behavior
microstructure characterization of constituent phases
physical and chemical properties
modeling and simulation

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Published Papers (10 papers)

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Research

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14 pages, 5698 KiB

Open AccessArticle

Understanding the High-Temperature Deformation Behaviors in Additively Manufactured Al6061+TiC Composites via In Situ Neutron Diffraction

by Minglei Qu, Dunji Yu, Lianyi Chen, Ke An and Yan Chen

Metals 2024, 14(9), 1064; https://doi.org/10.3390/met14091064 - 17 Sep 2024

Viewed by 356

Abstract

Aluminum matrix composites (AMCs) are designed to enhance the performance of conventional aluminum alloys for engineering applications at both room and elevated temperatures. However, the dynamic phase-specific deformation behavior and load-sharing mechanisms of AMCs at elevated temperatures have not been extensively studied and remain unclear. Here, in situ neutron diffraction experiments are employed to reveal the phase-specific structure evolution of additively manufactured Al6061+TiC composites under compressive loading at 250 °C. It is found that the addition of a small amount of nano-size TiC significantly alters the deformation behavior and increases the strength at 250 °C in comparison to the as-printed Al6061. Unlike the two-stage behavior observed in Al6061, the Al6061+TiC composites exhibit three stages during compression triggered by changes in the interphase stress states. Further analysis of Bragg peak intensity and broadening reveals that the presence of TiC alters the dislocation activity during deformation at 250 °C by influencing dislocation slip planes and promoting dislocation accumulation. These findings provide direct experimental observations of the phase-specific dynamic process in AMCs under deformation at an elevated temperature. The revealed mechanisms provide insights for the future design and optimization of high-performance AMCs. Full article

(This article belongs to the Special Issue Advances in Preparation Methods and Numerical Simulation of Composites: Formation and Properties)

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16 pages, 10345 KiB

Open AccessArticle

Effect of Electromagnetic Field Assistance on the Wear and Corrosion Resistance of Nickel-Based Coating by Laser Cladding

by Dianxian Zhan, Dezhi Jiang, Yonggang Tong, Mingjun Zhang, Jian Zhang, Hongwei Hu, Zhenlin Zhang and Kaiming Wang

Metals 2024, 14(9), 998; https://doi.org/10.3390/met14090998 - 1 Sep 2024

Viewed by 627

Abstract

Offshore wind turbine generators usually demand higher requirements for key component materials because of the adverse working environment. Therefore, in this study, electromagnetic-assisted laser cladding technology was introduced to prepare the nickel-based composite coating on the Q345R matrix of wind turbine generator key component material. By means of Scanning Electron Microscope (SEM), X-ray diffraction (XRD), Energy Dispersive Spectrometer (EDS), the Vickers hardness tester, friction and wear tester, and electrochemical workstation, the effects of different magnetic field intensities on the macroscopic morphology, microstructure, phase composition, microhardness, wear resistance, and corrosion resistance of the coating were analyzed. The experimental results show that the addition of a magnetic field can effectively reduce the surface defects, improve the surface morphology, and not change the phase composition of the coating. With the increase in magnetic field intensity, the microstructure is gradually refined, and the average microhardness increases gradually, reaching a maximum of 944HV_0.5 at 8 T. The wear resistance gradually increases with the increase in magnetic field intensity, especially when the magnetic field intensity reaches 12 T, the wear rate of the coating is reduced by 81.13%, and the corrosion current density is reduced by 43.7% compared with the coating without a magnetic field. The addition of an electromagnetic field can enhance the wear resistance and corrosion resistance of the nickel-based laser cladding layer. Full article

(This article belongs to the Special Issue Advances in Preparation Methods and Numerical Simulation of Composites: Formation and Properties)

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14 pages, 6789 KiB

Open AccessArticle

Multi-Physics Simulation and Optimization of Jet Electrodeposition for Ni–Diamond Composite Coatings

by Xiaoli Wang, Chau-Chang Chou, Xin Zhou, Xin Bao and Qian Zhang

Metals 2024, 14(8), 868; https://doi.org/10.3390/met14080868 - 28 Jul 2024

Viewed by 681

Abstract

This work investigated the influence of current density, plating solution flow rate, and nozzle outlet-to-cathode distance on the properties of Ni–diamond composite coatings. A multi-physics field simulation was employed to analyze the interplay between current density, plating solution flow rate, and nozzle outlet-to-cathode distance on the flow field and electric field distribution. Additionally, particle tracing simulations were incorporated into the model to evaluate the incorporation efficiency of diamond particles during composite electrodeposition. It was found that when the inlet flow rate of the electrolyte was 5 L/min, the distance between the nozzle outlet and the cathode was 3 mm, and the current density was 60 A/dm², the composite electrodeposited coating had a higher particle content and better uniformity. The simulation results were validated through experimental preparation and performance testing. This combined approach provides valuable insights for optimizing the jet electrodeposition process for Ni–diamond composite coatings with superior properties. Full article

(This article belongs to the Special Issue Advances in Preparation Methods and Numerical Simulation of Composites: Formation and Properties)

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16 pages, 17150 KiB

Open AccessArticle

Effects of ErF₃ Particles on the Structure and Physicomechanical Properties of A359 Alloy

by Nikolai Kakhidze, Vladimir Valikhov, Mikhail Selikhovkin, Anton Khrustalyov, Ilya Zhukov, Sergey Vasiliev and Alexander Vorozhtsov

Metals 2023, 13(8), 1463; https://doi.org/10.3390/met13081463 - 14 Aug 2023

Cited by 1 | Viewed by 1105

Abstract

In this work, the impact of ErF₃ submicroparticles on the microstructure and mechanical properties of the A359 alloy was studied. ErF₃ particles provided a homogeneous structure in castings produced via the casting method. The modifying effect of ErF₃ particles on the structure of Al–Si alloys is realized through the mechanism of restraining the crystallization front and is achieved through the reduction in the formation of clusters of iron phases and eutectic lamellar silicon. It was found that the addition of 1 wt% ErF₃ to the A359 alloy leads to a decrease in the average grain size by 21% and an increase in the yield strength by 14%, in tensile strength by 16%, in the microhardness of Al₁₅(FeMn)₃Si₂ phase by 34% and in the Al₁₅(FeMnCr)₃Si₂ phase by 7%. The heat treatment of the A359 alloy with ErF₃ particles increased the yield strength by 36% and the tensile strength by 34%. The absence of an effect of ErF₃ particles on the hardness values of the A359 alloy, as well as on the fracture process of the A359 alloy, was observed. The negative influence of ErF₃ particle agglomerates and clusters on the strength characteristics of the investigated alloys was observed. Approaches for further exploring the potential of ErF₃ particles as a strengthening phase in cast aluminum alloys of the Al–Si system were proposed. Full article

(This article belongs to the Special Issue Advances in Preparation Methods and Numerical Simulation of Composites: Formation and Properties)

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23 pages, 6206 KiB

Open AccessArticle

Elastoplastic Deformation of Rotating Disk Made of Aluminum Dispersion-Hardened Alloys

by Oleg Matvienko, Olga Daneyko, Vladimir Valikhov, Vladimir Platov, Ilya Zhukov and Aleksandr Vorozhtsov

Metals 2023, 13(6), 1028; https://doi.org/10.3390/met13061028 - 27 May 2023

Cited by 1 | Viewed by 1334

Abstract

This paper studies the plastic deformation of a rotating disk made of aluminum dispersion-hardened alloys using mechanical tensile tests and a structured study using optical microscopy methods. Alloys such as AA5056 and A356 with dispersed Al₃Er and TiB₂ particles are used as the initial materials. Tensile strength testing of the obtained alloys shows that the addition of Al₃Er particles in the AA5056 alloy composition leads to an increase in its ultimate stress limit (USL) and plasticity from 170 to 204 MPa and from 14.7 to 21%, respectively, although the modifying effect is not observed during crystallization. The addition of TiB₂ particles to the A356 alloy composition also leads to a simultaneous increase in the yield strength, USL, and plasticity from 102 to 145 MPa, from 204 to 263 MPa, and from 2.3 to 2.8%, respectively. The study of the stress-strain state of the disk was carried out in the framework of deformed solid mechanics. The equilibrium equations were integrated analytically, taking into account the hardening conditions obtained from the experimental investigations. This made it possible to write the analytical relations for the radial and circumferential stresses and to determine the conditions of plastic deformation and loss of strength. The plastic resistance of a disk depends on the ratio between its outer and inner radii. The plastic resistance decreases with increasing disk width at a constant inner radius, which is associated with a stronger effect from the centrifugal force field. At a higher rotational rate of narrow disks, the tangential stresses are high and can exceed the USL value. A356 and A356–TiB₂ alloys are more brittle than the AA5056 and AA5056–Al₃Er alloys. In the case of wide rotating disks, AA5056 and AA5056–Al₃Er alloys are preferable. Full article

(This article belongs to the Special Issue Advances in Preparation Methods and Numerical Simulation of Composites: Formation and Properties)

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15 pages, 8355 KiB

Open AccessArticle

Study on Microstructure and Properties of Ultra-thin Cu/Al Composite Sheets Using the Cold-Rolled Composite Method at the Microscale

by Dege Chen, Hongmei Zhang, Hongnan Li, Rui Zhu, Yuchuan Zhu and Zhengyi Jiang

Metals 2023, 13(4), 780; https://doi.org/10.3390/met13040780 - 16 Apr 2023

Cited by 5 | Viewed by 1332

Abstract

In this paper, an ultra-thin Cu/Al composite sheet with a thickness of 0.08 mm was obtained via the cold-rolling composite method using a four-high micro-rolling mill in the laboratory. The rolling reduction of a single pass was 65%. After the annealing of the ultra-thin Cu/Al composite sheets at temperatures ranging from 350 °C to 500 °C, the interface bonding mode of the Cu/Al composite sheets changed from mechanical bonding to metallurgical bonding, and the bonding strength was significantly improved. The microhardness value at the bonding interface of the ultra-thin Cu/Al composite sheets increases with the increase in annealing temperature. When the annealing temperature is 500 °C, the maximum microhardness value at the bonding interface reached 2.0 GPa. With the increase in annealing temperature, the tensile strength and elongation of the ultra-thin Cu/Al composite sheets decreases significantly. The peel strength of the extremely thin Cu/Al composite sheets increases at first and then decreases with the increase in annealing temperature, and reached the maximum value at an annealing temperature of 400 °C. When the annealing temperature was 400 °C, the tensile and peel properties of the ultra-thin Cu/Al composite sheet reached the best state. Full article

(This article belongs to the Special Issue Advances in Preparation Methods and Numerical Simulation of Composites: Formation and Properties)

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18 pages, 24335 KiB

Open AccessArticle

Effect of WC Content on Microstructure and Element Diffusion of Nano WC-Co-TiC/304 Stainless Steel Composites for Micro Drill

by Rui Zhu, Hongmei Zhang, Jianling Wang, Hongnan Li, Jinmeng Li, Zhisong Zhang, Yuchuan Zhu and Zhengyi Jiang

Metals 2023, 13(3), 475; https://doi.org/10.3390/met13030475 - 24 Feb 2023

Cited by 3 | Viewed by 1504

Abstract

In this study, WC-Co-TiC/304 stainless steel composites were successfully prepared by compression at room temperature and vacuum sintering in a special mold. Through analysis and comparison of the microstructure, density, and particle size of WC-Co-TiC/304 stainless steel composite, the effects of different WC contents on the structure and properties of WC-Co-TiC were studied. The results show that among different WC contents when the WC content is 60%, the distribution of each structure is relatively uniform and fine, and the agglomeration of each structure is not obvious. The bonding effect of WC-Co-TiC cemented carbide and 304 stainless steel composite interface is the best. With the increase of WC content, the side defects of WC-Co-TiC cemented carbide increase gradually. When WC content is 60%, the best ratio is 1:1 of Co/TiC, as the density is 94.45%, the particle size of 0.2–0.3 μm is 38.9%, and the highest hardness of WC-Co-TiC cemented carbide side is 1370 HV_0.1, but it is better when the ratio of Co/TiC is 3:2 at the composite interface, as the hardness value is 852 HV_0.1 and the diffusion of Cr element is more uniform, while other elements have little difference. Full article

(This article belongs to the Special Issue Advances in Preparation Methods and Numerical Simulation of Composites: Formation and Properties)

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18 pages, 11517 KiB

Open AccessFeature PaperArticle

The Dependence of the Strength of a Carbon Fiber/Aluminum Matrix Composite on the Interface Shear Strength between the Matrix and Fiber

by Sergei Galyshev and Bulat Atanov

Metals 2022, 12(10), 1753; https://doi.org/10.3390/met12101753 - 19 Oct 2022

Cited by 4 | Viewed by 2091

Abstract

Taking the example of a composite wire with an Al-25% Sn alloy matrix reinforced with carbon fiber, the dependence of composite bending strength on interface shear strength was determined. Samples of the composite wire with different interface shear strengths were obtained by heat treatment at temperatures from 300 to 600 °C. The highest bending strength of 2450 MPa was observed for composite wire samples with the lowest interface shear strength. With an increase in the shear strength of the interface, a decrease in the strength was observed. The study of the surface of carbon fiber extracted from the composite showed that heat treatment led to the formation of aluminum carbide crystals on the fiber surface, the size and number of which increased with increasing temperature. As a result, there was an increase in the shear strength of the interface. The evaluation of the work of fracture of a composite with different strengths of the interface between the matrix and the fiber demonstrated that as the strength of the interface increases, the work of fracture decreases, due to the premature fracture of the composite through crack propagation in one plane. Based on the experimental data, the refined mixture rule according to the Weibull distribution, and an assessment of the critical stress of crack propagation according to the Griffith–Orowan–Irwin concept, the dependence of composite strength on the shear strength of the interface was estimated. Due to this, the critical shear strength was calculated at which the greatest strength of the composite can be achieved, these values being 107 MPa and 2675 MPa, respectively. It is shown that the contribution of the work of overcoming the friction force to the total work of fracture at relatively small values of shear strength can be several times greater than the total contribution of all other types of energy. Full article

(This article belongs to the Special Issue Advances in Preparation Methods and Numerical Simulation of Composites: Formation and Properties)

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17 pages, 10311 KiB

Open AccessArticle

Enhancement of Wear Resistance on H13 Tool and Die Steels by Trace Nanoparticles

by Shu-Qing Kou, Jun-Nan Dai, Wen-Xin Wang, Chun-Kai Zhang, Si-Yu Wang, Tai-Yu Li and Fang Chang

Metals 2022, 12(2), 348; https://doi.org/10.3390/met12020348 - 16 Feb 2022

Cited by 4 | Viewed by 2567

Abstract

In order to improve the impact toughness and wear resistance of the tool and die steels, this study innovatively prepared strengthened H13 steels with different contents of single-phase TiC and dual-phase TiC + TiB₂ through in situ nanoparticle/Al master alloys at room temperature. The microstructure evolution and mechanical properties as well as wear resistance were investigated. Results indicate that the H13 steel with 0.02 wt.% dual-phase TiC + TiB₂ nanoparticles has a more uniform and finer microstructure, and the mechanical properties and wear resistance are significantly improved. The yield strength, maximum tensile strength, breaking strain, uniform elongation, product of strength plasticity, and unnotched and U-notched impact toughness of H13 steel with 0.02 wt.% dual-phase TiC + TiB₂ are higher than that of H13 steel. In addition, the volume wear rate, maximum scratch depth and width reach 7.1 × 10⁻¹¹ m³/m, 6050 nm and 90 μm, respectively, which are reduced by 44.5%, 30.1% and 45.5% compared with that of H13 steel. Refining the microstructure and improving impact toughness and wear resistance of H13 tool steel through trace nanoparticles can provide important inspiration for industrial applications. Full article

(This article belongs to the Special Issue Advances in Preparation Methods and Numerical Simulation of Composites: Formation and Properties)

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Review

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21 pages, 3037 KiB

Open AccessFeature PaperReview

Factors Affecting the Mechanical Performance of High Manganese Austenitic Steel

by Lei Xia, Ling Yan, Hongmei Zhang, Yan Li, Zhengyi Jiang and Guanglong Li

Metals 2022, 12(9), 1405; https://doi.org/10.3390/met12091405 - 25 Aug 2022

Cited by 2 | Viewed by 3100

Abstract

High manganese austenitic steel has attracted increasing attention for its application in liquefied natural gas storage tank materials due to its excellent ductility and low cost. This paper presents an overview of the research progress of high manganese austenitic steel in recent years. As a structural material used at a low temperature environment, high manganese steel should not only have certain strength, but also good toughness to prevent brittle fracture at a low temperature. In this work, factors affecting mechanical properties of high manganese steel are discussed, possible reasons for the deterioration of low-temperature properties are analyzed, and the strengthening and toughening mechanisms of materials are elaborated, which may be beneficial to improve properties of high manganese austenitic steel. Full article

(This article belongs to the Special Issue Advances in Preparation Methods and Numerical Simulation of Composites: Formation and Properties)

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