Structural Evaluation and Mechanical Properties of Aluminum/Tungsten Carbide Composites Fabricated by Continual Annealin
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INTRODUCTION
ALUMINUM matrix composites (AMCs) are promising materials for the aerospace, military, and automotive industries because of their excellent properties, such as high wear resistance, superior elastic modulus, high strength to density ratio, and thermal stability.[1] In recent years, the specific properties of tungsten carbide (WC), including high melting point [3143 K (2870 °C)], extreme hardness (2242 VH), and high Young’s modulus of elasticity (550 GPa), led to its application as a new reinforcement component in various composite coatings.[2] Among these, Al/WCp composite coatings have gained much interest and can be manufactured through several methods, such as sputtering, high-energy milling, laser alloying techniques, and high-velocity oxygen fuel spraying. The resulting composite displays significantly improved resistance to wear of the matrix, because the WC particles disperse in the surface layer of the aluminum matrix.[3] Conventional manufacturing processes for composites (e.g., casting, powder metallurgy, etc.) are not suitable for producing bulk Al/WCp SAJJAD AMIRKHANLOU, Ph.D. Candidate, and MOSTAFA KETABCHI and NADER PARVIN, Associate Professors, are with the Department of Mining and Metallurgical Engineering, Amirkabir University of Technology, Tehran, Iran. Contact e-mail: ketabchi@ aut.ac.ir G.P.C. DRUMMEN, Ph.D., is with the Bionanoscience and Bio-Imaging Program, Bio&Nano-Solutions, D-40472, Du¨sseldorf, Germany. Manuscript submitted February 17, 2014. METALLURGICAL AND MATERIALS TRANSACTIONS B
composites, because of the significantly higher density and melting point of WCp [15,630 kg/m3, 3143 K (2870 °C)] compared with aluminum [2700 kg/m3, 930 K (657 °C)].[2,3] In recent years, accumulative roll bonding (ARB) and continual annealing and roll bonding (CAR) processes have increasingly been used as plastic deformation methods to produce AMCs. ARB was pioneered by Saito and Tsuji in Utsunomiya’s lab for the production of ultra-fine grained bulk aluminum.[4,5] Kitazono and Kuribayashi[6] used the ARB method to distribute and incorporate TiH2 particulate material into the aluminum matrix for the manufacturing of closed-cell aluminum foams. Subsequently, Jamaati,[7–16] Amirkhanlou,[17–23] Rezayat,[24–27] and Liu[28–30] and their respective co-workers have successfully produced different types of particulate AMCs by both ARB and CAR methodologies. Some of the AMCs produced by these newly established methods include Al/Al2O3,[7] Al/SiC,[22,31] Al/B4C,[32] Cu/Al2O3,[8] Al/ CNT,[33] Al/Cup,[34] and Al/Wp.[29] Recently, we developed an improved process named accumulative press bonding (APB) for manufacturing AMCs.[17] Both ARB and CAR processes are effectively used in the production of various AMCs, but can only be applied to sheet materials. The APB process can be applied to a thick billet of relatively large-scale dimensions, and was developed based on the principle of ARB, but can be readily installed in both a laboratory and industrial environment. In the APB process, the strain and strain rate
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