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Information to Users INFORMATION TO USERS The most advanced technology has been used to photograph and reproduce this manuscript from the microfilm master. UMI films the text directly from the original or copy submitted. Thus, some thesis and dissertation copies are in typewriter face, while others may be from any type of computer printer. The quality of this reproduction is dependent upon the quality of the copy submitted. Broken or indistinct print, colored or poor quality illustrations and photographs, print bleedthrough, substandard margins, and improper alignment can adversely affect reproduction. In the unlikely event that the author did not send UMI a complete manuscript and there are missing pages, these will be noted. Also, if unauthorized copyright material had to be removed, a note will indicate the deletion. Oversize materials (e.g., maps, drawings, charts) are reproduced by sectioning the original, beginning at the upper left-hand corner and continuing from left to right in equal sections with small overlaps. Each original is also photographed in one exposure and is included in reduced form at the back of the book. Photographs included in the original manuscript have been reproduced xerographically in this copy. Higher quality 6" x 9" black and white photographic prints are available for any photographs or illustrations appearing in this copy for an additional charge. Contact UMI directly to order. UMI University Microfilms International A Bell & Howell Information Company 300 North Zeeb Road. Ann Arbor. Ml 48106-1346 USA 313/761-4700 800/521-0600 Order Number 9111734 Joining of aluminum-based particulate-reinforced metal-matrix com posites Kolli, Sudhakar, Ph.D. The Ohio State University, 1990 Copyright ©1991 by Kolli, Sudhakar. All rights reserved. U M“I 300 N. Zeeb Rd Ann Arbor, MI 48106 NOTE TO USERS THE ORIGINAL DOCUMENT RECEIVED BY U.M.I. CONTAINED PAGES WITH BLACK MARKS. PAGES WERE FILMED AS RECEIVED. THIS REPRODUCTION IS THE BEST AVAILABLE COPY. 1 JOINING OF ALUMINUM BASED PARTICULATE-REINFORCED METAL- MATRIX COMPOSITES DISSERTATION Presented in partial fulfillment of the Requirements for the Degree of Doctor of Philosophy in the Graduate School of the Ohio State University S u d h ak ar Kolli, B.E., M.Tech., M.S. ********** The Ohio State University 1990 Dissertation Committee Approved by D. W. Dickinson W. A. Baeslack HI D. G. Howden Advisor Department Of Welding Engineering To my dear parents Dr. Kolli Pitchaiah and Mrs. Sakuntala Devi for their wonderful love and affection and for their wise guidance and counseling which gave unlimited opportunities to me. 11 ACKNOWLEDGEMENTS I wish to express my sincere appi'eciation for my advisor Dr. D. W. Dickinson for his encouragement, understanding, guidance and counseling throughout the course of my dissertation work. I also want to thank my co - advisor. Dr. W. A. Baeslack HI, for his encouragement, very helpful technical discussions and advice. I wish to record my appreciation for Dr. D. G. Howden for his suggestions. Dr. John Lippold of the Edison Welding Institute, Columbus gets my special praise for his suggestions, advice and encouragement. I want to thank Drs. J. E. Gould and Robert Rivett of the Edison Welding Institute for their useful suggestions in the beginning of the project. Financial support from the Edison Welding Institute, Columbus is gratefully acknowledged. I also express my appreciation for my sister Jyotsna whose encouragement was veiy inspiring for my work. Finally, I wish to place on record my special thanks for my wife Vijaya and children Sireesha and Venkat who have endured my very long working hours and without whose help and support this effort would not have been possible. Ill YEA October 30,1949 Bom in Vuyyur, Andhra Pradesh, India 1970 B. E. ( Mechanical Engineering ) Andhra University, India 1972 M.Tech ( Mechanical Engineering ), Indian Institute of Technology, Kharagpur, India 1972-1980 Senior Scientific Officer, Department of Defence Research and Development, Hyderabad and Bangalore, India 1980-1982 Deputy Manager ( Production/Fabrication ), Bharat Heavy Electricals Limited, India 1982-1985 Lecturer, Department Of Production Engineering, Kwaratech, Doiin, Nigeria 1989 M. S. ( Welding Engineering ), The Ohio State University, Columbus, Ohio 1986-January 1990 Graduate Research Associate, Department of Welding Engineering, The Ohio State University, Columbus, Ohio IV Presentation " Joining of Metal Matrix Composites ", presented to the Industrial Advisory Board of the Edison V/elding Institute, Columbus, Ohio, October 1988. Fields of Study Major Field : Welding Engineering Studies in 1. Physical Metallurgy 2. Welding Processes Table of Contents EâgÊ Acknowledgements iii Vita iv List of tables viii List of Figures ix I Introduction 1 II Background 8 2.1.0 Processing of metal matrix composites 8 2.1.1 Reinforcement materials 8 2.1.2 Matrix materials 9 2.1.3 Solid state processing 10 2.1.4 Liquid metal infiltration 11 2.1.5 Other techniques 13 2.2.0 Physical metallurgy and mechanical properties 13 2.2.1 Physical metallurgy 14 2.2.2 Mechanical properties 20 2.3.0 Joining 24 2.3.1 Arc welding 26 2.3.2 Laser beam welding 27 2.3.3 Resistance welding 28 2.3.4 Soldering and brazing 29 2.3.5 Capacitor discharge welding 31 2.3.6 Inertia welding 32 2.3.7 Diffusion bonding 32 2.3.8 Transient liquid phase diffusion bonding 47 in Objectives 67 IV Materials and Experimental Procedures 69 4.1.0 Materials 69 vi 4.2.0 Composite materials 69 4.3.0 Interlayer materials 73 4.4.0 Experimental procedures 76 4.4.1 The Gleeble 1500 system 76 4.4.2 Fixture design 79 4.4.3 Specimen design 84 4.4.4 Base metal characterization ( thermo-mechanical simulation ) 88 4.4.5 Differential scanning calorimetry 94 4.4.6 Liquid phase diffusion bonding 94 4.4.7 Metallography procedures 97 4.4.8 Microstructui^ characterization 98 4.4.9 Evaluation of bond properties 99 V Results 100 5.1.0 Base metal heat treatment 100 5.2.0 Differential scanning calorimetry 102 5.3.0 Thermal simulation studies 110 5.3.1 Thermal simulation in furnace 110 5.3.2 Thermo - mechanical simulation with Gleeble 1500 113 ( Microhardness and optical microstructure evaluation ) 5.3.3 Thermo - mechanical simulation with the Gleeble 113 ( Analysis of strength and fracture behavior ) 5.4.0 Liquid phase diffusion bonding 126 5.4.1 Al-Si-Mg interlayer 126 5.4.2 Silver interlayer 135 5.4.3 Liquid phase bonding with the silver interlayer 135 5.4.4 Liquid phase diffusion bonding of the composite material 136 5.4.5 Macro & Microstructural characterization 139 5.4.6 Confirmation of the diffusional processes 160 5.4.7 Occurrence of the eutectic liquid phase 166 5.4.8 Mechanical properties 170 5.4.9 Fractography 181 5.5.0 Summary of bond data 187 5.6.0 Results from additional experimentation 196 VI Discussion 207 6.1.0 Base metal characterestics 207 Vll 6.2.0 Thermal and thermo - mechanical simulation 210 6.3.0 Summary of thermal and thermO - mechanical simulation 221 6.4.0 Liquid phase diffusion bonding 228 6.4.1 Time for isothermal solidification of the silver interlayer 228 6.4.2 Liquid phase diffusion bonding of the composite material widi the silver interlayer 231 6.5.0 Summary of the bonding trials 244 Vn Conclusions 251 List of references 254 Vlll List of Tables Table.No. Title Page 1 Typical mechanical properties of SiC particulate/ whisker 21 reinforced aluminum alloy composites. 2 Results of Gleeble thermo - mechanical simulation 114 ( Microhardness and optical microstructure analysis ). 3. Thermo-mechanical simulation results for the base metal on the 116 Gleeble ( Results of mechanical testing ) 4 Mechanical testing results of the bonded joints. 180 5 Summary of liquid phase diffusion bonds of 25 Vol % SiCp/ 197 6061A1MMC with the silver interlayer 6 Results of Additional liquid phase diffusion bonds of 25 Vol % 198 SiCp/ 6061 A1 MMC with a 0.001” silver interlayer IX ^SWfBgWrçs Fig. No. TlÜÊ Page 1. A continuous layer of polycrystalline oxide ( MgO ), 3nm thick, 17 along the SiC whisker - 6061 A1 matrix interface. 2. Variation of threshold deformation with temperature for aluminum 35 ( Ref. 68 ). 3. Typical Surface roughness and contaminants on a metallic surface 38 ( Ref. 71 ). 4. Illustration of the TLP bonding process ( Ref. 94 ). 50 5. Optical microstructure of 25 Vol% SiCp/6061 A1 MMC at low 71 magnification ( Note random distribution and sizes of the particulate material and lack of delineation of grain boundaries ). 6. Microstructure of a heat treated 25 Vol% SiCp/6061 A1 MMC, 72 (a) at 4000 x shows particulates in the extrusion direction and Ô)) at 30000 X shows a close view of two particulates. 7. 20 Vol% SiCp/6061 A1 MMC ( received as 0.100 " thick sheet ) 74 at a high magnification, Keller’s Etch ( Note particulate morphology and no noticeable debonding at the particulate-matrix interface ). 8. Al-Si-Mg temaiy equilibrium phase diagram, liquidus surface. 75 9. Ag-Al equilibrium phase diagram ( Note the binary eutectic at 77 567 0Cand28Wt% Al). 10. (a) An overview of the Gleeble 1500 system showing the 80 control cabinet and the control computer, (b) the moving and fixed jaws in the vacuum chamber. 11. A view of the vacuum chamber showing the arrangement 81 of the specimen in the stainless steel hot jaws. 12. An arrangement of the specimen held in the stainless steel 83 fixtures with the fixture themselves held in the stainless steel hot jaws. 13. (a ) Direct hotjaw specimen with metric threads (Design I) 85 and ( b ) hot jaw specimen with a reduced length of smaller diameter ( Design n ). 14. ( a ) Specimen Design in , used with the stainless steel 86 fixture ; and ( b ) specimen Design IV, used with the stainless steel fixture.
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