Effect of Lithium Addition in 8090 Aluminium Alloy on Strengthening Mechanisms and Wear Behaviour of New Generation Aerospace A

technical Paper

Effect of Lithium Addition in 8090 Aluminium Alloy on Strengthening Mechanisms and Wear Behaviour of New Generation Aerospace Alumina Nanoparticle Metal Matrix Composites

that molten aluminium does not readily wet alumina. Consequently, A Chennakesava Reddy the composite consists of nonuniform Professor, Department of microstructure, which attributes the Mechanical Engineering, reduction in strength, stiffness and JNT University, Hyderabad wear resistance of the composite[5, 6]. Telangana, India Several aluminium alloys such as E-mail: [email protected] 1xxx[7], 2xxx[8], 3xxx[9], 6xxx[10,11] and 7xxx[12] series of Al-alloys have been reinforced with alumina nanoparticles to estimate the strength, stiffness and wear resistance of the respective composites. Surface coating of the strengthening, precipitation Abstract reinforcement was adopted to improve strengthening and quench ery recently the use interfacial wettability[13, 14]. But the strengthening. of 8090 Al alloy has coating methods are applied on fibres tremendously increased Keywords and whiskers. Hard ceramic particles in the automotive and 8090 Al alloy, Lithium, Alumina, (e.g. SiO2, Al2O3, B4C, Si3N4, BN) and soft aerospace industries. This Strengthening mechanism, Wear rate, lubricants (e.g. graphite) have been work was focused to understand the V Coefficient of friction. used to enhance the wear resistance effect of lithium content in 8090 Al of the Al-alloy matrix[15-19]. The 8xxx alloy on the enhancement of tensile, Introduction series of Al-alloy has not been elastic modulus and wear resistance Nanoparticles reinforced metal combined with alumina nanoparticles of alumina/8090 Al alloy composites matrix composites are widely used till date. Lithium (Li) in alloy 8090 cast by stir casting route. The for aerospace and automotive delivers exceptionally high strength strength, stiffness and wear resistance applications [1]. If the composite is and modulus, and so this alloy is were improved due to increase in made of alumina nanoparticles as the used for aerospace applications[20]. wettability. The other mechanisms, reinforcement and aluminium as the Addition of lithium to aluminium which could boost properties of matrix, the alumina nanoparticles are assists in reducing density and alumina/8090 Al alloy composites, inclined to form clusters[2-4].The main increase in stiffness. High strength is were grain boundary strengthening, difficulty encountered in forming achieved through good load transfer sub-grain strengthening, nanoparticle alumina-aluminium composites is from the matrix to the particulates

INDIAN FOUNDRY JOURNAL | Vol 63, Issue 9, Sept 2017 23 technical Paper and it requires strong bonding at the of composite samples. Wear surfaces and particulate. As shown in Fig 3, interface. of the test samples were analysed the tensile strength increases with

The wetting of the alumina (Al2O3) with a scanning electron microscope increase in content of Li in 8090 Al nanoparticles by molten aluminium (SEM) using S-3000N Toshiba SEM. A alloy which was used to fabricate

(Al) alloy is critical to the formation schematic of pin-on-disc tribometer is Al2O3/8090 Al alloy composites. of useful metal matrix composites. shown in Fig 2. The Rule of Mixtures (ROM) is used To secure this, lithium alloying of to predict various properties of a aluminium has been anticipated Results and Discussion to increase the wetting of the alloy Table-1: Chemical composition of 8090 Al alloy on the alumina nanoparticles. Al Cr Cu Fe Li Mg Mn Si Ti Zn Zr The present investigation aims 94.35 % 0.10% 1.2% 0.25% 2.2 -3.0% 0.90% 0.10% 0.20% 0.10% 0.22% 0.08% at fabrication of alumina/8090 Al alloy composites and to assess the enhancement of strength, stiffness and wear resistance for increasing the R15 2 wettability of alumina nanoparticles by molten 8090 Al alloy. 6 10 Materials and Methods The composite, with 30 vol% alumina 10 50 content, was produced by the stir casting and low-pressure die-casting Fig 1: Shape and dimensions of tensile specimen (mm) process. The matrix was a 8090 aluminium alloy and the chemical composite material made composition with varying content of up of continuous and Lithium (Li) is given in Table-1. The unidirectional fibres[21]. reinforcement phases were alumina The ROM is not suitable nanoparticles with average size of 100 to predict the strength nm.The cast composites were given T3 of discontinuous fibre or heat treatment. The flat-rectangular particulate metal matrix tensile specimen used in the work composites. This is because, is shown in Fig 1. Tensile tests were in discontinuous metal conducted on a universal testing matrix composites, the machine with across load speed of 0.5 ends of each short fibre mm/min at room temperature (ASTM Fig 2: Schematic of pin-on-disc tribometer transfer lesser load than D3039. A strain gauge was used to the remainder of the fibre. Hence, determine elongation. The heat- The quality of adhesion at the other models are required to predict treated samples were also machined strength and stiffness of particulate interface is essential for the behaviour to get cylindrical specimens of 6 metal matrix composites. With some of particulate reinforced composites. mm diameter and 30 mm length for adhesion between the particle the wear tests. A pin-on-disc type Theories for Composite and the matrix, the strength of the friction and wear monitor (ASTM Strength composite is given by Lu et al [22]: G99) was employed to evaluate σ = σ (1-1.07v 2/3)...... (1) the friction and wear behaviour The adhesive strength at the c m p interface determines the load transfer This expression is inadequate as of Al2O3/8090 Al alloy composites against hardened ground steel (En32) from the matrix to the particulate. the experimental strength of the disc. Knoop microhardness was Different approaches were applied to composite is much higher than that conducted before and after wear tests evaluate adhesion between matrix obtained in Eq (1). This expression

24 INDIAN FOUNDRY JOURNAL | Vol 63, Issue 9, Sept 2017 technical Paper imparts low strength to the composite, were predicted for the range of B even though, the tensile strength of varying from 3.0 to 3.5. For B =3.4, the the matrix is high owing to insufficient composite strength was nearly equal adhesive mechanism between where B is an empirical constant, to the experimental value. nanoparticle and matrix in Eq (1). which depends on the surface area Hojo et al[25] found that the strength An empirical linear relationship of particles, particle density and of the composite decreased with increasing mean particle size dp according to the relation: 500 -1/2 Lu Pukanszky σc= σm+k(vp)dp ...... (4) Landon Hojo AC Reddy Exp where kp(vp) is a constant being a Matrix function of the particle loading; 450 kp is relative change in strength of matrix due to the presence of the

particulate. The values of kp are 0.37, 400 0.48 and 0.56, respectively, for the Li concentrations of 2.2, 2.6 and 3.0 vol% in aluminium as obtained from tensile Tensile strength, MPa strength, Tensile 350 strength plots. Even though, the results coincide with the test results, this model does not consider the voids/porosity formation during stir 300 casting of the composites. 2 2.2 2.4 2.6 2.8 3 3.2 A new criterion[26,27] has been % Lithium formulated considering adhesion,

Fig 3: Tensile strength of Al2O3/8090 Al alloy composites as a function of lithium concentration formation of precipitates, particle size, agglomeration, voids/porosity, between composite strength and interfacial bonding energy. For poor obstacles to the dislocation, and the particle size was anticipated by interfacial bonding, the particles do interfacial reaction of the particle/ Landon et al [23], which is given by: not carry any load, so B = 0. As shown matrix. The formula for the strength of in Fig 4, the composites strengths composite is given below: σc= σm (1-vp )-k(vp)dp ...... (2) where k(v ) is the slope of the tensile p 500 strength against the mean particle B=3.0 B=3.5 size and is a function of particle B=3.4 B=3.2 volume fraction v . As seen from Fig 3, Matrix Exp p B=3.1 the strength values were unchanged 450 for the change in the composition of 8090 Al alloy. This expression does not reflect the alloying effect of lithium in 400 Fig 4: Effect aluminium. Equation (2) is applicable of empirical to poorly bonded micro-particles constant on but cannot be applied to strong MPa strength, Tensile strength of 350 interfacial adhesion, especially for Al2O3/8090 Al alloy composites nanocomposites. for expression For very strong particle-matrix proposed by Pukanszky et al interfacial bonding, Pukanszky et 300 al[24] gave an empirical relationship as 2 2.2 2.4 2.6 2.8 3 3.2 mentioned below: % Lithium

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composites are shown in Fig 5. The orientation, it requires more energy strengthening mechanisms include: for a dislocation to change directions grain boundary strengthening and move into the adjacent grain. (Hall-Petch strengthening), sub- Arsenault and Fisher[28] proposed the k=E m /E m m m p p grain strengthening, nanoparticle enhanced strength observed in Al/ where vv and vp are the volume strengthening, precipitation SiC composites could be accounted fractions of voids and the strengthening and quench for by a high dislocation density nanoparticle in the composite, mm strengthening. in the aluminium matrix. This high and mp are the Poisson’s ratios of the A grain boundary can obstruct the dislocation density was considered matrix and nanoparticles and dp is the dislocation motion in two ways: (1) to be as a result of large difference mean diameter of the nanoparticle. by forcing the dislocation to change (10:1) between aluminium and SiC. The results obtained from the its direction of motion (Fig 6a) and (2) Hall-Petch strengthening is limited model considering voids in the discontinuity of slip plane because by the size of dislocations. Once the [26, 27] composites were nearly equal to of disorder (Fig 6b). Effectiveness grain size reaches about 10 nm, grain the experimental values. of grain boundary depends on boundaries start to slide (Fig 7). Also, The models proposed by Lu et its characteristic misalignment, the T3 heat treatment changes the [22] [23] al and Landon et al did not represented by an angle. This angle recrystallisation process leading to take into account microstructural is higher than 5 degrees in 8090 grain size modification. Decreasing changes in the matrix due to Al alloy (matrix) in Al2O3/8090 Al grain size decreases the number loading of nanoparticles. The alloy composites. Since, the lattice of dislocations at the boundary, microstructures of Al2O3/8090 Al alloy structure of adjacent grains differs in increasing the amount of applied

Fig 5: Microstructures of Al2O3/8090 Al alloy composites

(a) (b) Fig 6: Two ways to obstruct dislocations

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in the matrix, nanoparticle shape, volume fraction, average particle Maximum attainable yield strength through grain diameter and mean interspacing boundary strengthening of particles. The interspacing of nanoparticles is given by:

Dislocation slip Grain boundary sliding Smaller the nanoparticles, dislocations can cut through them at lower stresses. On the other hand, larger the particles, the dislocations are distributed at wider distances. The -1/2 d = 10 nm Grain size, d clustering allows the nanoparticles Fig 7: Hall-Petch strengthening to coalesce into larger and fewer particles. The interspacing is increased causing a decrease in the tensile stress necessary to move a dislocation during the solidification process. The strength (Fig 9). As the volume across a grain boundary[29]. The higher degree of nanoparticle strengthening fraction of alumina increased in the applied stress needed to move depends on nanoparticle distribution 8090 Al alloy (matrix), the clustering the dislocation, the higher the tensile strength. Sub-grain strengthening is owing to sub-grain within the grain that is slightly disoriented from other parts of the grain. When the 35 dislocations accumulate progressively 30 at the grain boundary, the stress concentration takes place at the tip 25 of the leading dislocation resulting in 20 the formation of sub-grain boundary in the 8090 Al alloy as shown in Fig 8. 15

In the nanoparticulate metal matrix % Transfer Load 10 composites, the hard nanoparticles Fig 9: Cluster formation of are loaded within the matrix. The 5 nanoparticles in reinforced nanoparticles would have Al2O3/8090 Al alloy composites 0 very little solubility in the matrix[30]. 2 15 20 25 30 Because of little solubility, the Vol. % Alumina nanoparticles resist growth of grains tendency increased leading to the formation of alumina nanoparticle clusters. The interspacing was smaller with smaller clusters than that with bigger clusters. Hence, the reduction load transfer from the matrix to the alumina nanoparticles. The other (a) (b) reason for nanoparticle-strengthened composites, containing 10-100 nm Fig 8: Formation of sub-grains in 8090 Al alloy particles, the matrix bears the major

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Al4Li, Al2Li3, AlLi and Al53Mg14Li33. From the Al-Li-Cu ternary phase diagram (Fig 12), the anticipated strengthening

precipitates could be Al4Li3, Al2Li3,

AlLi, Al2CuLi, Al15Cu3Li2. Figure 13(a) reveals the formation of strengthening precipitates in 8090 Al alloy. The δ and

T2 phases were present in the three examined samples. θ phases were detected in 8090 Al alloy (Fig 13b) consisting of 0.26% Li. Peaks associated

with θ, S’, Ω and T1 phases were found in 8090 Al alloy consisting of 0.30% Fig 10: Al-Li phase diagram Li. The precipitation of these phases additionally reduces the contribution portion of the applied load and the small particles hinder dislocation motion, limiting plastic deformation. As shown in Al-Li phase diagram (Fig 10), the maximum solubility of Lithium in Al is 4%. The strengthening precipitates could be α, β (AlLi), γ

(Al2Li3)and Al4Li9 phases. As 8090 Al alloy consists of considerable amount of Mg and Cu, there is a possibility of Al-Li-Mg and Al-Li-Cu ternary phase Fig 12: Al-Li-Cu diagrams. From the Al-Li-Mg ternary phase diagram[32] phase diagram (Fig 11), the expected strengthening precipitates could be

Precipitates

Fig 11: Al-Li-Mg phase diagram[32] Fig 13(a): Formation of precipitates in 8090 Al alloy (matrix)

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This equation did not consider the formation of voids during the fabrication of composites by stir casting technique. Ishai and Cohen[37] assumed that the two constituents are in a state of macroscopically homogeneous stress and adhesive bonding is perfect at the interface between particulate and matrix. When a uniform stress is applied on the boundary, the elastic modulus of the particulate composite is given by

Fig 13(b): EDS analysis of 8090 Al alloys used for Matrix of Al2O3/8090 Al alloy composites of δ phase to strengthening. The is nanoparticle volume fraction. coherent strain fields around Einstein’s equation for elastic the strengthening precipitate modulus of particulate composites δ=Ep ⁄ Em cause repulsive forces against the is valid only at low concentrations of dislocation[31]. When the precipitate reinforcement and assumes perfect Equation (10) and Eq. (11) are for is coherent and coplanar with the adhesion between reinforcement upper-bound and lower-bound matrix, dislocations in the matrix can and matrix and uniform dispersion solutions. The Rule of Mixtures (ROM) readily traverse through the precipitate of reinforced nanoparticles[34]. In the can also be used to predict the elastic particles, and if the precipitate and present work, the volume fraction modulus of particulate composites. matrix have different structures, then of Al2O3 nanoparticles was 30 vol%. Upper- bound elastic modulus, the dislocations which traverse the Hence, the estimated elastic modulus Ec=vm Em+vpEp ...... (12) precipitate create stacking faults in the was not correct representative of precipitate. This increase in hardness Al O /8090 Al alloy composites (Fig Lower-bound elastic modulus, 2 3 1 and strength can be attributed to 14a). Another equation to estimate E = ...... (13) c precipitate strengthening. the stiffness of a composite that vm / Em + vp / Ep contains spherical particles in a matrix The ROM is valid for continuous Theories for Composite is due to Kerner[35] and it is given Stiffness fibre-reinforced composites; while below: the reinforcement was nanoparticles The stiffness of a particulate metal in this work. Hence, the results could matrix composite is normally not reflect the experimental data. The determined by the elastic modulus of equations[26,27] to find elastic modulus its components (particle and matrix). This equation is valid for microparticles of composites including perfect Many empirical or semi-empirical of reinforcement. The present work boding, interphase between the equations have been proposed to dealt with alumina nanoparticles. particle and matrix and the effect of forecast the modulus of particulate Counto[36] proposed a simple model for voids/porosity are given below: metal matrix composites. Einstein’s a two-phase particulate composite by equation[33] predicts stiffness of assuming perfect bonding between particulate composites based on the filler and matrix. The composite rigid particle assumption as follows: modulus is given by

where Ec and Em are elastic modulus δ=E ⁄E of composite and matrix, and Vp p m

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The Eq. (14) and Eq. (15) represent, Al alloy (matrix). Einstein, Kerner which is dissipated at the material the upper limit and lower limit of models did not consider the adhesive contact surface. Adhesion and elastic modulus respectively. The bonding between the nanoparticle deformation are measured the source predicted values using Eq. (14) are and the matrix. Counto model gave of frictional forces[38].With increase of matching with the experimental data intermediate elastic modulus data on lithium in 8090 Al alloy, the coefficient as shown in Fig 14a. account of poor interface bonding. of friction was increased due to Ishai and Cohen model number of craters formed on the

gave higher value for worn surfaces of Al2O3/8090 Al alloy the lower limit of elastic composites. The tendency of crater modulus than that formation increased with an increase obtained by AC Reddy’s in the content of lithium. model (Fig 14b). The lower limit of elastic 0.064 modulus obtained by (a) the rule of mixtures 0.062 (ROM) is intermediate 0.060 to that computed by AC 0.058 Reddy model and Ishai 0.056 0.054 and Cohen model. Every mg/m rate, Water 1% by weight of lithium 0.052 0.050 added to aluminium 0.2 0.25 0.3 reduces the density of Vol % Li the resulting alloy by

3% and increases the 0.6000 stiffness by 5%. (b) 0.5500 Wear Behaviour Figure 15a shows the 0.5000 dry sliding wear results 0.4500 obtained by conducting of frictionCoefficient pin-on-disc tribometer. 0.4000 The wear test was 0.2 0.22 0.24 0.26 0.28 0.3 Vol % Li conducted at a sliding velocity of 1.5 m/s, normal force of 30 N Fig 15: Wear properties of Al2O3/8090 Al alloy composites as a function of lithium: (a) wear and sliding distance rate and (b) coefficient of friction of 1000 m. Owing to the enhancement of For all the cases, the wear surfaces wettability by lithium in were nearly alike as shown in Fig 16. 8090 Al alloy with the Development of craters were detected

Al2O3 nanoparticles, the on the worn surfaces, demonstrating As seen from Fig 14a, Ishai and wear rate decreased with an increase the deformation and delamination Cohen model and AC Reddy’s model in adhesive bonding between Al2O3 of the surface material. In the early could predict nearly equal elastic nanoparticles and 8090 Al matrix stage of wear, nanoparticles are modulus (upper limit) of Al2O3/8090 alloy. The influence of lithium content bred from the contact surfaces due Al alloy composites. These models in 8090 on the coefficient of friction to the rubbing possessions of the [39-40] consider perfect bonding between of Al2O3/8090 Al alloy is shown in Fig asperities . Some refined particles alumina nanoparticles and 8090 15b. Friction is the value of energy are dislodged from the composites

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Al2CuLi and Al15Cu3Li2. Owing to the enhancement of wettability by lithium in 8090 Al alloy with

the Al2O3 nanoparticles, the wear rate decreased with an increase in

adhesive bonding between Al2O3 nanoparticles and 8090 Al matrix alloy. A narrow increase in hardness Fig 16: Worn surfaces of AAl2O3/8090 Al alloy composites was observed after wear test due to work hardening of the composites. whereas some nanoparticle Conclusions Acknowledgement clusters stack at spaces. Since, the Every 1% by weight of lithium added The authors thanks University Grants nanoparticles have been embedded to aluminium reduces the density in very fine-sized debris, the 8090 Commission (UGC), New Delhi for of the resulting alloy by 3% and sponsoring this project. Al alloy components especially the increases the stiffness by 5%. Its use is aluminium and magnesium can be aimed at applications where damage References oxidised quickly. Due to the good tolerance and the lowest possible 1. A C Reddy, B Kotiveerchari, wettability between 8090 Al alloy density are critical.The higher the P Rami Reddy, Saving of Thermal and Al O , the Al-Al O interfaces are 2 3 2 3 applied stress needed to move the Energy in Air-Gap Insulated Pistons not the preferential places for the dislocation, the higher is the tensile Using Different Composite Materials initiation and growth of subsurface strength. As the volume fraction of for Crowns, International Journal of cracks. The hardness values of the alumina increased in 8090 Al alloy Scientific & Engineering Research, composites were unchanged with (matrix), the clustering tendency was Vol 6, No 3, 2015, p 71-74. increase of lithium in 8090 Al alloy increased leading to the formation 2. A C Reddy, Cause and (Fig 17). A narrow increase in hardness of alumina nanoparticle clusters. The Catastrophe of Strengthening was observed after wear test due to strengthening precipitates could be Mechanisms in 6061/Al O work hardening of the composites. 2 3 α, β (AlLi), γ (Al2Li3), Al4Li9, Al53Mg14Li33, Composites Prepared by Stir Casting Process and Validation Using FEA, International Journal of Science and 750 Research, Vol 4, No 2, 2015, p 1272- 1281. 3. A C Reddy, Cause and Catastrophe of Strengthening 500 Mechanisms in 6063/Al2O3 Composites Prepared by Stir Casting Process: Validation through FEA, International Journal of Scientific & Harrdness, KHV Harrdness, 250 Engineering Research, Vol 6, No 3, Before wear test 2015, p 75-83. After wear test 4. A C Reddy, Cause and Catastrophe of Strengthening Mechanisms in 7020/

0 Al2O3 Composites Prepared by Stir 0 10 20 30 40 Casting Process and Validation through Volume fraction, %Vp FEA, International Journal of Advanced Research, Vol 3, No 3, 2015, p 603-614. 5. A C Reddy, Essa Zitoun, Matrix Fig 17: Function of Knoop hardness with volume fraction of CB nanoparticles Al-alloys for Alumina Particle Reinforced

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