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International Journal of Advanced Chemical Science and Applications (IJACSA)
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ISSN (Print):2347-7601, ISSN (Online): 2347-761X, Volume -5, Issue -2, 2017
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Processing of Carbon fiber reinforced Aluminium (7075) metal matrix
composite
1Madhuri Deshpande,
2Rahul Waikar,
3Ramesh Gondil,
4S.V.S Narayan Murty,
5T.S.Mahata
1,2,3 Production Engineering Dept, Vishwakarma Institute of Technology, Pune, India
4Material Characterization Division, Vikram Sarabhai Space Centre, Thiruvanantapuram, India
5Powder Metallurgy Division, Bhabha Atomic Research Centre, Vashi Complex, India
Email: [email protected]; [email protected]; [email protected];
[email protected]; [email protected]
[Received:15th Jun.2017; Accepted:30th Jun.2017]
Abstract : Carbon fiber reinforced Al metal matrix
composites are potential materials for aerospace and
electronic industries. Various manufacturing methods that
would give uniform distribution of carbon fibers are
adopted to manufacture this composite. In the present
work, Powder Metallurgy route was used to make
composite using uncoated (UnCf) and coated milled pitch
based carbon fibers (NiCf) and AA7075 as matrix with
different volume contents of carbon fibers. Uncoated and
Ni coated carbon fibers were mixed with AA7075
aluminium alloy powder and subsequently hot pressed. Hot
pressing was carried out using single action and double
action vacuum assisted hot press and its effect on
densification was studied. Effect of contents of uncoated
carbon fibers and coated carbon fibers on hardness was
studied. Optical and Scanning electron microscopic
examination was carried out.
The fabricated composites exhibited uniform distribution
of carbon fibers and also good bonding between fibers and
matrix. Results of X-ray diffraction (XRD) revealed that
Al4C3 formation was absent. In case of uncoated carbon
fibers, as the amount of carbon fiber content increased,
hardness decreased. However, with coated carbon fibers,
increase in hardness values was observed as amount of
coated fibers increased.
Keywords—metal matrix composite, carbon fiber, hot
pressing
I. INTRODUCTION
Metal-Matrix composites (MMCs) consist of a metal or
alloy as the continuous matrix and a reinforcement
which may be particulate, short fiber or continuous fiber.
In light MMCs, important metal matrices are Aluminium
alloys, Titanium alloys, Copper, Magnesium alloys etc.
In case of light weight metal matrix composite,
most of the researche works done so far, revolves
around Aluminium MMCs. Aluminium alloy metal
matrix (AMCs) composites find applications mainly
in automobile, defense, transport and aerospace sectors.
These composites are also used as thermal
management materials in electronic industries. In
this category, matrices that are tried mainly are pure
Aluminium, and various Al-Si alloys [1,2], Al6061 [3, 4,
5], Al2024 [6], Al7075 [7-8] etc. 7XXX series of Al
alloys are widely used in aerospace industry, in transport
applications including marine and auto due to their high
strength/ductility ratio [9] yet it is not a very commonly
used matrix for AMCs.
The most commonly used reinforcement materials
for metal matrix composite are Alumina, B4C, and SiC
etc. Carbon fibers are also used as reinforcing
material in milled, chopped or in continuous form,
in metallic, ceramic or in polymer matrix also, due to its
high specific strength and specific modulus, light
weight, low coefficient of thermal expansion, high
thermal and electrical conductivities [5].
Polyacrilonitrile (PAN) based carbon fibers improve
mechanical properties [5, 2, 10, 11] while Pitch base
fibers improve thermal properties [12,
13]. Depending upon requirement, suitable type of
carbon fibers is used as reinforcement. In the current
research, attempts are made towards making AMC with
AA7075 as matrix and milled pitch based carbon fibers
as reinforcing material.
Carbon fibers exhibit high reactivity with Al and its
alloys forming undesirable interfacial reaction product
as Al4C3 which limits the development of such kind of
composites [14-16, 3, 12]. Carbon fibers and Aluminium
have poor wetability [17]. So, surface modification of
carbon fibers is essential to improve the wetability
and to prevent formation of interfacial reactions.
Metallic coatings improve the wetting behavior of
carbon fibers with aluminium leading to improved
uniform distribution of carbon fibers in the matrix
with reduced interfacial reactions [2,14]. Wetability can
also be improved by addition of Mg to the matrix
material[18]. Among all the aerospace and automotive
materials, Al and its alloys have been very popular
matrices for development of high strength, ultra low
weight and superior tribological properties with metallic
coated carbon fibers as reinforcement [19, 20].
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Manufacturing methods of MMC can be broadly divided
into two categories: One is Liquid Metallurgy and
second is Solid state process.
Many researchers have adopted Liquid Metallurgy route
like Stir casting [5], Liquid infiltration [20] and Squeeze
casting [21] to process the Al based carbon fiber
reinforced composites due to its ease and simplicity of
processing. [2, 4, 5, 22].
Although Liquid Metallurgy is an easier and simpler
method of composite manufacturing. The main problems
encountered in this technique of manufacturing the
Aluminium/Carbon fiber Composites are
1) Poor wettability between the reinforcement
and matrix material.
2) Formation of interfacial reaction product (Al4C3)
which is detrimental to mechanical as well as
thermal properties.
3) Volume of reinforcement is limited in the matrix.
4) Surface modification of the reinforcement
material is essential to avoid the interfacial reactions.
Due to the above mentioned problems encountered in
Liquid Metallurgy route, Aluminium alloy (AA7075)
matrix composites with pitch based carbon fiber
reinforcement were prepared by Powder Metallurgy
route.
Powder Metallurgy is very widely used by the
researchers [13, 22, 23, 24] for the manufacturing of
fiber/particulate reinforced composites. Major
advantages of this method are ability to process wide
variety of matrix metals, control of fiber orientation and
high volume fraction of reinforcement. As PM processes
are carried out in solid state, this minimizes the reactions
between reinforcement and matrix which reduces the
risk of brittle interfacial reactions.
II. EXPERIMENTAL
A. Raw Materials
Aluminium alloy (AA7075) powder having spherical
shape with average particle size of 35m was selected as
matrix material which was supplied by AMPAL, INC
(Table1 shows chemical composition of AA7075) and
the reinforcement material used was pitch based milled
uncoated carbon fibers (10µm diameter and 200 µm
length) supplied by MITSUBISHI PLASTICS, INC and
the same fibers were subjected to electroless nickel
coating as described in our earlier works after
pretreatment [25]. Fig No.1 shows the surface
morphology of the uncoated carbon fiber (a), AA7075
powder (b) and uniformly Ni coated carbon fiber (c & d)
respectively . Fig.No.2 shows the EDS analysis of the Ni
coated carbon fiber.
Fig. No.1a SEM images of as received Pitch based
carbon fiber
Fig. No. 1b SEM image of as received AA7075 alloy
powder
Fig. No. 1c SEM image of nickel coated carbon fiber
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Fig. No. 1d SEM image of nickel coated carbon fiber
Fig. No. 2 EDS Analysis of electroless nickel plated
Carbon fiber
Table No.1 Chemical composition of AA7075 powder
Element Cu Mg Zn Si Fe Ti Mn Cr Al
Wt% 1.2-2 2.1-2.9 5.1-6.1 0.4 0.5 0.2 0.3 0.2-0.3 Rest
B. Fabrication of the composite
Aluminium alloy (7075) matrix composites with
pitch based uncoated carbon fiber and Ni coated carbon
fiber reinforcement were prepared by powder metallurgy
route. Fabrication of the composites was carried out in
two major steps.
1. Mixing: To obtain homogeneous powder
mixtures containing 5 to 50 volume % of uncoated
carbon fibers and AA7075 powder, laboratory mixer
was used. Mixtures were also formed by using Nickel
coated carbon fibers up to 30vol%.
The mixer was rotated at standard rpm of 20, while the
total mixing time was set to 45±5 minutes.
2. Compaction: The hot pressing of the
composites was carried out using single action and
double actionpress. The homogenous mixture of
AA7075 powder and carbon fibers was filled in the
high density graphite die and consolidated by hot
pressing. At the bottom and top surface of the powder
mixture, circular graphite sheet of 0.5mm thick was
placed in order to prevent the adhesion between punch
and hot pressed specimen.
After that the die-punch-powder assembly was placed
into the vacuum chamber. A thermocouple was then
attached to the assembly to read out the temperature of
the system as well as that of graphite die. Once the
required temperature, vacuum and pressure were
reached (listed in Table 2), pressing of powder
mixture was started, which was maintained during the
remainder of the process. After completion of hot
pressing, the whole assembly was cooled down to room
temperature. Then specimen was removed from the die
and the graphite sheets were removed from the hot
pressed specimen. The entire hot pressing process for
each composition took around 3 hours.
Parameters used for single action and double action
pressing are summarized in Table 2
Table 2 Hot Pressing Parameters
Parameters Single action press Double action press
Pressure 35Mpa 50Mpa
Temperature 560±20°C 580±10°C
Vacuum 0.25bar 1.8×10-3
bar
Pressing
Time
30 Min 1.5 Hrs
Heating rate 14°C/min 8°C/min
Cooling rate 10°C/min. 12°C/min.
C. Characterization of composites
After hot pressing, specimens were cut into two pieces
along the longitudinal and perpendicular direction of hot
pressing, ground and polished for metallographic
studies. Microstructures were examined using optical
microscope and Zeiss scanning electron microscope
(SEM) equipped with EDS facility.
The densities of the composites were determined using
Archimedes principle. Theoretical density of the
composites was calculated using rule of mixtures
(ROM). The mechanical property of the composites was
evaluated by hardness test. The samples were polished
and made flat and smooth, for Brinell hardness
measurements. A minimum of 6 readings were taken
for each specimen. Brinell hardness of the composites
was measured using 31.25 kg load and 2.5mm diameter
ball indentor.
III. RESULTS AND DISCUSSION
A. Density of the composites
Theoretical and measured density of the composites
decreases as uncoated carbon fiber content increases
(listed in Table 3) because of the low density of carbon
fiber compared to matrix alloy. But, as the Ni coated
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ISSN (Print):2347-7601, ISSN (Online): 2347-761X, Volume -5, Issue -2, 2017
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carbon fiber content increases, the theoretical and
measured density of composite (listed in Table No.4)
increases because of the high density of nickel. A
reduction in the density of the composites with uncoated
carbon fiber has been observed as reported in Table 3.
A maximum of 11% reduction in density is observed for
50Vol% Cf Composite compared to cast
AA7075. Fig.No.3 shows the comparison of
densification of composites fabricated using single
action and double action pressing.
Table 3 Density values of Al/Cf Composites
Content of
carbon fibres
Density
by ROM
Density
obtained
(single
action)
Density
obtained
(double
action)
Vol% g/cm3 g/cm3 g/cm3
(Pure 7075) 2.81 2.72 2.76
5 2.78 2.68 2.72
10 2.75 2.64 2.68
15 2.72 2.6 2.64
20 2.69 2.55 2.61
25 2.66 2.51 2.56
30 2.63 2.47 2.52
35 2.60 2.43 2.49
40 2.57 2.37 2.44
45 2.54 2.33 2.40
50 2.51 2.29 2.37
Table 4 Density values of Ni coated Carbon fiber
Composites
Specimen
No.
Content of Ni
coated carbon
fibers
Density
by
ROM
Density
obtained (single
action)
Vol% g/cc g/cc
1 5 2.92 2.81
2 10 3.02 2.89
3 15 3.13 2.96
4 20 3.24 3.02
5 25 3.35 3.10
6 30 3.45 3.11
Fig No.3 Effect of carbon fiber content on densification
of Al/Cf Composites
B. Hardness
Brinell hardness test results are listed in Table 5.
Hardness variation with volume content of carbon fibers
for coated and uncoated carbon fibers is graphically
represented in Fig.8
Fig. 8 Effect of uncoated and coated fiber on vol. % of
fiber on hardness of composites
Table 5 Hardness of the Composites
Vol % of Carbon
fiber
0 5 10 15 20 25 30 35 40 45 50
UnCf_MMC
(Double action
pressing)
Hard
ness,
BHN
116
102
97
80
73
68
63
66
58
52
46
UnCf_MMC (Single
action pressing)
101
75
71
69
65
61
60
56
51
48
45
NiCf MMC (Single
action
pressing)
101
116
124
130
139
134
127
C. Microstructures of composites
SEM micrographs of uncoated carbon fiber reinforced
aluminium alloy composites (parallel section) are shown
in Fig.No.4 (a-d and g). Fig.4 e shows the SEM image of
40 vol% composite (cross section) Fig.4 (f) shows the
SEM micrograph of Nickel-coated carbon fibers
composite. Fig.5 (a and b) are SEM images of parallel
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section of 15Vol% uncoated carbon fibers MMC near
the bottom of the punch and away from the punch
respectively. Microstructures of composites containing
different volume % of uncoated carbon fibers are shown
in Fig. 6 .Figs 6 (a-c and d-f) show the parallel section
and cross section images respectively. Fig.7 represents
XRD analysis of Al/Cf Composites containing 10, 20
and 30 Vol% Cf.
Fig. 4a. SEM image parallel section of 10Vol uncoated
carbon fiber MMC
Fig. 4b. SEM image parallel section of 20Vo uncoated
carbon fiber MMC
Fig. 4c. SEM image parallel section of 40Vol% uncoated
carbon fiber MMC
Fig. 4d. SEM image parallel section of 50Vol%
uncoated carbon fiber MMC
Fig. 4f. SEM image parallel section of 10Vol% Ni
coated carbon fiber MMC
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Fig. 4e. SEM image cross section of 40Vol% uncoated
carbon fiber MMC
Fig. 4g. SEM image parallel section of 50Vol%
uncoated carbon fiber MMC
Fig. 5a. SEM image parallel section of 15Vol%
uncoated carbon fiber MMC showing good bonding
Fig. 5b. SEM image parallel section of 15Vol%
uncoated carbon fiber MMC showing porosity
Fig. 6a. Microstructure image parallel section of
10Vol% uncoated carbon fiber MMC
Fig. 6b. Microstructure image parallel section of
20Vol% uncoated carbon fiber MMC
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Fig. 6c. Microstructure image parallel section of
50Vol% uncoated carbon fiber MMC
Fig. 6d. Microstructure image cross section of 10Vol%
uncoated carbon fiber MMC
Fig. 6e. Microstructure image cross section of 20Vol%
uncoated carbon fiber MMC
Fig. 6f. Microstructure image cross section of 50Vol%
uncoated carbon fiber MMC
Composite properties
It is observed that the composites developed with
uncoated carbon fiber exhibit lower values of hardness
as compared with Pure AA7075 hot pressed specimen.
This decrease in hardness is due to increase of non
metallic phase (uncoated carbon fibers) in the matrix.
Whereas the Ni coated carbon fiber composites show the
increase in hardness up to 20Vol% and then it decreases.
The enhancement in the bulk hardness of the Ni coated
carbon fiber composite (20Vol% Cf) is 19% as
compared to pure AA7075 hot pressed specimen. This
may be due to the formation of hard intermetallic
compound of Al3Ni and coating also improves the
interfacial bonding between the carbon fiber and
AA7075 alloy. Drop in hardness for composites
with 25 and 30 Vol% carbon fiber content is attributed to
lower densification.
Fig. 7 XRD Analysis of Al/Cf Composites containing
10, 20 & 30Vol% Cf
Processing
It is important to consider the type of press used for hot
compaction of such composites when the specimen size
is big. Hot pressing by single action or double action is
reflected not only in densification but in density
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gradient as well. Composites which were hot
pressed in single action press show density gradient
along the thickness of the developed composites. Fig. 5a
shows the top portion of the composite (15Vol% Cf)
which was near the punch and it shows good
densification. Fig. 5b shows the bottom portion of the
same composite having porosity because of poor
compaction. Higher densification with no porosity and
no density gradient along the thickness of composites
were observed in composites which were prepared by
using double action hot press. Due to high pressure and
pressing from both the ends, better densification was
observed (Table 3).
Microstructures of Composites
It is seen from the microstructures that carbon fibers are
uniformly distributed in the aluminium matrix for all
compositions. The optical micrographs of composites
containing different volume % of fibers show no pores
in the composites. In all the specimens, good bonding is
seen between carbon fibers and matrix. Fig.7 shows
XRD analysis of composites containing 10, 20 and 30
vol % carbon fibers, from which, it appears that Al4C3
has not formed. In Powder Metallurgy route, pool of
liquid metal is absent and hence there is no reaction
between molten Aluminium and carbon fibers due to
which Al4C3 formation is prohibited.
IV. CONCLUSION
1. Pitch based carbon fiber reinforced Al matrix
composites are successfully fabricated by the Powder
Metallurgy (PM) route.
2. The fabricated composites show good bonding
between the fibers and Aluminium alloy matrix with
uniform distribution of carbon fibers in the matrix even
with high volume fraction of reinforcement.
3. The application of electroless nickel coating on the
fiber surface enhances the interfacial bonding which
results in increased hardness of the composite.
4. Fabrication of Carbon fiber reinforced Aluminium
matrix composites by PM route eliminates interfacial
reaction and thus the formation of Al4C3 which is
detrimental to mechanical and thermal properties of
composite.
5. Double action hot pressing gives better
densification and does not show density gradient in the
composite.
6. Therefore PM route possesses a great potential to
fabricate the short/milled carbon fiber reinforced
Aluminium matrix composites.
V. ACKNOWLEDGMENT
Authors gratefully acknowledge the financial support
of ISRO UoP Space Technology cell,SPPU, Pune and
support of BARC, Vashi complex, for providing their
double action hot pressing facility.
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