氧化铝增强Al-Si基复合材料的组织结构和疲劳行为研究
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摘要
本文采用挤压铸造法制备了高Cu、Ni、Mg含量的Al-Si共晶合金和氧化铝增强Al-Si基复合材料，通过拉伸试验、疲劳试验、金相观察、扫描和透射电子显微分析等手段研究了材料的微观组织、拉伸变形行为、疲劳行为及断口特征，阐明了微观结构和增强体对力学性能和疲劳寿命的影响规律，揭示了拉伸断裂和疲劳失效微观机制。
拉伸试验结果表明，10vol.%、17vol.%和25vol.%纤维含量的氧化铝增强Al-Si基复合材料，室温抗拉强度随纤维含量的增加而下降，纤维含量从17vol.%增加到25vol.%，抗拉强度下降明显。但当拉伸温度高于275°C时，随着纤维含量增加，抗拉强度升高，纤维含量从10vol.%增加到17vol.%，抗拉强度升高明显。17vol.%氧化铝纤维+5vol.%氧化铝颗粒混合增强Al-Si基复合材料中氧化铝颗粒粘附在纤维表面，增大了纤维拔出阻力，进一步提高了抗拉强度。室温拉伸时，Al-Si共晶合金裂纹主要沿Al/Si界面扩展，断口上形成较大刻面，并造成阻碍裂纹扩展的金属间化合物破碎；Al-Si基复合材料中裂纹不仅沿Al/Si界面扩展，而且也沿Al/Intermetallic界面扩展，断口上形成较小的刻面。在200°C至350°C之间拉伸时，Al-Si共晶合金呈现微孔聚集型断裂，断口上形成较大韧窝；Al-Si基复合材料断口上存在大量韧窝，但韧窝尺寸相对较小。
疲劳试验结果表明，高Cu、Ni、Mg含量的Al-Si共晶合金，室温疲劳循环时表现出独特的双阶段硬化现象。第一阶段循环硬化发生在1～20周，在200周以后出现第二阶段循环硬化；100°C和200°C时，先出现循环硬化，随后表现为轻微的循环软化；当温度高于275°C时，只呈现出循环软化。适量的纤维含量显著提高了氧化铝纤维增强复合材料的疲劳寿命。10vol.%、17vol.%和25vol.%三种纤维含量的复合材料中，17vol.%含量的疲劳寿命最长。17vol.%氧化铝纤维+5vol.%氧化铝颗粒混合增强Al-Si基复合材料，则进一步延长了疲劳寿命。氧化铝纤维增强Al-Si基复合材料室温疲劳循环时，在1～10周内出现循环硬化现象，随后是循环软化；在200°C和350°C主要表现为循环软化。
微观结构分析发现，高Cu、Ni、Mg含量的Al-Si共晶合金中形成多种金属间化合物，主要有Al_7Cu_4Ni、Al_5Cu_2Mg_8Si_6、Al_3CuNi、Mg_2Si、Al_2Cu等，呈现出不规则的板状、块状、条状等形貌特征。Al-Si共晶合金室温疲劳循环时双阶段循环硬化与塑形变形过程中位错增殖以及显微组织中存在金属间化合物有关。大量形状各异的金属间化合物和片层状共晶硅分隔了铝合金基体，难于形成导致软化的滑移带。第一阶段循环硬化起源于位错与析出物之间的交互作用，而位错与位错之间的交互作用导致出现第二阶段循环硬化。
断口分析发现，当温度低于200°C时，Al-Si共晶合金疲劳裂纹萌生于靠近试样表面的粗大初晶硅处、或者聚集的金属间化合物处；温度高于275°C时，疲劳裂纹主要萌生于靠近试样表面的粗大初晶硅处。在室温至350°C温度范围内，氧化铝纤维增强Al-Si基复合材料的疲劳裂纹萌生于接近试样表面的粗大纤维或者纤维聚集处。当温度低于200°C时，Al-Si共晶合金疲劳裂纹主要沿着Al/Si界面扩展，断口上形成较大的刻面；Al-Si基复合材料疲劳裂纹主要沿着Al/Intermetallic界面扩展，断口上刻面较小。当温度高于275°C时，Al-Si共晶合金及其复合材料在疲劳试验过程中Al/Si界面和Al/Intermetallic界面出现脱粘，进而发生微孔聚集，在断口上形成大量韧窝，Al-Si合金断口上韧窝尺寸明显大于Al-Si基复合材料断口上韧窝。
This paper studied the microstructures, tensile strain, fatigue and fractography ofAl-Si matrix alloy strengthened by high-content alloy elements, such as Cu, Ni, Mg, etc.,and its composites which are produced by squeeze casting with the measurement oftensile test, fatigue test, optical microscope, scanning and transmission electronmicroscope. The mechanical properties, fatigue and fracture mechanisms of thesematerials are evaluated and analyzed as well in this paper.
It can be concluded from the tensile test results that the tensile strength at roomtemperature of the Al2O3f/Al-Si composites decreases as the increasing fiber volumefraction (10vol.%,17vol.%and25vol.%), which changes evidently from17vol.%to25vol.%. While it is totally different if the temperature is more than275°C. The tensilestrength at the temperature over275°C increases evidently from10vol.%to17vol.%.The Ai-Si composite hybrid with17vol.%Al2O3fiber and5vol.%particulates, in whichthe particulates adhere to the surface of fibers, increases the resistance force when thefibers are pulled out from the matrix and enhances the tensile strength. At roomtemperature, the crack in the Al-Si alloy propagates along the boundary between the Siplate and the Al matrix in the eutectic and breaks up the blocking intermetallics, whichexhibits brittle fracture characteristics. The crack in the composite propagates along theAl/Si or Al/Intermetallic boundary due to the constraint effect from the fibers, whichresults in a large number of small facets in the fracture surface. At the temperature from200°C to350°C, the crack in the Al-Si matrix alloy propagates along the gatheringmicropores, which exhibits ductile fracture with dimples. The composite shows similarductile fracture characteristics with dimples which have smaller size than the Al-Si alloy.
The low cycle fatigue tests show that the Al-Si matrix alloy peculiarly exhibitstwo-stage cyclic hardening at room temperature. The first cyclic hardening stage happensat1～20cycles, while the second one after the200th cycle. At100°C and200°C, thematerial shows cyclic hardening behavior at the beginning of low cycle fatigue test andafterwards presents slight cyclic softening behavior. When the temperature is over275°C,the alloy shows only cyclic softening. The Al2O3f/Al-Si composites reinforced with10vol.%,17vol.%and25vol.%fibers all have better fatigue properties than the Al-Si alloy.The composite with17vol.%fibers has best fatigue property among the three ones.Based on this composite (17vol.%fiber), Al2O3particulates (5vol.%) are added byadhering to the fibers, which results in an excellent fatigue property for the compositesimultaneously reinforced with Al2O3fibers and particulates. During the low cycle fatigue testing, all the composites show slight cyclic hardening at the first10cycles andthen presents cyclic softening behavior at room temperature. At the temperature range of200°C～350°C, the composites show obvious cyclic softening behavior.
The microstructural analysis reveals that the eutectic Al-Si alloy strengthened withhigh-content Cu, Ni and Mg has a lot of intermetallics, such as Al_7Cu_4Ni、Al_5Cu_2Mg_8Si_6、Al_3CuNi、Mg_2Si、Al_2Cu with various morphologies. The plentiful intermetallics togetherwith plate-like eutectic Si separate the Al alloy matrix, which leads to disappearance ofslip bands due to inhomogeneous deformation during fatigue cycling. The first hardeningstage initiates from the interaction between the dislocations and the precipitates. And thesecond one is related to the interaction among the dislocations.
The fracture analysis shows that the fatigue crack initiates close the surface of largeprimary silicon particles or intermetallic agglomerates in the Al-Si matrix alloy duringlow cycle fatigue test(the temperature is less than200°C). When the temperature ishigher than275°C, the bulky primary Si particles are the mainly crack source. For thecomposites, cracks frequently begin at a huge fiber or a fiber agglomerate. While thetemperature under200°C, the crack in the Al-Si matrix alloy propagates mainly along theAl/Si boundary with many facets formed at the fracture surface, and the crack in thecomposites propagates mainly along the Al/Intermetallic boundaries with smaller facets.When the temperature is higher than275°C, debonding of Al/Si or Al/Intermetallicboundaries as well as breaking of fibers result in appearance of micropores and dimplesat the fracture surface. And the dimple size of Al-Si alloy is bigger than that of thecomposites.
拉伸试验结果表明，10vol.%、17vol.%和25vol.%纤维含量的氧化铝增强Al-Si基复合材料，室温抗拉强度随纤维含量的增加而下降，纤维含量从17vol.%增加到25vol.%，抗拉强度下降明显。但当拉伸温度高于275°C时，随着纤维含量增加，抗拉强度升高，纤维含量从10vol.%增加到17vol.%，抗拉强度升高明显。17vol.%氧化铝纤维+5vol.%氧化铝颗粒混合增强Al-Si基复合材料中氧化铝颗粒粘附在纤维表面，增大了纤维拔出阻力，进一步提高了抗拉强度。室温拉伸时，Al-Si共晶合金裂纹主要沿Al/Si界面扩展，断口上形成较大刻面，并造成阻碍裂纹扩展的金属间化合物破碎；Al-Si基复合材料中裂纹不仅沿Al/Si界面扩展，而且也沿Al/Intermetallic界面扩展，断口上形成较小的刻面。在200°C至350°C之间拉伸时，Al-Si共晶合金呈现微孔聚集型断裂，断口上形成较大韧窝；Al-Si基复合材料断口上存在大量韧窝，但韧窝尺寸相对较小。
疲劳试验结果表明，高Cu、Ni、Mg含量的Al-Si共晶合金，室温疲劳循环时表现出独特的双阶段硬化现象。第一阶段循环硬化发生在1～20周，在200周以后出现第二阶段循环硬化；100°C和200°C时，先出现循环硬化，随后表现为轻微的循环软化；当温度高于275°C时，只呈现出循环软化。适量的纤维含量显著提高了氧化铝纤维增强复合材料的疲劳寿命。10vol.%、17vol.%和25vol.%三种纤维含量的复合材料中，17vol.%含量的疲劳寿命最长。17vol.%氧化铝纤维+5vol.%氧化铝颗粒混合增强Al-Si基复合材料，则进一步延长了疲劳寿命。氧化铝纤维增强Al-Si基复合材料室温疲劳循环时，在1～10周内出现循环硬化现象，随后是循环软化；在200°C和350°C主要表现为循环软化。
微观结构分析发现，高Cu、Ni、Mg含量的Al-Si共晶合金中形成多种金属间化合物，主要有Al_7Cu_4Ni、Al_5Cu_2Mg_8Si_6、Al_3CuNi、Mg_2Si、Al_2Cu等，呈现出不规则的板状、块状、条状等形貌特征。Al-Si共晶合金室温疲劳循环时双阶段循环硬化与塑形变形过程中位错增殖以及显微组织中存在金属间化合物有关。大量形状各异的金属间化合物和片层状共晶硅分隔了铝合金基体，难于形成导致软化的滑移带。第一阶段循环硬化起源于位错与析出物之间的交互作用，而位错与位错之间的交互作用导致出现第二阶段循环硬化。
断口分析发现，当温度低于200°C时，Al-Si共晶合金疲劳裂纹萌生于靠近试样表面的粗大初晶硅处、或者聚集的金属间化合物处；温度高于275°C时，疲劳裂纹主要萌生于靠近试样表面的粗大初晶硅处。在室温至350°C温度范围内，氧化铝纤维增强Al-Si基复合材料的疲劳裂纹萌生于接近试样表面的粗大纤维或者纤维聚集处。当温度低于200°C时，Al-Si共晶合金疲劳裂纹主要沿着Al/Si界面扩展，断口上形成较大的刻面；Al-Si基复合材料疲劳裂纹主要沿着Al/Intermetallic界面扩展，断口上刻面较小。当温度高于275°C时，Al-Si共晶合金及其复合材料在疲劳试验过程中Al/Si界面和Al/Intermetallic界面出现脱粘，进而发生微孔聚集，在断口上形成大量韧窝，Al-Si合金断口上韧窝尺寸明显大于Al-Si基复合材料断口上韧窝。
This paper studied the microstructures, tensile strain, fatigue and fractography ofAl-Si matrix alloy strengthened by high-content alloy elements, such as Cu, Ni, Mg, etc.,and its composites which are produced by squeeze casting with the measurement oftensile test, fatigue test, optical microscope, scanning and transmission electronmicroscope. The mechanical properties, fatigue and fracture mechanisms of thesematerials are evaluated and analyzed as well in this paper.
It can be concluded from the tensile test results that the tensile strength at roomtemperature of the Al2O3f/Al-Si composites decreases as the increasing fiber volumefraction (10vol.%,17vol.%and25vol.%), which changes evidently from17vol.%to25vol.%. While it is totally different if the temperature is more than275°C. The tensilestrength at the temperature over275°C increases evidently from10vol.%to17vol.%.The Ai-Si composite hybrid with17vol.%Al2O3fiber and5vol.%particulates, in whichthe particulates adhere to the surface of fibers, increases the resistance force when thefibers are pulled out from the matrix and enhances the tensile strength. At roomtemperature, the crack in the Al-Si alloy propagates along the boundary between the Siplate and the Al matrix in the eutectic and breaks up the blocking intermetallics, whichexhibits brittle fracture characteristics. The crack in the composite propagates along theAl/Si or Al/Intermetallic boundary due to the constraint effect from the fibers, whichresults in a large number of small facets in the fracture surface. At the temperature from200°C to350°C, the crack in the Al-Si matrix alloy propagates along the gatheringmicropores, which exhibits ductile fracture with dimples. The composite shows similarductile fracture characteristics with dimples which have smaller size than the Al-Si alloy.
The low cycle fatigue tests show that the Al-Si matrix alloy peculiarly exhibitstwo-stage cyclic hardening at room temperature. The first cyclic hardening stage happensat1～20cycles, while the second one after the200th cycle. At100°C and200°C, thematerial shows cyclic hardening behavior at the beginning of low cycle fatigue test andafterwards presents slight cyclic softening behavior. When the temperature is over275°C,the alloy shows only cyclic softening. The Al2O3f/Al-Si composites reinforced with10vol.%,17vol.%and25vol.%fibers all have better fatigue properties than the Al-Si alloy.The composite with17vol.%fibers has best fatigue property among the three ones.Based on this composite (17vol.%fiber), Al2O3particulates (5vol.%) are added byadhering to the fibers, which results in an excellent fatigue property for the compositesimultaneously reinforced with Al2O3fibers and particulates. During the low cycle fatigue testing, all the composites show slight cyclic hardening at the first10cycles andthen presents cyclic softening behavior at room temperature. At the temperature range of200°C～350°C, the composites show obvious cyclic softening behavior.
The microstructural analysis reveals that the eutectic Al-Si alloy strengthened withhigh-content Cu, Ni and Mg has a lot of intermetallics, such as Al_7Cu_4Ni、Al_5Cu_2Mg_8Si_6、Al_3CuNi、Mg_2Si、Al_2Cu with various morphologies. The plentiful intermetallics togetherwith plate-like eutectic Si separate the Al alloy matrix, which leads to disappearance ofslip bands due to inhomogeneous deformation during fatigue cycling. The first hardeningstage initiates from the interaction between the dislocations and the precipitates. And thesecond one is related to the interaction among the dislocations.
The fracture analysis shows that the fatigue crack initiates close the surface of largeprimary silicon particles or intermetallic agglomerates in the Al-Si matrix alloy duringlow cycle fatigue test(the temperature is less than200°C). When the temperature ishigher than275°C, the bulky primary Si particles are the mainly crack source. For thecomposites, cracks frequently begin at a huge fiber or a fiber agglomerate. While thetemperature under200°C, the crack in the Al-Si matrix alloy propagates mainly along theAl/Si boundary with many facets formed at the fracture surface, and the crack in thecomposites propagates mainly along the Al/Intermetallic boundaries with smaller facets.When the temperature is higher than275°C, debonding of Al/Si or Al/Intermetallicboundaries as well as breaking of fibers result in appearance of micropores and dimplesat the fracture surface. And the dimple size of Al-Si alloy is bigger than that of thecomposites.
引文
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