Stab resistance of flexible composite reinforced with warp-knitted fabric like scale structure at quasi-static loading

The stab-resistant fabric like scale structure has a promising application prospect for areas of stab prevention owing to its great flexibility and excellent stab-resistance performance. In this paper, a kind of novel stab-resistant fabric has been designed by coating with epoxy resin (ER) and silicon carbide (SiC) particles, which was based on the warp-knitted fabric like scale structure (WKFS). The uniformity of dispersion has been investigated with different diameter and mass fraction of SiC, and polymerization degree of polyglycols (PEG); the flexibility and quasi-static properties of different kinds of WKFS treated with different coating solution has been studied, and the coating solution was prepared by mixing SiC particles and ER at different ratios. The results showed that the dispersion uniformity of the dispersion was the best when the diameter of SiC is 1 μm, the content is 50%, and the polymerization degree of PEG is 600. The longitudinal flexibility of the stab-resistant fabric is greater than that of transverse due to the gap between the longitudinal scales, and the addition of SiC particles can increase the transverse and longitudinal flexibility of stab-resistant fabric, and the flexible properties were the greatest when SiC:ER = 50:30. In addition, the WKFS treated with SiC of 16.7% has fatigue resistance; the damage mechanism of the fabric treated with pure ER is thankful to the brittleness of the resin; the added SiC particles hinder the further crack propagation of the resin, and the failure mode is mainly in stretch.

Investigation of the microstructure and thermo-mechanical properties of functionally graded materials fabricated by the vibrating centrifugal solid particle method

In this research, SiC/Al A413.1 functionally graded materials (FGMs) were fabricated by the vibrating centrifugal solid particle method (VCSPM), and the effects of the SiC particles on the microstructure and thermo-mechanical properties of an A413.1 aluminium alloy were investigated. The benefits of a vibration during centrifugal casting of FGMs are illustrated. After designing and fabricating the centrifugal casting machine, cylindrical FGM specimens were produced using the centrifugal solid particle method (CSPM) and VCSPM. This study used SiC particles with an average particle size from 50 to 62 μm as reinforcements to fabricate A413.1-10 wt% SiC functionally gradient composites at three annular mould speeds (900–1500 and 2100 rpm) and with or without a vibration of the mould. The Brinell hardness was measured; the yield strength (YS), ultimate tensile strength (UTS) and Young’s modulus (E) were determined by tensile testing; the density was determined by the Archimedes method; and the thermal expansion coefficients were measured with a dilatometer. A comparison of the samples produced by the conventional method and VCSPM shows a significant reduction in the porosity and an increase in the distribution gradient of the reinforcing particles for the VCSPM case. It can be concluded that in both processes, the mechanical and thermal properties improved in most cases by moving from the inner radius to the outer radius because of the movement of particles towards the outer radius from the centrifugal force. The results also show that the use of a vibration dramatically increased the rate and speed of migration of gas bubbles towards the inner radius, and the mechanical properties (hardness, YS, UTS and E) improved by moving from the inner to outer radius due to an increase in the percentage of silicon carbide particles. Upon increasing the velocity and using the VCSPM, the slope of these changes becomes steeper than those for the vibration-free mode and at low rotation speeds.

Wear Resistance of Aluminum Matrix Composites’ Coatings Added on AA6082 Aluminum Alloy by Laser Cladding

Ceramic-reinforced metal matrix composites are known for their high wear resistance. A coating based on these materials would be helpful to improve the wear behavior of aluminum alloys. Laser cladding has been used to deposit a coating consisting of an aluminum alloy reinforced with SiC particles on an AA6082 aluminum alloy. Laser cladding is a very energetic technique that causes the SiC particles to react with the molten aluminum to form Al4C3, which degrades the particles and reduces the properties of the coating. The formation of this detrimental compound was successfully achieved with the addition of Silicon and Titanium to the composite matrix. The microstructures of the newly developed material were characterized and the wear behavior was studied under dry sliding conditions on a pin-on-disc tribometer. The relationship between the microstructure and wear behavior was identified. The absence of Al4C3 in the Al40Si/SiC and Al12Si20Ti/SiC coatings’ microstructures resulted in an abrasion mechanism instead of a delamination mechanism. The wear behavior changed along the sliding distances. During the first 200 m of sliding distances, the wear rate of all coatings was lower than the uncoated one due to their higher microhardness. For longer sliding distances, the wear resistance of the uncoated AA6082 was higher than the coated ones due to the formation of a lubricant oxide layer on the AA6082 worn surface. For 1000 m of wear distances, the wear behavior was different for each coating. The wear rate of the Al12Si/SiC coating continued growing due to the delamination mechanism and the presence of Al4C3 that acted as starting crack points. The wear rate of the Al40Si/SiC coating decreased due to the formation of a thin, superficial oxide layer. The wear rate of the Al12SiTi/SiC progressively decreased along the sliding distance to below the substrate wear rate.

Study on formation mechanism of edge defects of high-volume fraction SiCp/Al composites by longitudinal-torsional ultrasonic vibration-assisted milling

SiCp/Al composites are a kind of particle-reinforced composite material, which has been widely used in various fields due to its excellent performance. However, during the machining, the damage and failure of the SiC particles, the aluminum matrix, and the interface phase will cause many surface and edge defects. These defects will seriously affect the application of SiCp/Al composites. In this paper, a finite element model of randomly distributed multi-cell SiCp/Al composites with longitudinal-torsional ultrasonic vibration-assisted milling was established to analyze the formation mechanism of edge defects of the material. The simulation results showed that the main reason for the formation of edge defects was that the interface, SiC particles, and the Al matrix will produce cracks during machining, and these cracks will propagate and cause particle breakage, matrix tearing, and edge gaps. According to different machined parameters, the ultrasonic vibration-assisted milling experiment was carried out. The test results showed that the actual processed workpiece does have defects such as edge gaps. The depth of cut and the feed per tooth had a serious influence on the edge defect value, while the cutting speed had a small effect. Moreover, under the condition of applying appropriate ultrasonic amplitude, the phenomenon of edge defects and the surface quality were significantly improved. Therefore, the application of ultrasonic vibration-assisted milling can improve the surface and edge quality of SiCp/Al composites.

Study on cutting performance of SiCp/Al composite using textured YG8 carbide tool

Precision machining of SiCp/Al composites is a challenge due to the existence of reinforcement phase in this material. This work focuses on the study of the textured tools’ cutting performance on SiCp/Al composite, as well as the comparison with non-textured tools. The results show that the micro-pit textured tool can reduce the cutting force by 5–13% and cutting length by 9–39%. Compared with non-textured tools, the cutting stability of the micro-pit textured tools is better. It is found that the surface roughness is the smallest (0.4 μm) when the texture spacing is 100 μm, and the residual stress can be minimized to around 15 MPa in the case of texture spacing 80 μm. In addition, the SiC particles with size of around 2–12 μm in the SiCp/Al composite may play a supporting role between the texture and the chips, which results in three-body friction, thereby reducing tool wear, sticking, and secondary cutting phenomenon. At the same time, some SiC particles enter into the micro-pit texture, so that the number of residual particles on the surface is reduced and the friction between the tool and the surface then decreases, which improves the surface roughness, and reduces the surface residual stress.