Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
Keywords Dual function Self-lubricating nanocomposites G-coated-SiCNP
Ball milling Wear resistance
A. El Ghazaly
American University, Cairo, Egypt
M.M. Emara
Manufacturing Engineering Department, Canadian International College,
El Tagamoa El Khamis, South of Police Academy, P.O. Box 59,
New Cairo 11835, Egypt
M. Shokeir S.N. El Moghazi A. Fathy H.G. Salem (&)
Mechanical Engineering Department, American University in Cairo,
American University in Cairo, AUC Avenue, P.O. Box 74,
New Cairo 11835, Egypt
e-mail: hgsalem@aucegypt.edu
Introduction
Over the last decades, growing interest of both automotive and aerospace sectors in
aluminum-based composites properties has been evident. Those multiple industries
are now expecting a lift that takes them to new levels of safety, comfort, and
efficiency. High performance tribological parts such as pistons, cylinder heads,
cylinder liners, drive shafts, and brake disks represent applications which motivated
the research and development of aluminum-based metal matrix composites [1–3].
Their enhanced specific strength, higher thermal conductivity, compared to
ceramics and lower coefficient of thermal expansion (CTE) are of some great
importance to multiple industrial applications [4–7].
Metal and refractory (ceramic based) carbides including SiC, TiC, Al2O3, and
NiAl3, among others, are commonly used as hardening fillers in the aluminum
matrices to enhance their wear resistance. The addition of SiC (3.18 g/cm3) to
Al-matrices is commonly used as reinforcement fillers in Al-matrices for such
applications [8–11]. SiC reinforcements are denser than that of Al-alloys
(2.7 g/cm3); hence the SiC reinforcements increase the overall density of the
composite depending on their content [12]. Another drawback to the addition of
SiC particles is the increased hardness of composite, resulting in machining diffi-
culty, especially for the cast components. Moreover, incorporation of such hard
particles within the Al-matrices is associated with a loss in toughness of the
composite; therefore an optimization of the ceramic filler content and size is
required to achieve the combined strength/toughness [13]. Identification of the
various parameters controlling the composite’s final properties was investigated by
many researchers. A number of the investigated parameters were the reinforcing
particles size, particle distribution within the matrix, particle content, and dispersion
method [14, 15]. The reduced size of the reinforcement phase down to the
nano-scale is of significant importance. It results in a remarkable improvement of
mechanical properties with excellent dispersion. Many applications require mate-
rials that combine both temperature and corrosion resistance, especially if the
component is under heavy load. However, one of the encountered issues is the
agglomeration of the nanoparticles into coarse clusters within the Al-matrices due
to their poor wettability and high surface-to-volume ratio. Clustering results in
forming stress concentration sites leading to premature failure of the nanocomposite
[16–18]. A number of processing techniques were employed by various researchers
aiming at enhancing the distribution of the micron and nanoscale ceramic particles
within the aluminum matrices. Some of the techniques include stir casting [19],
squeeze casting [19], friction stir processing (FSP) [20] and high energy ball milling
of mixed powders. High energy ball milling is one of the most popular techniques
used for enhancing the distribution of the nanoparticles. However, high energy ball
milling results in hardening of the mixed nanoceramic-Al-matrix powders resulting
in the formation of incompressible powder that is necessary during the compaction
and sintering steps. To overcome this problem, increasing the sintering tempera-
tures or durations becomes inevitable which results in the loss of the strengthening
Nanocomposites Mechanical and Tribological Properties … 405
Experimental Procedure
was maintained at 400 RPM. The ball-to-powder ratio (BPR) was 15:1, while the
milling time was 2 h.
Figure 2a–d shows the mixed and milled powders of G and SiC, respectively;
the GCSiCNP powders are represented at low and high magnifications, respectively.
It is clear from the images that mixing resulted in the formation of uniform coating
of the SiCNP on the G-micron-clusters (Fig. 2a, b). Due to the huge particle size
scale ratio between the SiCNP and the G-micron-clusters, the ceramic nanoparticles
almost fully covered the surfaces G-clusters forming powdered particles (Fig. 2b).
On the other hand, milling for 2 h of the mixed powders resulted in de-clustering of
both the SiCNP and graphene. The obvious refinement of the graphene particles is
shown in Fig. 2c, which was associated with the uniform distribution of the SiCNP
on the G-cluster surfaces (Fig. 2d). The G-mono-layered structure with uniform
distribution of SiCNP was evident in the milled powders (pointed at by arrows) as
shown in Fig. 2d.
AA 2124 powders were mixed with 0.5 wt% SiCNP and 5 wt% GCSiCNP for 1 h
at 96 rpm. Knowing that the 5 wt% GCSiCNP constituted 3/8 wt% G and 5/8 wt%
SiCNP. Ball milling (BM) of the mixed powders of the AA2124-wt% SiCNP and
GCSiCNP compared to the plain milled AA2124 powders was carried out at
400 rpm and 15:1 BPR for 2 h. Consolidation of the milled powders were green
compacted in a die under pressure of 525 MPa at room temperature followed by
sintering at 450 °C for 75 min followed by hot extrusion at 4:1 extrusion ratio. The
extruded rods were 10 mm in diameter and 89 mm long. The produced rods were
then air-cooled down to room temperature.
Characterization
The low energy associated with the mixing process led to a uniform distribution of
the SiCNP-nanoclusters on the surfaces of the aluminum powders as pointed out by
arrows in Fig. 3a, b for the AA2124-5 wt% SiCNP at low and high magnification,
respectively. Figure 3c, d shows the mixed AA2124 with 5 wt% GCSiCNP pow-
ders, where clusters and individual NP of SiC are uniformly coating the graphene
micron-clusters and the AA2124 particles as well (Fig. 3d). This was an indication
that the SiCNP were not strongly bonded to the G-clusters, which was evident by the
observed SiCNP on the surfaces of the Al-particles.
Figure 4a, b shows SEM images for the AA2124-AR and BM powders,
respectively. Evidence for cold welding of the soft AR-particles associated with
partial fragmentation and refinement (10 µm average particle size) was observed
via 2 h BM [37]. Al2O3 was also observed either in the form of fully fragmented or
partially delaminated films on the surfaces of the milled Al-particles as pointed out
by the arrows in Fig. 4b and the corresponding XPS scans for Oxides (Fig. 4c).
Similar observations were evident by Salem et al. [21]. Ball milling of the mixed
AA2124 with 5 wt% SiCNP nano-clusters for 2-h was not enough for producing a
significant refinement of the Al-particles (20 µm in average size) as evident in
Fig. 5a. Cold welding between the individual AA2124 particles and the AA2124
with SiCNP was the dominant mechanism [22, 37]. However, BM resulted in
de-clustering of the SiCNP, which was manifested by the impinged individual SiCNP
on the surfaces of the polycrystalline Al-softer particles as pointed at by white
arrows in Fig. 5b. This agrees with BM model described by Varol [37] for the effect
of reinforcement relative size and hardness that of the soft matrix particles.
Ball milling of the mixed AA2124-5 wt% GCSiCNP powders is shown if
Fig. 5c, d at low and high magnifications, respectively. Comparing the particle size
of the BM AA2124 with SiCNP and GCSiCNP at a low magnification (Fig. 5a, c),
respectively show evidence for spherodization and slight reduction in particle size
O1s Scan
4 Scans, 40.2 s, 400μm, CAE 50.0, 0.10 eV
4.00E+04
3.00E+04
Counts / s
2.00E+04
1.00E+04
0.00E+00
(c)
545 544 543 542 541 540 539 538 537 536 535 534 533 532 531 530 529 528 527 526
Binding Energy (eV)
Fig. 4 SEM images for AA2124 a (AR), b BM and c XPS scans for oxides in the BM powders
Table 1, lists the influence of reinforcement type (SiCNP and GCSiCNP) compared
to the as milled plain AA2124 on the densification degree, and the mechanical
properties’ variations post the hot extrusion (HE). The calculated percent relative
density (RD%) was based on the ratio of the experimental measured density of the
hot extrudates to the theoretical density calculated based on rule of mixtures. From
the displayed results BM of the mixed powders for 2 h followed by HE at 450 °C
resulted in relatively high densification, which can be revealed by the achieved >
99% relative densities. Addition of 5 wt% SiCNP and GCSiCNP resulted in the
enhancement of the composite densification compared with the plain BM AA2124
hot extruded powders [26, 38]. As commonly known, 2-h of BM was mainly
responsible for the cold welding of the soft Al-particles and was not enough for the
formation of refined, hard, and hence incompressible particles [21, 22]. However,
the measured slight increase in density with the addition of 5 wt% SiCNP (99.7%)
compared to the plain BM powders (99.1%) could be attributed to the oxide layers
readily fragmented and induced by the impingement of the SiCNP on the surfaces
during milling. This allowed the exposure of oxide free surfaces, which facilitated
diffusion during HE. The relatively ultrafine nano-scaled ceramic hard particles of
Table 1 Relative density (RD%), micro (Hv), yield strength, ultimate tensile strength, and
elongation % for the hot extruded (HE) BM plain AA2124 and nanocomposites
Hot extruded-BM powders RD% (HV) rY rUTS Elong. (%)
T L (MPa) (MPa)
AA2124 99.1 95 94 150 290 9.8
AA2124-5 wt% SiCNP 99.7 131 120 235 299 6.4
AA2124-5 wt% GCSiCNP 99.9 249.5 234.5 290 350 3.4
Nanocomposites Mechanical and Tribological Properties … 411
SiC compared to the soft-coarse AA2124 did not allow for the SiCNP segregation
on the boundaries and triple junctions but rather caused their impingement on the
surfaces and inside the cold welded soft particles [37], which facilitated consoli-
dation during HE. Addition of 5 wt% GCSiCNP enhanced the nanocomposite
densification (99.9%). This could be explained by the formation of GCSiCNP layer
around the Al-particles. Graphene forms a layer surrounding the Al-particles, which
facilitates the deformation of the composite powders via its lubrication effect and
hence provides a soft media for closing pores during extrusion [31, 36, 38]. This
disagrees with the reported results by Jafari et al. [39] who reported a significant
decrease in density (82%) when 1.5 wt% MWCNT were added to AA2024 BM and
hot pressed discs at 450 °C.
Table 1, also displays the variation of hardness on the extrudates’ transverse and
longitudinal sections of the nanocomposites compared to the plain AA2124.
HV-values exhibited by the AA2124 reinforced with 5 wt% GCSiCNP were almost
100 and 162% higher than that of 5 wt% SiCNP and the plain AA2124 extrudates,
respectively. The exhibited HV-values increase applies for both the transverse and
longitudinal sections. The reported values for the plain BM for 2 h is lightly higher
than that reported by Carreno and coworkers for 2024 at 2 h BM powders [40]. The
highest achieved hardness (95-vs.-70, respectively). According to Carreno,
HV-values were achieved for the AA2024-2.5 and 5 wt% SiCNP (106 and 102 HV),
while in this current research the measured hardness for the AA2124-5 wt% SiC
was 131 HV. The higher hardness values reported in the current research could be
due to the slight difference in composition between AA2124 and 2024 and mainly
due to the difference in consolidation method used. The employment of cold
compactions followed by hot extrusion (current work) compared to pressure-less
sintering (Carreno’s work) could explain the observed difference in the results.
Moreover, the processed AA2124-GCSiCNP nanocomposite (current research)
displayed higher hardness (250-HV) compared to that reported by Varol et al. [37]
who investigated the mechanical properties of AA2024-5 wt% B4C (199-Hv) [40].
The displayed tensile behavior for the nanocomposites compared to the plain alloy
BM extrudates, shows agreement with the displayed Hv-results, where the highest
yield and ultimate tensile strength and lowest ductility was achieved by the
AA2124-5 wt% GCSiCNP compared to that reinforced with SiCNP and the plain
aluminum.
Figure 6a presents the on-load and residual scratch depth and Fig. 6b represents the
scratch width variation for the BM and HE nano-composites compared to the plain
AA2124 alloy consolidates. The sliding direction is represented by the arrow shown
412 A. El Ghazaly et al.
(a) (b)
Fig. 6 Nanoscratch test results at constant load of 50 mN over a scratch distance of 700 µm for
the BM-HE nanocomposites compared to the plain alloy a scratch depth as a function of distance
and b scratch width
on the diagram. It is clear from the nano-scratch profile that addition of GCSiCNP in
the Al-matrices resulted in high resistance to the indenter penetration, which was
depicted by the lowest average penetration depth (−873 nm) and lowest scratch
width of 8.5 µm in average size. AA2124-reinforced with SiCNP displayed higher
average scratch depth (−1155 nm) and wider scratches about 13.7 µm in average
size. The highest scratch depth was recorded for the plain AA2124 alloy BM
extrudates (−1240 nm), which was associated with 18.5 µm width. It is also
observed that presence of graphene as reinforcement in the nanocomposite results
in fluctuating scratch depth profile, while the AA2124-SiCNP and the plain one
displayed more uniform scratch depth profile. The presence of graphene layers
confronts the Berkovich tip and forces it to shift upwards [41].
Figure 7 shows SEM images for the scratches produced on the surfaces of the
extruded nanocomposites compared to the plain alloy. Results displayed for the
crack depth and width were averaged over 10 scratches per condition. It is clear that
deformation by ploughing was significantly dominating the scratching behavior of
both the plain AA2124 (Fig. 7a) and the AA2124-5 wt% SiCNP (Fig. 7b), with
excessive damage on the scratch edges [42]. Conversely, the AA2124-GCSiCNP
(Fig. 7c) showed the least damage manifested by the symmetrical marks on the
scratch edges. The GCSiCNP reinforced nanocomposite shows uniform appearance
with limited amount of debris compared to the other two conditions. Evidence for
smeared appearance on the edges of the plain alloy (Fig. 7a, circled) resulting from
plastic deformation associated with indenter tip and surface of the rod [42]. On the
other hand, high magnification images for the SiCNP reinforced nanocomposite
shows evidence for adhesive wear, which was manifested by the torn out alligator
skin-like feature (Fig. 7b, circled).
Nanocomposites Mechanical and Tribological Properties … 413
Fig. 7 SEM images for the scratches of the HE a plain AA2124 alloy, b AA2124-SiCNP and
c AA2124-GCSiCNP nanocomposites
Conclusions
In the current research, the processing of almost fully consolidated mixed and BM
AA2124-GCSiCNP and SICNP were carried to produce hot extrudates which were
conducted at 0.67Tm. BM of G micron-clusters with SiCNP nanoclusters produced
G-clusters fully coated (powdered) with de-clustered SiCNP. Addition of 5 wt%
GCSiCNP instead of 5 wt% SiCNP produced a nanocomposite with uniform dis-
tribution of G-coated SiCNP within the soft aluminum matrix. Nonetheless, cold
welded particles of GCSiCNP were present on the AA2124 and this is associated
with BM. BM of GCSICNP with AA2124 induced the highest lattice strain and
finest crystallite size compared to SiCNP addition. AA2124-GCSiCNP compared to
AA2124-SiCNP and plain AA2124, displayed higher consolidation densities, higher
hardness, higher tensile properties and higher resistance to scratching. The
enhanced hardness, strength and resistance to scratch provide preliminary indicators
for the production of nanocomposites with dual function for ultrahigh wear
resistance-self-lubricating component.
Acknowledgements Authors of the work would like to acknowledge the Youssef Jameel Science
and Technology Research Center (YJSTRC) for facilitating the characterization of the tested
composites. Extended gratitude is given to the effort exerted by Mr. Zakarya Taha and Eng.
M. Bakr for their technical assistance.
References
1. Basavarjappa, S., Chandramohan, G., & Paulo Davim, J. (2007). Applications of Taguchi
techniques to study dry sliding wear behavior of metal matrix composites. Materials &
Design, 28(4), 1393–1398.
2. Palanikumar, K., Rajasekaran, T., & Paulo Davim, J. (2010). Modelling and analysis on wear
behavior of metal matrix composites. In J. Paulo Davim (Ed.), Tribology of composite
materials (pp. 157–174). New York, NY: NOVA Publishers.
3. Paulo Davim, J. (Ed.). (2012). Wear of advanced materials. London, UK: Wiley-ISTE.
4. Niskanen, P., & Mohn, W. R. (1988). Versatile metal matrix composites. Advanced Materials
and Processes, 133(3), 39–41.
414 A. El Ghazaly et al.
5. Hunt, M. (1989). Making metal matrix composites stronger and tougher. Mechanical
Engineering, 7, 43–46.
6. Kempfer, L. (1990). Materials take hypersonic leap into space. Mechanical Engineering, 8,
19–22.
7. Hunt, M. (1990). Form and function in metal matrix composites. Mechanical Engineering, 6,
27–31.
8. Macke, A. J., Schultz, B., & Rohatgi, P. K. (2012). Metal matrix: Composites offer the
automotive industry an opportunity to reduce vehicle weight, improve performance. Advanced
Materials and Processes, 170(3), 19–23.
9. Christy, T. V., Murugan, N., & Kumar, S. (2010). A comparative study on the microstructures
and mechanical properties of Al 6061 alloy and the MMC Al 6061/TiB2/12p. Journal of
Minerals & Materials Characterization & Engineering, 9(1), 57–65.
10. Miracle, D. B. (2005). Metal matrix composites—From science to technological significance.
Composites Science and Technology, 65(15), 2526–2540.
11. El-Garaihy, W. H., Oraby, S. E., Rassoul, E. S. M., & Salem, H. G. (2015). On the effect of
SiC content and processing temperature on relative density and hardness of hot compacted
aluminum AA6061 composite-mathematical empirical and response surface approach.
Journal of Materials Science Research, 4(3), 1–14.
12. Prabu, S. B., Karunamoorthy, L., Kathiresan, S., & Mohan, B. (2006). Influence of stirring
speed and stirring time on distribution of particles in cast metal matrix composite. Journal of
Materials Processing Technology, 171(2), 268–273.
13. Li, S., et al. (2016). Enhanced mechanical behavior and fabrication of silicon carbide particles
covered by in-situ carbon nanotube reinforced 6061 aluminum matrix composites. Materials
and Design, 107, 130–138.
14. Ibrahim, I. A., Mohamed, F. A., & Lavernia, E. J. (1991). Particulate reinforced metal matrix
composites—A review. Journal of Materials Science, 26(5), 1137–1156.
15. Suh, Y. S., Joshi, S. P., & Ramesh, K. T. (2009). An enhanced continuum model for
size-dependent strengthening and failure of particle-reinforced composites. Acta Materialia,
57(19), 5848–5861.
16. Wang, Z., Song, M., Sun, C., Xiao, D., & He, Y. (2010). Effect of extrusion and particle
volume fraction on the mechanical properties of SiC reinforced Al-Cu Alloy. Materials
Science and Engineering A, 527(24–25), 6537–6542.
17. Tjong, S. C. (2007). Novel nanoparticle-reinforced metal matrix composites with enhanced
mechanical properties. Advanced Engineering Materials, 9(8), 639–652.
18. Kollo, L., et al. (2011). Nano-silicon carbide reinforced aluminum produced by high-energy
milling and hot consolidation. Materials Science and Engineering A, 528(21), 6606–6615.
19. Shalaby, E. A. M., Churyumov, A. Y., Solonin, A. N., & Lotfy, A. (2016). Preparation and
characterization of hybrid A359/(SiC + Si3N4) composites synthesized by stir/squeeze casting
techniques. Materials Science and Engineering A, 674, 18–24.
20. Jeon, C. H., et al. (2014). Material properties of graphene/aluminum metal matrix composites
fabricated by friction stir processing. International Journal of Precision Engineering and
Manufacturing, 15(6), 1235–1239.
21. Salem, H. G., & Sadek, A. W. (2010). Fabrication of high performance PM nanocrystalline
bulk AA2124. Journal of Materials and Engineering Performances, 19(3), 356–367.
22. Salem, H. G., El-Eskandarany, S., Kandil, A., & Abdel Fattah, H. (2009). Bulk behavior of
ball milled AA2124 nanostructured powders reinforced with TiC. Journal of Nanomaterials,
1–12.
23. Sadek, A., Salem, H. G., & Attallah, M. (2009). Nanocrystalline powder consolidation in
AA2124 using uniaxial compaction and severe plastic deformation. Paper Presented at the
San TMS 2009 Annual Meeting and Exhibition, San Francisco, California, February 15–19.
24. Sadek, A., & Salem, H. G. (2009). Controlling the processing parameters for consolidation of
nanopowders into bulk nanostructured material. In: T. Hinklin & K. Lu (Eds.), Processing of
nanoparticle structures and composites (pp. 1–12). Hoboken, NJ: Wiley.
Nanocomposites Mechanical and Tribological Properties … 415
25. Kumar, P. H. G., & Xavior, M. A. (2014). Graphene reinforced metal matrix composite
(GRMMC): A review. Procedia Engineering, 97, 1033–1040.
26. Sharma, P., Khanduja, D., & Sharma, S. (2015). Production of hybrid composite by a novel
process and its physical comparison with single reinforced composites. Materials Today:
Proceedings, 2, 2698–2707.
27. Flores-Zamora, M. I., Estrada-Guel, I., Gonalez-Hernandez, J., Miki-Yoshida, M., &
Martinez-Sanchez, R. (2007). Aluminum-graphite composite produced by mechanical milling
and hot extrusion. Journal of Alloys and Compounds, 434–435, 518–521.
28. Deaquino-Lara, R., et al. (2014). Structural characterization of aluminum alloy 7075-graphite
composites fabricated by mechanical alloying and hot extrusion. Materials and Design, 53,
1104–1111.
29. Al-Qutub, A., Khail, A., Saheb, N., & Hakeem, A. (2013). Wear and friction behavior of
Al6061 alloy reinforced with carbon nanotubes. Wear, 297(1), 752–761.
30. Bartolucci, S. F., et al. (2011). Graphene-aluminum nanocomposites. Materials Science and
Engineering A, 528, 7933–7937.
31. Ghazaly, A., Seif, B., & Salem, H. G. (2013). Mechanical and tribological properties of
AA2124-graphene self-lubricating nanocomposite. Paper Presented at the San TMS 2013
Annual Meeting and Exhibition, Antonio, Texas, March 2–7, 2013.
32. Alizadeh, A., Abdollahi, A., & Biukani, H. (2015). Creep behavior and wear resistance of Al
5083 based hybrid composites reinforced with carbon nanotubes (CNTs) and boron carbide
(B4C). Journal of Alloys and Compounds, 650, 783–793.
33. Fallahdoost, H., Nouri, A., & Azimi, A. (2016). Dual functions of TiC nanoparticles on
tribological performance of Al/graphite composites. Journal of Physics and Chemistry of
Solids, 93, 137–144.
34. Kaushik, N Ch., & Rao, R. N. (2016). Effect of grit size on two body abrasive wear of Al
6082 hybrid composites produced by stir casting method. Tribology International, 102, 52–
60.
35. Liu, J., et al. (2016). Graphene oxide and graphene nanosheet reinforced aluminum matrix
composites: Powder synthesis and prepared composite characteristics. Materials and Design,
94, 87–94.
36. Ted Guo, M. L., & Tsao, C.-Y. A. (2000). Tribological behavior of self-lubricating
aluminum/SiC/graphite hybrid composites synthesized by the semi-solid powder-densification
method. Composites Science and Technology, 60, 65–74.
37. Varol, T., & Canakci, A. (2013). Effect of particle size and ratio of B4C reinforcement on
properties and morphology of nanocrystalline Al2024-B4C composite powders. Powder
Technology, 246, 462–472.
38. Tabandeh-Khorshid, M., Omrani, E., Menezes, P. L., & Rohatgi, P. K. (2016). Tribological
performances of self-lubricating aluminum matrix nanocomposites: Role of graphene
nanoplatelets. Engineering Science and Technology, and International Journal, 19, 463–469.
39. Jafari, M., Abbasi, M. H., Enayati, M. H., & Karimzadaeh, F. (2012). Mechanical properties
of nanostructured A2024-MECNT composite prepared by optimized mechanical milling and
hot pressing methods. Advanced Powder Technology, 23, 205–210.
40. Carreno-Gallardo, C., Estrada-Guel, I., Lopez-Melendez, C., & Martinez-Sanchez, R. (2014).
Dispersion of silicon carbide nanoparticles in a AA2024 aluminum alloy by a high-energy
ball mill. Journal of Alloys and Compounds, 586, S68–S72.
41. Shokrieh, M. M., Hosseinkhani, M. R., Naimi-Jamal, M. R., Tourani, H. (2013).
Nanoindentation and nanoscratch investigations on graphene-based nanocomposites.
Polymers Testing, 32(1), 45–51.
42. Hodge, A. M., & Nieh, T. G. (2004). Evaluating abrasive swear of amorphous alloys using
nanoscratch technique. Intermetallics, 12, 741–748.