Investigation of Casting Efficiency of Silicon Carbide (SiC) Reinforced Aluminum Matrix Composites (AMCs)

1. Introduction
A composite material is a macroscopic combination of two or more distinct materials, having a recognizable interface between them. It is a system which is composed of a discrete constituent (the reinforcement) distributed in a continuous phase (the matrix). Composite materials are usually classified on the basis of the physical or chemical nature of the matrix phase, e.g., polymer matrix, metal-matrix and ceramic composites. In addition, there are some reports to indicate the emergence of Inter metallic-matrix and carbon-matrix composites. On the basis of reinforcement they can also be divided into two forms, discontinuously reinforced matrix composites and continuously reinforced matrix composites. Metal matrix composites have some significant behaviors, such as their

improved strength, corrosion resistance, friction resistance and wear resistance, high electrical and thermal conductivity, and high temperature mechanical [1 to 5]. Composites are used not only for their structural properties, but also for electrical, thermal, tribological, hard-tissue replacement, and environmental applications [6, 7]. Modern composite materials are usually optimized to achieve a particular balance of properties for a given range of applications. Discontinuously reinforced metal-matrix composites (DRMMCS) are commonly used today in many aerospace and industrial applications. They offer a wide range of attractive material properties, both mechanical and physical, that cannot be achieved using conventional engineering alloys. These enhanced materials properties are the direct result of the interaction between the metallic matrix and the reinforcement. One of the dominant forms of these kind of composites is Aluminum Matrix Composites (AMCs). Aluminum matrix composites (AMCs) refer to the class of light weight high performance aluminum centric material systems. The reinforcement in AMCs is usually in the form of discontinuous fibers, whisker or particulates, in volume fractions ranging from a few percent to 70%. One of the constituent is aluminum/aluminum alloy, which forms percolating network and is termed as matrix phase. The other constituent is embedded in this aluminum/aluminum alloy matrix and serves as reinforcement, which is usually non-metallic and commonly ceramic such as SiC and Al2O3. Properties of AMCs can be tailored to the demands of different industrial applications by suitable combinations of matrix, reinforcement and processing route. 1

2. Problem Statement
Virtually every casting method that can be used with unreinforced aluminum has been used with AMCs. These include the sand, gravity die (permanent mold), investment, squeeze, and lost foam casting processes as well as high-pressure die casting, which is emphasized subsequently. However, several modifications must be considered to the normal melting and casting practice in order to produce high-quality castings. AMCs are melted in a manner very similar to that used for unreinforced aluminum alloys, but one of the problems is the formation of Al4C3 during the melting, according to the following reaction. 4Al + 3SiC Al4C3 + 3Si This Al4C3 adversely affects the properties of casting and consumes SiC which is reinforcement and necessary for good properties. However, it is essential that SiC particles are dispersed uniformly through the matrix. It improves the mechanical properties of AMC significantly, also conventional degassing techniques, such as plunging tablets or gas injection can cause nucleation of gas bubbles on the SiC particles and subsequent dewetting of the ceramic and salt fluxing removes the SiC

3. Causes
The above mentioned problems may be caused by following factors; 1) Overheating during pouring can cause formation of Al4C3. This reaction occurs very slowly at temperatures to about 750 C (1380 F), but accelerates with increasing temperatures from 780 to 800 C (1435 to 1470 F) for matrices containing a nominal 9% Si 2) Different densities between SiC particles and aluminum alloys. The density of most aluminum alloys is approximately 2.7 g/cm3, while the density of SiC is ~3.2 g/cm3. So there is a possibility for SiC particles to sink during melting. The settling rate of the SiC particles is quite slow. So, before pouring approximately the top 30 mm of the unstirred bath becomes devoid of SiC particles. 3) In conventional degassing processes, fluxes composed of chlorine and fluorine containing salts are used. The flux components react with aluminum forming gaseous compounds (aluminum chloride, aluminum fluoride). The gas is bubbling 2

and rising through the melt. Partial pressure of hydrogen in the formed bubbles is very low therefore it diffuses from the molten aluminum into the bubbles, but if SiC particles are present these bubbles will nucleate on these particles as a result dewetting will occur.

4. Effects
Possible effects are enlisted below; 1) This Al4C3 precipitates as crystals that adversely affect melt fluidity (Al4C3 is soluble in water and its formation during the fabrication process increases significantly the melt viscosity), which as a consequence weaken the cast material, and decrease the corrosion resistance of the casting (Al4C3 is unstable in some environments). 2) Brittle Al4C3 formed at the interface between the reinforcement and the matrix degrades the interfacial strength. Having uniform dispersion of SiC particles result in higher strength, stiffness, and temperature capacity. 3) Dewetting can cause porosity and resultant inferior mechanical properties.

5. Research Questions
The questions which have to be addressed are following 1) How to overcome overheating damage? 2) How to homogenize SiC particles in the melt? 3) What are the design considerations for casting AMCs? 4) What majors should be taken to improve degassing?

6. Tentative Answers
Composite foundry practice is different from conventional metal casting processes due to the problems stated earlier; in order to make the process efficient following factors should be kept in mind, close control of melt temperature is needed to avoid overheating and subsequent formation of aluminum carbide, the melt must be gently stirred during casting to maintain a uniform dispersion of SiC particles in order to avoid settling down of these 3

particles and also turbulence during casting must be minimized to avoid entrapping gas. As mentioned before, the SiC particles have low settling rate after stirring. So, to avoid the bath to become devoid of SiC particles it is important to stir the metal immediately before pouring, regardless of whether the metal was stirred during the melting. Although the casting of conventional aluminum is usually included gas bubbles, the composite is so sensitive to turbulence of gas bubble in the liquid. So, it is essential to design a perfect gating system to optimize running and feeding as well as trapping oxides. In order to obtain a sound casting melt should have good fluidity; unlike aluminum alloys temperature has negative effect on the fluidity of AMCs, it is also decreases with increase in the volume fraction, size angularity and agglomeration of the reinforcement particles, so in order to increase the fluidity Mg can be added to the melt which can increase fluidity at lower melt temperature. A rotary injection system is available that can successfully flux and degas the melt. It uses an argon-SF6 gas mixture. Additionally, simply bubbling argon through the melt using a diffuser tube can be used to remove hydrogen that has been absorbed by the melt. It also can be used to keep the SiC particles in suspension. The system employs a six-blade graphite impeller, which is connected to a threaded graphite drive shaft (Figure 1).

7. Hypotheses
1- Rising the temperature of the melt will increase porosity. 2- The turbulence of the melt will increase dispersion of reinforcements. 3- Disadvantages of degassing in AMCs is more than advantages.