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MM ee ttaa ll lloo gg rraa pp hh iicc Prree pp aa rraa tt iioo nn oo ff MM ee ttaa ll MM aa tt rr iixx CC oo mm pp oo ssii ttee ss MMC -Asse ss The ma tic Netwo rk
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C O N T E N T
AA6061/ Al2O3 /10-22p...................................................................................................2
A359/SiC/22p ..................................................................................................................2
AA2XXX / SiC / 25p .......................................................................................................4
AlSi7/SiC/(50+16)p-bimodal .........................................................................................5
Dispal...............................................................................................................................6
AA 357 / C-KC139 /UD or laminates...........................................................................8
AA1099 / Al2O3 Nextel 610 / 50f-UD..........................................................................9
AlZn6Mg / Al2O3 Altex/UD50f .................................................................................10
Carbon fiber reinforced magnesium alloys ..............................................................11
Magnesium/ C-T300 /50f-UD......................................................................................12
Micrographs of C/Mg-composites with Al-content in the magnesium matrixand without...................................................................................................................13
Micrographs of C/Mg-composites with Al2O3 particles as spacers.....................14
Cu-C (SFRM)// vol. 44% ..............................................................................................15
Cu-C (CFRM)// vol 40, 50,60% ...................................................................................15
Stainless Steel AISI 316 / 10-20 Vol.% Al2O3 ...........................................................16
Stainless Duplex Steel (UNS 31803) + 30 w.% Cr3C2 ..............................................17
Titan-alloys / continuous SiC fibre ............................................................................19
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AA6061/ Al2O3 /10-22p
A359/SiC/22p
T1,T4 or T6 condition.
POLISHING CONDITIONS
• Automatic polishing. MECAPOL P320 machine with rotating polishing disk +PERE rotating
specimen holder
• Polishing cloths and diamond pastes PRESI (http://www.presi.com)
Table 1:Polishing stages of AA6061/ Al2O3 /10-22p and A359/SiC/22p
Stage
N°Support Abrasive
Force*
(daN)
Disc
Rotating
speed (rpm)
Specimen
Rotating speed
(rpm)
Time
(min)Lubricant
1 paper SiC P400 6 150 100 1 water
2 paper SiC P800 6 150 100 1 water
3 paper SiC 1200 6 150 100 1 water
4
Polishin
g cloth
RAM
diamond
paste 6?m
LD33
1spray/45
sec
6 150 100 5
GH
(2drop /
5s)
5
Polishin
g cloth
RAM
diamond
paste 3?m
LD33
1spray/45
sec
6 150 100
1
+
30”
GH
(2drop /
5s)
6
Polishin
g cloth
SUPRA
Suspensio
n SPM
1/3 SPM+
2/3 H2O
1drop/sec
6 150 100 3 ///
* Pressure of 0,15 MPa for typical 32 mm diameter polish
Fig.1:AA6061/ Al 2O3 /10p (Duralcan W6A10A)
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Fig.2: AA6061/ Al 2O3 /22p (Duralcan W6D22A)
Fig.3: A359/SiC/22p (Duralcan F3S.20S)
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AA2XXX / SiC / 25p
POLISHING CONDITIONS
• Manual polishing with rotating disk (? 300mm)• All grinding and polishing products purchased from Struers (http://www.struers.com)
Table 2:Polishing stages of AA2XXX / SiC / 25p
Stage N° Support AbrasiveDisc Rotating
speed (rpm)
Time
(min)Lubricant
1 paper SiC 180 300 1 water
2 paper SiC 320 300 1 water
3 paper SiC 500 300 1 water G r i n d i n g
4 paper SiC 1200 300 2 water
1
Polishing
cloth
DP-Plan
diamond paste
6?m SYNXI150 2-3
DP-Blue
(DEPIF)
(1drop / 3s)
2
Polishing
cloth DP-
MOL
diamond paste
3?m SYNTE150 2-3
DP-Blue
(DEPIF)
(1drop / 3s) P o l i s h i n g
3
Polishing
cloth OP-
Chem
OP-S
Suspension150 3-4 ///
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AlSi7/SiC/(50+16)p-bimodal
POLISHING CONDITIONS
• Polishing and grinding by Planopol-3 with Pedemax-2 (STRUERS)
Table 3:Polishing stages of AlSi7/SiC/(50+16)p-bimodal
Stage
Nr. Support
Abrasi
vePressure
Disc Rotating
Speed
(rpm)
Specimen
Rotating
Speed
Time
(min)Lubricant
1Diamond
disc
Piano
220F=170N 150 110
to
plainWater
2 Largo-disc 15µm F=170N 150 110 8-10min
Diamond-suspension
3
Polishing
Cloth
PAN
15µm F=170N 150 1105-6
min
Diamond-
suspension
4
Polishing
Cloth
DUR
6µm F=170N 150 110 6minDiamond-
suspension
5
Polishing
Cloth
MOL
3µm F=170N 150 110 6minDiamond-
suspension
6
Polishing
Cloth
OP-CHEM
OPS or
OPUF=65N 150 110 2min
100ml OPS
+1ml H2O2
+1ml
Ammoniak
Fig.4: AlSi7/SiC/(50+16)p-bimodal
FOR MORE INFORMATION
Heidemarie Knoblich, [email protected]
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Dispal
DISPAL M1xx (M = reactive milling); AA1085 + submicron Al4C3/Al2O3
DIS PAL M2xx (M = reactive milling); AlSi(12-20) + submicron Al4C3/Al2O3
DISPAL A2xx (A = RS-powder by spraying); AlSi(12-40) + further alloying elements
DIS PAL S2xx (S = spray compaction); AlSi(12-40) + further alloying elementsDISPAL S7xx (S = spray compaction); AlZn(6-15) + further alloying elements
POLISHING CONDITIONS
• Automatic polishing with RotoPol-31 + RotoForce-4 top (rotating polishing disk (? 200 or
300 mm) and rotating specimen holder of ? 100mm)
• Polishing cloths: Struers (http://www.struers.de)
• Diamond pastes Wirtz-Bühler (http://www.buehlerltd.com), Fig.1
Table 4:Polishing stages of Dispal
Stage N° Support Abrasive
Disc Rotat
ing speed
(rpm)
Force*
[N]
Time
[min] Lubricant
1 SiC 80 120 0.25 water
2 SiC 220 90 0.25 water
3 SiC 800 90 0.25 water
4 SiC 1200 90 0.25 water G r i n d i n g
5
SiC-Paper
on MD-
Fuga
SiC 2400
150
90 0.25
1 Polishingcloth
MD-DAC
diamond paste 6µm
90 5 Struers blue
2
Polishing
cloth MD-MOL
diamond paste 3
µm 60 5
Struers
red
3
Polishing
cloth MD-MOL
diamond paste 1
µm 60 5
Struers
red P o l i s h i n g
4Polishing
cloth MD-NAP
Mastermet-
Polish suspension
Fa. Wirtz Buehler(SiO2; 0,06 µm)
150
60 2
* Pressure of 0,15 MPa for typical 32 mm diameter polish
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Fig.5:DISPAL S250 (AlSi20Fe5Ni2, spray compacted and extruded, LT)
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AA 357 / C-KC139 /UD or laminates
POLISHING CONDITIONS
• Cutting under water using a diamond cut-off wheel.• Polishing with rotating (? 230mm) polishing plate. Polishing cloths and diamond pastes :
PRESI (http://www.presi.com)
STRUERS (http://www.struers.com),
LAM PLAN (http://www.lamplan.fr),
TRIEFUS France (28011 CHARTRES CEDEX, Tel : 02-37-24-40-40)
Table 5:Polishing stages of AA 357 / C-KC139 /UD or laminates
Stage
N°Support Abrasive Supplier
Disc Rotating
speed (rpm)
Time
(min)Lubricant
1 paper SiC 320 PRESI 250 1-2 water
2 paper SiC 600 PRESI 250 1-2 water
3 paper SiC 1200 PRESI 250 1-2 water
4 Flocked
cloth PSF
(TRIEFUS)
diamond
paste
6?m
LAM
PLAN
250-300 1-3 alcohol
5 Woven
cloth 432
(LAM
PLAN)
diamond
paste
3?m
LAM
PLAN
250-300 1-3 alcohol
6 Flocked
cloth TF-R(PRESI)
Diamon
d paste0.25 ?m
LAM
PLAN
250-300 1-3 alcohol
Cleaning with alcohol in an ultrasonic bath and drying after stages 3, 4, 5, 6
Fig.6:AA 357 / C-KC139 /UD or laminates
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AA1099 / Al2O3 Nextel 610 / 50f-UD
POLISHING CONDITIONS
• Automatic polishing with rotating polishing disk ( ? 200mm) and rotating specimen holder(? 100mm)
• Grinding, polishing cloths and diamond pastes of
Table 6:Polishing stages of AA1099 / Al2O3 Nextel 610 / 50f-UD
Stage
N°Support Abrasive
Pres-
sure
(bar)
Disc
Rotation
(rpm)
Specimen
Rotation
(rpm)
Time
(min)Lubricant
1 SiC 320 1 flat
2 SiC 600 1 1
3 SiC 12001
14
Paper1
Dia-
mond
disc 2
SiC 4000 1
PIANO
1202
0.6 1 150110
2
water
5Polishing
cloth
RAM 1
LARGO
disc 2
diamond paste
6?m DESY 1
9µm 20.6 150 110 3-5
PM 1
(1drop / 3s)
suspension 2
6Polishing cloth
RAM 1
DAC 2
diamond paste 3?m
DESY 1 0.6 150 1103-5
PM 1
(1drop / 3s)
suspension 2
7
Polishing cloth
SUPRA1
MD-Chem 2
Suspension
25%SPM 1
+75%H2O;
OPS or OPU 2
0.6 150 110 1-2
As above 1 or
100ml OPS 2
+1ml H2O
+1ml NH3
8 1Polishing cloth
HS 1As above 1 0.4 150 110 1 water
1 PRESI (http://www.presi.com), 2 STRUERS (http://www.struers.de)
Fig.7:AA1099 / Al2O3 Nextel 610 / 50f-UD
FOR MORE INFORMATION:
1 [email protected]; 2 [email protected]
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AlZn6Mg / Al2O3 Altex/UD50f
POLISHING CONDITIONS
• Automatic polishing with rotating polishing disk (? 300mm) and rotating specimen holder(? 160mm)
• Polishing cloths: Struers (http://www.struers.de)
• Diamond pastes Wirtz-Bühler (http://www.buehlerltd.com), Fig.1
Table 8:Polishing stages of AlZn6Mg / Al2O3 Altex/UD50f
Stage
N°
Support Abrasive Pressure
(bar)
Disc Rotating
speed (rpm)
Specimen
Rotating speed
(rpm)
Time
(min)
Lubricant
1 paper SiC 180 1 - 5 300 150 until
flat
water
2 Largo °
Honey-
comb
disc
diamond
suspensi
on 9?m
1 - 5 300 150 3 Dialub sw
3 Texmet
W *
diamond
suspensi
on 3?m
1 - 5 150 150 3 Dialub sw
4 Polishin
g cloth F
*
Masterm
et II *
1 - 5 150 150 2.1 water
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Carbon f iber reinforced magnesium alloys
• Fiber: Tenax HTA 5331, Toray T300J, Toray T800H, Torray T1000
Fiber coating: TiN and uncoated
• Matrix: cp-Mg, AM20, AM50, AZ91
POLISHING CONDITIONS
• Manuel polishing with a very low pressure
• The same preparation conditions like mentioned in the table below are used for the
combination of all fiber matrix types listed above:
Table 9:Polishing stages of Carbon fiber reinforced magnesium alloys
Stage
No Support Abrasive Pressure
Disc Rotating
speed (rpm)
Time
(min)Lubricant
1 Paper SiC 320 Low 300 1 Ethanol
2 Paper SiC 500 Low 300 1 Ethanol
3 Paper SiC 800 Low 300 1 Ethanol
4 Paper SiC 1200 Low 300 1 Ethanol
5 Paper SiC 2400 Low 300 1 Ethanol
6 Paper SiC 4000 Low 300 1 Ethanol
7 Polishing
Cloth
MOL*
Dp
suspen-
sion 3
µm
(Samte*)
Low 300 5-10 Struers Lubricant red*
+ blue*
* Products of Struers (www.struers.de)
Comment : In the case of Al2O3 particles as spacers for producing graded carbon fibre
reinforced magnesium alloys, the metallographic preparation stays the same
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Magnesium/ C-T300 /50f-UD
POLISHING CONDITIONS
• Automatic polishing. MECAPOL P320 machine with rotating polishing disk +PERE rotatingspecimen holder
• Polishing cloths and diamond pastes PRESI (http://www.presi.com)
Table 10:Polishing stages of Magnesium/ C-T300 /50f-UD
Stage
N°
Support Abrasive Force*
(daN)
Disc Rotating
speed (rpm)
Specimen
Rotating speed
(rpm)
Time
(min)
Lubricant
1 paper SiC P240 6 150 100 2 EXXSOL
D80
2 paper SiC P600 6 150 100 2 EXXSOLD80
3 paper SiC 1200 6 150 100 2 EXXSOL
D80
4 Polishin
g cloth
RAM
diamond
paste
6?m
PM
6 150 100 5 EXXSOL
D80 (1drop
/ 2s)
5 Polishin
g cloth
RAM
diamond
paste
3?m
LD33
6 150 100 3 EXXSOL
D80 (1drop
/ 2s)
** Pressure of 0,15 MPa for typical 32 mm diameter polish
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Micrographs of C/Mg-composites with Al-content in the
magnesium matrix and without
The two SEM micrographs show composites with a Tenax HTA 5331 carbon fibre (similar to
Toray T300J) as reinforcement and two different magnesium matrix alloys. On the left picture
micrograph you see the fibres in a pure magnesium matrix (cp-Mg). On the right micrograph
the fibers are infiltrated in a magnesium matrix with an aluminum content of 5% (AM50). To
make the fiber/matrix-interface better visible the matrix has been e tched for 15 seconds with 2%
HNO3. On the right picture micrograph plate shape Al2MgC2 precipitates can be seen at the
fiber/matrix-interface.
Fig.7: Tenax HTA5331/cp-Mg (SEM) Tenax HTA5331/AM50 (SEM)
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Micrographs of C/Mg-composites with Al2O3 particles as spacers
The two SEM micrographes show composites with a pure magnesium matrix (cp-Mg) andToray T300J fibres as reinforcement. The Al2O3 particles are used as spacers to get a graded
fibre volume fraction. On the left micrograph on the bottom there are no Al2O3 particles and
the composite has a fiber volume fraction of about 60%. Only on top of this micrograph a few
Al2O3 particles (white) are visible. One the right micrograph the fiber volume fraction is about
30% and a lot of Al2O3 are visible in white color.
Fig.7: T300J/cp-Mg composite with a very low content of Al2O3 particles on top of the
micrograph (SEM)
Fig.8: T300J/cp-Mg composite with high content lot of Al2O3 particles (SEM)
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Cu-C (SFRM)// vol. 44%
Cu-C (CFRM)// vol 40, 50,60%
POLISHING CONDITIONS
• Polishing and grinding by hand. The time for grinding depends on the surface morphology
which was determined by a visual control of the surface.
Table 10:Polishing stages of Cu-C (SFRM)// vol. 44% and u-C (CFRM)// vol 40, 50,60%
Stage
N°Support
Abrasi
ve
Pressure
(bar)
Disc Rotating
speed (rpm)
Specimen
Rotating speed
(rpm)
Time
(min)Lubricant
1 paper SiC 320 - ~750 - dep. water
2 paper SiC
1200
- ~750 - dep. water
3 paper SiC
2400
- ~750 - dep. water
4 paper SiC
4000
- ~750 - dep. water
5 Polishing
with felts
3µ
and/or
1µm
- ~750 - dep. alcohol
Fig.9: Cu-C-SFRM (x-y-direction) Cu-C-SFRM (z-direction)
100 µm
100 µm
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Stainless Steel AISI 316 / 10-20 Vol.% Al2O3
POLISHING CONDITIONS
• Manual polishing with rotating polishing disk (? 250mm in stages 1-5 and ? 200mm instages 6-8). Duration of each stage - polishing until apparent scratches from the previous
stage has been disappeared (Table 1. and Fig. 1.).
• Abrasive papers: Buehler (http://www.buehlerltd.com/)
• Polishing cloths and diamond pastes: Struers (http://www.struers.com/)
Table 11:Polishing stages of the AISI 316 + 20 Vol.% Al 2O3 PRM MMC.
Stage
No.Support Abrasive
Disc Rotating
speed (rpm)Lubricant
1 paper SiC 60 300 water2 paper SiC 320 300 water
3 paper SiC 400 300 water
4 paper SiC 600 300 water
5 paper SiC 2400 300 water
6polishing cloth
DP-Moldiamond paste 3? m 70 etanol + glycerin
7polishing cloth
DP-Napdiamond paste 1? m 70 etanol + glycerin
8polishing cloth
DP-Nap
magnesium oxide
(MgO)70 water
Fig. 10:Polished microstructure of AISI 316 + 20 Vol.% Al2O3 PRM MMC (200x).
FOR MORE INFORMATIONS
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Stainless Duplex Steel (UNS 31803) + 30 w.% Cr3C2
POLISHING CONDITIONS
• Manual polishing with rotating polishing disk (? 250mm in stages 1-5 and ? 200mm
in stages 6-8). Duration of each stage - polishing until apparent scratches from the
previous stage has been disappeared, Table 1.
• Polished microstructure, Fig. 1.
• • Abrasive papers: Buehler (http://www.buehlerltd.com/)
• • Polishing cloths and diamond pastes: Struers (http://www.struers.com/)
ETCHING
Etching solution Aqua regia + glycerin. Etched microstructure, Fig. 2.
Table 12:Polishing stages of composite sample.Stage
No.
Support Abrasive Disc Rotating
speed (rpm)
Lubricant
1 paper SiC 60 300 water
2 paper SiC 320 300 water
3 paper SiC 400 300 water
4 paper SiC 600 300 water
5 paper SiC 2400 300 water
6 polishing cloth
DP-Mol
diamond paste 3?m 70 etanol + glycerin
7 polishing clothDP-Nap diamond paste 1?m 70 etanol + glycerin
8 polishing cloth
DP-Nap
magnesium oxide
(MgO)
70 water
Fig. 11: Polished microstructure of Duplex Stainless Steel+30 w.% Cr3C2 PRM MMC (200x).
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Fig. 12:Polished+etched microstructure of Duplex Stainless Steel+30 w.% Cr3C2 PRM MMC (200x).
FOR MORE INFORMATIONS
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Titan-alloys / continuous SiC fibre
CUTTING CONDITIONS
• low speed precision saw• resin bonded diamond wheel, thickness 0.6 mm, diamond grain size ca. 126 µm
POLISHING CONDITIONS
• Automatic polishing device, rotating disk (diameter 300 mm), rotating specimen holder
(diameter 140 mm)
• Polishing cloths: Struers (http://www.struers.de)
• Diamond pastes Wirtz-Bühler (http://www.buehlerltd.com), Fig.1
Table 13:Polishing stages of Titan-alloys / continuous SiC fibre
Stage
No.
Support Abrasive Lubri-
cant
Load
(N)
Disc
Rotating
Speed
(rpm)
Specim
en
Rotatin
g
Speed
(rpm)
Time
(min)
1 diamond
pad
Ni-
bonded
diamond
grain
size
20 µm
water hand 150 2
2 SiC-paper
SiC 800 water hand 150 1
3 SiC-
paper
SiC 1200 water hand 150 1
4 synthetic
woven
silk
polishin
g
cloth
diamond
grain
size
3 µm
alcoholic
suspensi
on
90 150 140 6
5 synthetic
leather
polishin
g
cloth
SiO2
0,04 µm
colloidal
silica
suspensi
on
pH 9.8
40 150 140 1
ETCHING, ALTERNATING WITH POLISHING, STAGE 5
100 ml water, 15 ml nitric acid (65 %), 10 ml hydrofluoric acid (40 %) for several seconds at
room temperature
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Fig. 13: cross section of a metal matrix composite Ti (Timetal 834)/ SiC (SCS-6) fibre
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MMC-Assess Publications
Volume 1: Glossary of Terms sp ecific to Metal M atrix Compo sit es
Volume 2: Thermal Treatm ents of A ge-hardenable Metal M atrix Compos ites
Volume 3: Metallographic Preparation of M etal M atrix Compos ites
Volume 4: X-R ay Computed Tomography on M etal Mat rix Composit es
Volume 5: Qualit y control and nondestructiv e tests in metal mat rix composit es
Volum e 6: Machining guidelines of Al/SiC parti culate MM C
Volume 7: Thermophy sical Properties of M etal M atrix Compos ites
Volume 8: Guidelines for joining of m etal m atrix composit es
Volume 9: Bomding and interface format ion in M etal M atrix Compo sites
Copyright: MMC-Assess Consortium, August 2000Content: P.Merle
Design: P.Prader
Contact: Insitut e of M aterials Science and Testing – Vienna Univ ersity of Technology
[email protected]: http://mmc-assess.tuwien.ac.at/
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