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Materials Science and Engineering A 527 (2010) 7545–7551

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Materials Science and Engineering A


journal homepage: www.elsevier.com/locate/msea

Experiment and modeling of mechanical properties on iron matrix composites


reinforced by different types of ceramic particles
J. Li, B.Y. Zong ∗ , Y.M. Wang, W.B. Zhuang
Key Laboratory for Anisotropy Design and Texture Engineering of Materials (Ministry of Education), Northeastern University, Shenyang 110004, PR China

a r t i c l e i n f o a b s t r a c t

Article history: The strength, Young’s modulus and hardness properties of iron matrix composites reinforced by differ-
Received 3 February 2010 ent types of ceramic particles (SiC, Cr3 C2 , TiC and Ti(C, N)) prepared by the dynamic temperature control
Received in revised form 15 July 2010 direct current heating technology were investigated experimentally. The stress–strain curves of the dif-
Accepted 12 August 2010
ferent composites and stress in reinforcing particles were simulated by Eshelby approach modeling in
order to interpret the experiments and to reveal the strengthening mechanisms. It was found that SiC
reinforcing particles show the strongest effect on improving the strength of the composite among the
Keywords:
four types of reinforcements experimentally. The theoretical analysis exposes the reason as its higher
Iron matrix composite
Reinforcing particles
fracture toughness and hardness as well as a limited decomposition to increase matrix strength. The
Stress–strain curve strength of the four composites all presents a maximum value at 10% volume fraction and the reason
Modeling can be interpreted by that glomeration of particulate reinforcements happens remarkably only when the
Strengthening mechanism fraction is over 10%. The stress–strain curves by the modeling agree well with those of the experiments
on TiC/Fe and Ti(C, N)/Fe composites but not on SiC/Fe and Cr3 C2 /Fe composites. This suggests that the
strengthening mechanisms of the composites rely not only on load sharing of the reinforcements but also
on increasing matrix strength.
© 2010 Elsevier B.V. All rights reserved.

1. Introduction The most commonly used ceramic particles for reinforcement


of various types in metal matrix composites include various oxides
Metal matrix composites, especially aluminum matrix com- (e.g., Al2 O3 and ZrO2 ), nitrides (e.g., TiN and Si3 N4 ), and car-
posite, have been used widely in many advanced engineering bides (e.g., SiC, TiC, Cr3 C2 , VC, and B4 C) [11]. It was reported that
applications, such as modern automobile and aerospace indus- Cr3 C2 and TiN have better effect on improving the properties of
tries [1,2]. It is interesting to use iron as the matrix material in the iron matrix composites than A12 O3 and TiC particles, but the
the composite system because of its low cost and the possibility reinforcing particles were not in the same size in the investiga-
of heat treatment, as well as better machinability and weldabil- tion [12]. It is extremely interesting to know the fundamental
ity [2,3]. Iron matrix composites were popularly manufactured by effects of different types and volume fraction of reinforcement
liquid-phase processes or conventional powder metallurgy [3–6]. on mechanical properties of the composites and the reports on
However, iron melt reacts strongly with silicon carbide but wets it the effects are far from enough and consistent to draw any con-
moderately [6], so it is not suitable by liquid-phase sintering. The clusions. Nevertheless, the most relevant investigations on iron
normal powder metallurgy (P/M) and even hot isotropic press sin- matrix composite in literature were carried out by the con-
tering both take a long time sintering more than 2 h and result in ventional processes to result in low mechanical properties and
heavy interface reaction between the SiC particles and the matrix the data have less applicability to compare each other. A sys-
[6,7]. The mechanical properties of the iron matrix composites tematical investigation is needed to establish such conclusions
reported in literature are not good because of the decomposition of using the advanced two-stage direct current heating technol-
SiC particles [3–7]. A dynamic temperature control direct current ogy.
heating technology based on our previous work has been devel- A number of theoretical models have been brought forth to dis-
oped, which makes the manufacture feasible and low cost with cuss the mechanical behaviors of particle-reinforced metal matrix
excellent properties due to less than 300 s short processing time composites [13–17]. Effective medium approximation model was
[8–10]. introduced to study the effects of particle size, size distribution
and volume fraction on the deformation response by comparing
the simulated and experimental stress–strain curves for SiC/Al
∗ Corresponding author. Tel.: +86 24 83681311; fax: +86 24 23906316. and Si/Al composite [15]. The Paul model, the Paul estimation
E-mail address: ypzong@mail.neu.edu.cn (B.Y. Zong). of modulus upper and lower bounds and the Halpin-Tsai model

0921-5093/$ – see front matter © 2010 Elsevier B.V. All rights reserved.
doi:10.1016/j.msea.2010.08.029
7546 J. Li et al. / Materials Science and Engineering A 527 (2010) 7545–7551

were proposed to predict the variation of the elastic modulus for means of optical microscopy and SEM with an energy spectrome-
graphite/Al and SiC/Al composite [16]. The Mori–Tanaka model, the ter.
two-phase self-consistent model and so on were developed to sim-
plify predictions of the monotonic uniaxial response of an isotropic 2.2. Model
particle-reinforced metal by calculating the stress–strain curves
of Al2 O3 /Al and Al/Al composites [17]. The particle-compounded Following Eshelby’s idea, based on the concept of mismatch
mechanical model based on Eshelby approach has been devel- strain between the reinforcing particles and the matrix during com-
oped to calculate load partition between reinforcements and matrix posite straining, the compliance tensor of the composite with two
during straining based on the load transfer mechanism [18–20]. random types of reinforcements, Cc−1 , can be derived [20]:
The model was used to simulate the stress–strain curves of SiC
particulate reinforced aluminum alloy matrix composites success- Cc−1 = Cm
−1
(I + fI QI (I + L) + f2 Q2 (I + L)), (1)
fully [18–20]. Such modeling on iron matrix composites is needed where QI = ((CI − Cm )SI + Cm )−1 (Cm − CI ), SI is the Eshelby ten-
to supply a theoretical analysis on experimental results by cal- sor of particle type 1, Q2 = ((C2 − Cm )S2 + Cm )−1 (Cm − C2 ),
culating stress in different reinforcing particles and stress–strain S2 is the Eshelby tensor of particle type 2,
curves. L = (I + fI (SI − I)QI + f2 (S2 − I)Q2 )−1 ( − fI (SI − I)QI − f2 (S2 − I)Q2 ), I
The purpose of the present work is to reveal the strength- is the unit matrix, fI and f2 are the volume fractions of two types
ening mechanisms of the iron matrix composites reinforced of particles respectively, CI , C2 and Cm are the stiffness tensors of
by different types of ceramic particles prepared by the direct particle type 1, type 2 and the matrix respectively. The composites
current heating technology. The SiC, TiC, Cr3 C2 and Ti(C, N) studied here have only one type of reinforcing particles, so f2 = 0
in the same size were chosen to study effect of differ- and C2 = 0 in this paper.
ent reinforcing particles and volume fraction (5%, 10% and Young’s modulus and Poisson ratio of both the reinforcing
15%) on properties of the composite. Modeling based on particles and the matrix are constant within elastic stage of the
ours previous work is carried out to explain experimental composite during tension so composite modulus can be calculated
results. by Eq. (1). However, when the plastic deformation takes place in
composite, that is the matrix begins to yield, the stress and strain
of the matrix is no longer linear relationship but may follow the
2. Materials and methods constitutive relation of measured matrix alloy stress–strain curve,
and the Young’s modulus and Poisson ratio of the matrix should be
2.1. Materials and experimental procedure substituted by secant ones. The secant modulus Es and the secant
Poisson ratio s of a material are defined as [18–20]:
The four types of SiC, Cr3 C2 , TiC and Ti(C, N) reinforcing
particles used in the experiment are all commercial pow- 1
Es = , (2)
der products with ≥99.85% purity rate. The average particle 1/E 0 + (ε̃p /(y + h(ε̃p )n ))
size of all the ceramic powders is 3 ␮m in commercial nomi- 1
1  Es
nal standard. The iron powder used is commercial deoxidized s = − − 0 , (3)
2 2 E0
powder of 98.68 wt.% purity, and the maximum C content is
0.015 wt.%. The average particle size of iron powder is 50.6 ␮m where ε̃p is the equivalent plastic strain, and it can be calculated
and 1 wt.% zinc stearate was added as caking agent and lubri- according to the equation ε̃p = ε − /E 0 in which ε and  are the
cant. flow strain and flow stress. (y + h(ε̃p )n ) is the flow stress, .
Each powder mixture was blended for 16 h and then com- The numerical secant modulus of matrix from experimental
pressed into a block of 60 mm × 30 mm × 10 mm in volume by tensile test curve of the matrix has been used to calculate the
240 MPa pressure. All the green compact blocks were sintered secant modulus of the composite at different strains by Eq. (1).
by a dynamic temperature control direct current heating tech- To begin with a small strain of the matrix, we set a strain incre-
nology, which has been developed in our laboratory with new ment of 0.001 and repeat the process so that one more point on
equipment adapted from a traditional hot pressing furnace [8–10]. the curve of the composite can be simulated. After a number of
Intense current passes the powder compacts directly by using repetitions, the stress–strain curve of the composite will be finally
ceramic dies in addition of a dynamic temperature control to simulated.
speed up the sintering for the purpose of avoiding the reaction The stress in the particles under the applied stress  0 is found
between reinforcements and the iron matrix. The pressure dur- out as [19]:
ing the sintering in this study was limited to 40 MPa according
I = m + I0 + ¯ I = 2Cm (I + (SI − I) QI ) (I + L) e0 , (4)
to the performance of the ceramic die and the sinter volts were
5 V. The sintering includes two stages, i.e. heating stage and hold- where e0 is the elastic strain of the matrix under the applied stress
ing stage. The heating up time of the first stage was 100 s and the  0 , eT is the transformation strain or eigenstrain, ec is the con-
holding time of the second stage was 200 s. The current was con- strained strain with ec = SI eT . Therefore, we can also calculate the
ducted for 1 s and broken for 1 s alternately during the holding load sharing of reinforcing particles during straining the composite.
stage. The model was applied to simulate the stress–strain curve of SiC
Tensile tests were performed at room temperature with a veloc- particulate reinforced aluminum alloy matrix composites [18–20]
ity of 0.3 mm/min and the specimens are of 28 mm gauge length formerly and shown a very good agreement with the measured
and 5 mm diameter. At least three tests were carried out on each curves. The model is used here for the iron matrix composites and
experimental datum. The extension to the tensile strength was will be compared with the experiment to check flexibility of the
measured from load–displacement curves. The tensile test was model. The modeling will be used to examine the effect of different
carried out on CCS electronical stretcher and both the extensome- reinforcing particles on improving the strength of the composite as
ter and the strain gauge were used in order to obtain whole a function of volume fraction to discuss the strengthening mecha-
stress–strain curves. Specimens were unloaded just after yield- nism.
ing and then reloaded until failure to measure elastic modulus The stress–strain curve of monolithic iron matrix is needed in
accurately. The microstructure of the composites was observed by order to simulate the stress–strain curves of the composites. There-
J. Li et al. / Materials Science and Engineering A 527 (2010) 7545–7551 7547

Fig. 2. Comparison of yield strength between modeling and experiments: (a) by


Fig. 1. Comparison of the stress–strain curves between modeling and experiments:
experiment and (b) by modeling.
(a) for TiC/Fe and Ti(C, N)/Fe composites and (b) for SiC/Fe and Cr3 C2 /Fe composites.

ment between the modeling and the experiment tells us that load
fore, a monolithic iron matrix alloy was prepared by the same
sharing of the reinforcements is the chief strengthening mecha-
processing as for the composites. The stress–strain curve of the
nism of those composites. However, the experimental stress–strain
alloy was obtained from tensile test and is shown in Fig. 1(b). The
curves of the composites reinforced by SiC and Cr3 C2 particles are
0.2% proof stress and Young’s modulus of the iron matrix alloy
both much higher than the curves predicted by modeling shown
are 422 MPa and 168 GPa respectively by tensile test and used in
in Fig. 1(b). This suggests that better strengthening effect of the SiC
the modeling. The elastic properties of the reinforcements are tab-
and Cr3 C2 ceramic particles comes not from their good elastic prop-
ulated in Table 1, which are used for the present modeling. The
erties that the modeling takes account for but may come from their
Poisson ratio of the iron matrix is taken as 0.28 [21] and the aspect
good mechanical properties and better chemical properties to the
ratio of all the reinforcing particles is selected as 1.2 approximately
iron matrix. The much higher stress–strain curves of the compos-
according to the microstructure observation.
ites than the predictions indicate that the reinforcements are not
only to share load from the matrix but also to increase the strength
3. Results
of the matrix.
Fig. 2 shows the comparison of the yield strength between
Comparison of the stress–strain curves between modeling and
modeling and experiment for the composites. The experimental
experiments for the composites reinforced by different types of
data in Fig. 2(a) indicates the SiC reinforcing particles having the
ceramic particles is shown in Fig. 1 and the volume fraction of
strongest effect on improving the yield strength among the other
reinforcements is 10% for all the composites. It is shown that the
reinforcements. This can offer a very significant reference for the
curves of TiC/Fe and Ti(C, N)/Fe composite predicted by the model-
development of particulate reinforced iron matrix composite and is
ing agree well with the corresponding experimental curves shown
first reported in literature. The Cr3 C2 reinforcements also present
in Fig. 1(a). This is a quite cheerful result to prove the great flexi-
a good strengthening effect over the TiC and Ti(C, N) reinforcing
bility of the Eshelby mean field model, which we have only proved
particles. However, the modeling results show a very small differ-
its affectivity for aluminum matrix composites before. The agree-
ence between the four types of reinforcement shown in Fig. 2(b)
and even expose the best effect of Ti(C, N) owing to its highest
Table 1 elastic modulus over the others. This suggests that the mechan-
Elastic properties of the reinforcements used in present modeling.
ical, chemical or physical properties of reinforcing particles may
Reinforcement Young’s modulus (GPa) Poisson ratio Reference play very important roles on strengthening the composite. It can be
SiC 450 0.17 [18] found out in Table 2 that SiC reinforcing particles have higher frac-
Cr3 C2 380 0.24 [21] ture toughness than the other three reinforcing particles, as well
TiC 438 0.19 [21] as higher hardness. These two factors probably make SiC the best
Ti(C, N) 525 0.21 [22]
reinforcement type in iron matrix.
7548 J. Li et al. / Materials Science and Engineering A 527 (2010) 7545–7551

Table 2
Mechanical and physical properties of the different types of reinforcing particles used in present study.

Reinforcing particles Fracture toughness Hardness (HV) Electrical resistivity Melting point (◦ C) Coefficient of Reference
(MPa m1/2 ) (×10−6  m) thermal expansion
(×10−6 K−1 )

SiC 4.8 3000–3500 5.3 2700 4.0 [21,23]


Cr3 C2 4.6 2700 5.64 1895 10.3 [21,23]
TiC 4.5 2900–3200 1.8 3200 7.4 [21,24]
Ti(C, N) 4.5 1800–2100 0.334 3000 6.8 [21,22,24]

It is surprisingly noticed that the yield strength of four compos- and experiment. The successful prediction of the modeling on the
ites all demonstrates a same phenomenon of maximum value at modulus implies the load sharing nature of the reinforcements in
volume fraction of 10% by experiment shown in Fig. 2(a) whereas the composites during straining. However, it can be seen if with
the yield strength of the four composites all increases continu- a careful examination of Fig. 3 that the modulus value of the com-
ously with the increase of reinforcement volume fraction linearly posites by experiment comes a series of SiC/Fe, Cr3 C2 /Fe, TiC/Fe and
by modeling shown in Fig. 2(b). The discrepancy here suggests not Ti(C, N)/Fe from high to low whereas the modeling gives the series
only a further strengthening mechanism apart from load sharing in a consequence of Ti(C, N)/Fe, SiC/Fe, TiC/Fe and Cr3 C2 /Fe. The
in the composites but also the complexity in effects of process- affectivity of different reinforcements on stiffness of the compos-
ing procedures upon the property. A most possible explanation ite predicted by modeling goes wrong in the series, which suggests
may rely on that there are some micro-voids in the composites that the stiffness of the composites is not depended on elasticity of
if the volume fraction is higher than 15%, which would result in a reinforcement but on the bond condition with the matrix because
fracture mechanism of the composite instead of yielding failure to the yield strength of the composites comes the same series as the
lead to a strength abrupt drop. This needs a further observation of stiffness both in experiment.
microstructure to provide evidence in next section later. The influence of reinforcement type and volume fraction on ten-
The comparison of Young’s modulus between modeling and sile strength of iron matrix composites by experiment is shown
experiments for the composites is given in Fig. 3. Young’s modulus in Fig. 4(a). It is apparent that the trend of tensile strength as a
of the composites by the modeling agrees well with the experi- function of reinforcement volume fraction as well as types of rein-
ments for all the four composites as a function of volume fraction. forcing particles is similar to that observed for the yield strength.
The modulus of the composites increases with increasing volume The Vickers hardness values of the composites by experiment are
fraction of reinforcing particles monotonously both in modeling given in Fig. 4(b). The hardness shows general same phenomena

Fig. 3. Comparison of Young’s modulus between modeling and experiments: (a) by Fig. 4. Influence of reinforcement type and volume fraction on the tensile strength
experiment and (b) by modeling. and hardness of the composites by experiment: (a) tensile strength and (b) hardness.
J. Li et al. / Materials Science and Engineering A 527 (2010) 7545–7551 7549

modulus, which implies that Young’s modulus of reinforcement


plays an important role in transferring load from matrix to the rein-
forcing particles. Moreover, stress in particles begins to decrease as
the increase of volume fraction of the reinforcement. These imply
that load transfer from matrix to reinforcing particles by mismatch
strain depends more on particle elastic features.
It is also revealed in Fig. 5 that the contribution of the four exam-
ined different reinforcements to load sharing is nearly the same
owing to their close value of elastic modulus each other. However,
Fig. 2(a) by experiment presents that the composites with different
types of reinforcements make the strength remarkably various and
the SiC/Fe has the highest strength rather than Ti(C, N)/Fe predicted
by the modeling. Therefore, the different effects of the four types of
reinforcements on composite strength are not due to the difference
of elastic properties of the reinforcements each other. And, even the
mechanical properties of the reinforcements may only play a minor
role on the strength because the stress level in the different rein-
forcements predicted by the modeling is not high enough to break
them at the yielding point of the composites. These suggest that the
effect of different reinforcements must rely on their different roles
made to the matrix and we will discuss that later by microstructure
observation.

4.2. Distribution of reinforcing particles

The tensile and yield strengths of all the four composites


demonstrate a remarkable drop at the volume fraction of 15% by
experiment shown both in Fig. 4(a) and Fig. 2(a), whereas the
yield strength of all the composites increases continuously with
the increase of the volume fraction linearly by modeling shown in
Fig. 2(b). An explanation may rely on that there are many micro-
voids in the composites at the high volume fraction, which would
Fig. 5. Stress in the reinforcing particles as a function of (a) volume fraction and (b)
result in a fracture mechanism instead of yielding to lead to a
Young’s modulus of reinforcement by modeling.
strength abrupt drop. The micro-voids may be resulted from clus-
ters of reinforcing particles, which are reported to deteriorate the
as the tensile strength, i.e. high tensile strength is generally consis- properties of materials by serving as sites for stress localization and
tent with high hardness. However, Cr3 C2 particles demonstrate the crack initiation [12].
strongest effect in improving hardness of the composite over the Typical microstructure of the iron matrix composites reinforced
other ceramic particles but the SiC particles have the best effect by SiC and Ti(C, N) particles is presented in Fig. 6 to show the rein-
in tensile strength. The high tensile strength is more difficult to forcement distribution. It can be seen that the distribution of SiC
achieve so that SiC particles can still be concluded as the best rein- and Ti(C, N) particles varies with different reinforcement volume
forcement in present study. fractions. The reinforcements with the low volume fractions dis-
tribute uniformly whereas in the composites with high volume
4. Discussion fraction of 15 vol.%, the reinforcement distribution is uneven with
numbers of clusters. The reinforcement clusters may produce local
4.1. Stress in reinforcing particles stress intensity to induce premature local yielding and even grad-
ually result in micro-voids to lower the strength of the composites
Our modeling reveals a good agreement with experiment for during straining. Therefore, the strength of the composites will
two composites but not for the other two composites. However, increase as the increase of volume fraction to reach a maximum
modeling work here is not really intended to meet experiment but value at 10% and then drops to a low value at the fraction of 15%
to understand strengthening mechanism and to examine the fac- only at which the reinforcements form many clusters.
tors that influence the strength. The present model is based on the
load sharing mechanism so that the stress in the reinforcing parti- 4.3. Effect of reinforcement on increase of matrix strength
cles need to be calculated to reveal the effect of different types of
reinforcements theoretically as a function of the volume fraction. The most significant result of present study is to reveal the effect
The stress in particles at yield point of the composites in differ- of different types of reinforcements on strength of iron matrix com-
ent reinforcing particles is calculated by the modeling, as illustrated posites shown in Fig. 2(a) and Fig. 4(a). It has been demonstrated
in Fig. 5(a). An important fact is that the average stress in the par- that SiC reinforcing particles have the strongest effect in improv-
ticles predicted by modeling decreases with the increase of the ing the strength, and Cr3 C2 , TiC and Ti(C, N) come next in a series of
volume fraction given in Fig. 5(a), but the strength of the compos- the effectiveness from strong to weak. The microstructure observa-
ites is improved gradually. Besides, there is no significant difference tions were carried out to find the reason because previous modeling
in average stress in the different types of reinforcing particles. suggests a strengthening mechanism on the matrix.
Fig. 5(b) illustrates the average stress in particles at yield point Fig. 7 illustrates the microstructure of the iron matrix com-
of composites as a function of the reinforcement Young’s modulus posites reinforced by different reinforcing particles at the volume
by the modeling. It can be seen that the stress in particles with dif- fraction of 10% for example to expose details of the matrix espe-
ferent volume fraction increases with the increase of the Young’s cially. It can be seen that the TiC and the Ti(C, N) particles have no
7550 J. Li et al. / Materials Science and Engineering A 527 (2010) 7545–7551

Fig. 6. Microstructure of iron matrix composites reinforced by SiC and Ti(C, N) particles with different volume fractions, respectively: (a) 5 vol.% SiC, (b) 10 vol.% SiC, (c)
15 vol.% SiC, (d) 5 vol.% Ti(C, N), (e) 10 vol.% Ti(C, N), and (f) 15 vol.% Ti(C, N).

Fig. 7. Microstructure of the iron matrix composites reinforced by different types of reinforcing particles: (a) 10%TiC/Fe, (b) 10%Ti(C, N)/Fe, (c) 10%Cr3 C2 /Fe, and (d) 10%SiC/Fe.

reaction with the iron matrix to leave a pure Ferrite microstructure SiC/Fe composite to have a higher strength over the Cr3 C2 /Fe com-
shown in Fig. 7(a) and (b), whereas the Cr3 C2 and the SiC particles posite to become the best composites among the investigated four
take a slight reaction with iron to form some Pearlite in the matrix composites.
shown in Fig. 7(c) and (d). The Pearlite + Ferrite matrix has much
higher strength than the pure Ferrite matrix [25] so that the SiC/Fe 5. Conclusions
and Cr3 C2 /Fe composites should have much higher strength than
the TiC/Fe and Ti(C, N)/Fe composites. Moreover, the SiC/Fe com- (1) SiC reinforcing particles show the strongest effect on improving
posite in Fig. 7(d) has more Pearlite in the matrix than the Cr3 C2 /Fe strength of the iron matrix composite compared with the other
composite shown in Fig. 7(c). The SiC has higher fracture tough- three types of Cr3 C2 , TiC and Ti(C, N) reinforcements experi-
ness than the Cr3 C2 (please see Table 2). These two factors help the mentally. The reason may rely on that SiC has higher fracture
J. Li et al. / Materials Science and Engineering A 527 (2010) 7545–7551 7551

toughness and hardness as well as a limited decomposition to Innovative Research Team in University (IRT0713) is also acknowl-
increase matrix strength. edged.
(2) The strength of all the four composites reinforced by different
ceramic particles presents a maximum value at 10% volume References
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50471024, and support from Program for Changjiang Scholars and

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