Research Papers

Fabrication of Aluminum–SiC Laminate Nanocomposite by Ultrasonic Spray Deposited Sheet Bonding1

[+] Author and Article Information
Mina Bastwros

Department of Mechanical Engineering,
Iowa State University,
2034 H.M. Black Engineering,
Ames, IA 50011
e-mail: minamhb@iastate.edu

Gap-Yong Kim

Department of Mechanical Engineering,
Iowa State University,
2034 H.M. Black Engineering,
Ames, IA 50011
e-mail: gykim@iastate.edu

Paper presented at the 2014 ASME International Manufacturing Science and Engineering Conference (MSEC), Detroit, MI, June 9–13, 2014, Paper No. MSEC2014-3998.

2Corresponding author.

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MICRO- AND NANO-MANUFACTURING. Manuscript received October 19, 2014; final manuscript received May 27, 2015; published online June 25, 2015. Assoc. Editor: Don A. Lucca.

J. Micro Nano-Manuf 3(3), 031005 (Aug 01, 2015) (8 pages) Paper No: JMNM-14-1070; doi: 10.1115/1.4030705 History: Received October 19, 2014; Revised May 27, 2015; Online June 25, 2015

One of the challenges in making layered metal composites reinforced at interfaces has been controlling the dispersion and microstructure of the reinforcement particles. The reinforcement elements are typically applied at the interface by manual spreading using brush or by immersing the substrate in a suspension. In this study, an ultrasonic spraying technique has been used to deposit silicon carbide (SiC) nanoparticles on aluminum 6061 (Al6061) substrate foils to fabricate a laminate metal composite to control the deposited structure. The suspension parameters and the spraying parameters were investigated, and their influence on the deposited microstructure was analyzed. The laminate composite was consolidated using hot compaction, and a three-point bend test was performed to evaluate the mechanical properties. The yield and ultimate flexural strengths of the laminate composite reinforced with SiC nanoparticles increased by 32% and 15%, respectively, compared with those of the unreinforced sample prepared at the same condition.

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Fig. 1

Ultrasonic spray deposition system

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Fig. 2

Overview of the spraying process

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Fig. 4

The effect of SiC loading and particle size on the surface tension of ethanol–SiC suspension system

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Fig. 3

Experimental setup for semisolid powder processing

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Fig. 9

Effect of temperature change on the deposition structure with spraying condition at Q = 0.25 ml/min, D = 25 mm, and P = 0.24 kPa

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Fig. 8

Effect of flow rate change on the deposition structure with spraying condition at T = 300 °C, D = 25 mm, and P = 0.24 kPa

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Fig. 7

Single droplets deposited by single spray pass

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Fig. 6

Prediction of the droplet size from the atomization using different atomization frequencies

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Fig. 5

Prediction of the droplet size from the atomization

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Fig. 11

Effect of spraying distance change on the deposition structure with spraying condition at T = 300 °C, Q = 0.24 ml/min, and P = 0.24 kPa

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Fig. 10

Effect of air pressure change on the deposition structure with spraying condition at T = 300 °C, Q = 0.24 ml/min, and D = 25 mm

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Fig. 12

Effect of SiC loading on the flexural stress–strain curves

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Fig. 13

SEM images of SiC reinforcement layer on the fracture surfaces of (a) Al6061–0.3 wt. % SiC composite and (b) Al6061–0.6 wt. % SiC composite

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Fig. 14

SEM images of Al6061 layer on the fracture surfaces of (a) Al6061–0.3 wt. % SiC composite and (b) Al6061–0.6 wt. % SiC composite

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Fig. 15

SEM images of reinforcement layer on the fracture surfaces of (a) Al6061–0.3 wt. % SiC composite and (b) Al6061–0.6 wt. % SiC composite



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