An experimental determination of optimum processing parameters for Al/SiC metal matrix composites made using ultrasonic consolidation

Ultrasonic consolidation, an emerging additive manufacturing technology, is one of the most recent technologies considered for fabrication of metal matrix composites (MMCs). This study was performed to identify the optimum combination of processing parameters, including oscillation amplitude, welding speed, normal force, operating temperature, and fiber orientation, for manufacture of long-fiber-reinforced MMCs. A design of experiments approach (Taguchi L25 orthogonal array) was adopted to statistically determine the influences of individual process parameters. SiC fibers of 0.1 mm diameter were successfully embedded into an Al 3003 metal matrix. Push-out testing was employed to evaluate the bond strength between the fiber and the matrix. Data from push-out tests and microstructural studies were analyzed and an optimum combination of parameters was achieved. The effects of process parameters on bond formation and fiber/matrix bond strength are discussed.

[1]  R. Roy.  A Primer on the Taguchi Method , 1990 .

[2]  J. Eldridge,et al.  Investigation of interfacial shear strength in a SiC fibre/Ti-24Al-11Nb composite by a fibre push-out technique , 1989 .

[3]  C. Chao,et al.  Effects of carbon fiber/Al interface on mechanical properties of carbon-fiber-reinforced aluminum-matrix composites , 2004 .

[4]  D. White.  Ultrasonic consolidation of aluminum tooling , 2003 .

[5]  N. Chandra,et al.  ANALYSIS OF INTERFACIAL BEHAVIOR IN MMCs AND IMCs BY THE USE OF THIN-SLICE PUSH-OUT TESTS , 1995 .

[6]  Charalabos C. Doumanidis,et al.  Mechanical modeling of ultrasonic welding , 2004 .

[7]  Phill Dickens,et al.  Optimum process parameters for ultrasonic consolidation of 3003 aluminium , 2004 .

[8]  Rupert Soar,et al.  Method for embedding optical fibers in an aluminum matrix by ultrasonic consolidation. , 2005, Applied optics.

[9]  D. Marshall,et al.  Measurement of Interfacial Mechanical Properties in Fiber‐Reinforced Ceramic Composites , 1987 .

[10]  Rupert C. Soar,et al.  Characterisation of aluminium alloy 6061 for the ultrasonic consolidation process , 2003 .

[11]  P. Withers,et al.  An introduction to metal matrix composites , 1993 .

[12]  R. C. Soar,et al.  Ultrasonic consolidation for embedding SMA fibres within aluminium matrices , 2004 .

[13]  C. Robinson,et al.  Improving Linear Weld Density in Ultrasonically Consolidated Parts , 2006 .

[14]  Rupert C. Soar,et al.  Fabrication of metal-matrix composites and adaptive composites using ultrasonic consolidation process , 2005 .

[15]  Yuan Gao,et al.  Mechanical Analysis of Ultrasonic Bonding for Rapid Prototyping , 2002 .