Mechanical properties and tribological behavior of aluminum matrix composites reinforced with Fe-based metallic glass particles: Influence of particle size

Journal Pre-proof Mechanical properties and tribological behavior of aluminum matrix composites reinforced with Fe-based metallic glass particles: Influence of particle size

Tianbing He, Tiwen Lu, Nevaf Ciftci, Hui Tan, Volker Uhlenwinkel, Kornelius Nielsch, Sergio Scudino PII:

S0032-5910(19)31048-4

DOI:

https://doi.org/10.1016/j.powtec.2019.11.088

Reference:

PTEC 14970

To appear in:

Powder Technology

Received date:

8 July 2019

Revised date:

12 November 2019

Accepted date:

25 November 2019

Please cite this article as: T. He, T. Lu, N. Ciftci, et al., Mechanical properties and tribological behavior of aluminum matrix composites reinforced with Fe-based metallic glass particles: Influence of particle size, Powder Technology(2019), https://doi.org/ 10.1016/j.powtec.2019.11.088

This is a PDF file of an article that has undergone enhancements after acceptance, such as the addition of a cover page and metadata, and formatting for readability, but it is not yet the definitive version of record. This version will undergo additional copyediting, typesetting and review before it is published in its final form, but we are providing this version to give early visibility of the article. Please note that, during the production process, errors may be discovered which could affect the content, and all legal disclaimers that apply to the journal pertain.

© 2019 Published by Elsevier.

Journal Pre-proof

Mechanical properties and tribological behavior of aluminum matrix composites reinforced with Fe-based metallic glass particles: Influence of particle size

Tianbing He

a, *

, Tiwen Lu

a, b

, Nevaf Ciftci c, Hui Tand, Volker Uhlenwinkel

c, e

, Kornelius Nielsch

, Sergio Scudino

a, *

a

Leibniz IFW Dresden, Institute for Complex Materials, 01069 Dresden, Germany

b

Guangdong Key Laboratory for Advanced Metallic Materials Processing, South China University

of Technology, Guangzhou, Guangdong 510640, China

oo

f

h

f, g,

Leibniz Institute for Materials Engineering IWT, 28359 Bremen, Germany

d

State Key Laboratory of Solid Lubrication, Lanzhou Institute of Chemical Physics, Chinese

Pr

Academy of Sciences, Lanzhou 730000, China

e-

pr

c

University of Bremen, Faculty of Production Engineering, 28359 Bremen, Germany

f

Leibniz IFW Dresden, Institute for Metallic Materials, 01069 Dresden, Germany

g

TU Dresden, Institute of Materials Science, 01062 Dresden, Germany

h

TU Dresden, Institute of Applied Physics, 01062 Dresden, Germany

*

Corresponding authors

Jo u

rn

al

e

Tel: +49 351 4659714, E-mail address: [email protected]; [email protected] (Tianbing He)

Tel: +49 351 4659838, E-mail address: [email protected] (Sergio Scudino)

Abstract Aluminum matrix composites consisting of Al2024 and Fe-based metallic glass powders were prepared via powder metallurgy by using an optimized matrix to reinforcement particle size ratio, the influence of glassy particle size on mechanical properties and dry sliding wear behavior of the composites were investigated. The composites showed dense structure and homogenous three-dimensional distribution of the reinforcements independent of particle size. The particle size 1

Journal Pre-proof has negligible influence on yield strength, while ultimate tensile strength and ductility gradually decrease with increasing particle size. Reduced specific wear rate was observed when particle size increases, most likely because of the evolution of the surface topography during sliding where the wear of matrix is protected when particles are large.

Keywords: Aluminum matrix composite (AMC); Metallic glass (MG); Particle size; Mechanical

f

property; Dry sliding wear

oo

1 Introduction

pr

Using metallic particles as reinforcements in light weight metal matrix composites has attracted increasing attention in recent years. For reinforcements such as intermetallics [1, 2], quasicrystallines

e-

[3, 4], metallic glasses [5, 6] and high entropy alloys [7, 8], a better interface compatibility can be

Pr

achieved compared to traditional ceramic reinforcements. Moreover, metallic reinforcements own functional properties (e.g. shape memory effect, magnetic properties) can be utilized to design and

al

fabricate intelligent composites [9-12]. Metallic glasses exhibit ultra-high strength, hardness, as well

rn

as good wear and corrosion resistance [13], which are promising candidates for the strengthening of aluminum and magnesium matrixes [6, 14]. A variety of reports have indeed shown the remarkable

particles [5, 15-18].

Jo u

strengthening effect achieved in these composites by adding Ni-, Zr-, Al-, Mg- or Fe-based glassy

The particle size has a great influence on the composite properties. Previous studies in ceramic reinforced composites show enhanced strength with decreasing reinforcement particle size under the prerequisite of a homogenous microstructure, since particle agglomeration usually degrade the properties [19, 20]. Another important aspect is the particle size ratio between the matrix and reinforcement: ratios close to one ensure a homogeneous distribution of the reinforcement [21-23], otherwise techniques like high energy ball milling, chemical assisted dispersion is usually required [24]. The reports on the effect of particle size on the tribological behavior of metal matrix composites are not univocal. Conflicting results show a lower wear rate [25-28], higher wear rate [29, 30] with

2

Journal Pre-proof increasing reinforcement particle size or even negligible influence of particle size [31] under dry sliding wear conditions. As a class of promising reinforcements, previous studies on aluminum matrix composites reinforced with metallic glass particles were focused on the effect of different metallic glasses, and the characterization of mechanical properties were mostly under compressive load. In addition, there is rather limited information regarding the tribological behavior for this type of composites. Our recent results showed that a uniform distribution of Zr-based glassy reinforcements can be obtained

f

with a matrix to reinforcement particle size ratio ranging from 1/3 to 3 [32]. In this work, we

oo

continue our investigation on Al-based composites reinforced with metallic glass particles by

pr

synthesizing composites consisting of an Al2024 matrix and Fe 43.2 Co28.8 B19.2Si4.8 Nb4 glassy reinforcement. Tuning the particle size ratio with reported optimum range was made by altering the

e-

Fe-based glassy particle size and keeping the Al2024 aluminum powder constant. The effect of

Pr

particle size on microstructure, tensile properties and dry sliding tribological behavior of the

rn

2 Material and methods

al

composites have been systematically studied.

Al2024 aluminum alloy powder with a mass median particle diameter of 42 μm was used as the

Jo u

matrix. The composition of Al2024 is shown in Table 1. Fe 43.2 Co28.8B19.2Si4.8 Nb4 (at.%) metallic glass powder was synthesized via argon gas atomization (for details, see [33, 34]) and subsequently air-sieved into following particle size classes: 0 – 20 μm, 20 – 45 μm, 45 – 63 μm and 63 – 90 μm. The corresponding mass median particle diameters were measured with a laser diffraction system (Malvern, Mastersizer 2000) and detected to be 16, 30, 49 and 72 μm, respectively. Powder mixing was conducted by ball milling using a Retsch PM 400 planetary mill equipped with hardened steel vials and balls. Al2024 powder and 20 vol.% of Fe-based glassy particles with different sizes were filled into the vials and sealed in a glove box (Braun MB 150B-G) under argon atmosphere with O 2 and H2 O less than 0.5 ppm. Ball milling was proceeded for 2 hours at 100 rpm with a ball to powder mass ratio of 10:1. No process control agent was used. Composite powder consolidation was carried out via hot pressing at 723 K (holding time 10 min and pressure 640 MPa) followed by hot extrusion 3

Journal Pre-proof with an extrusion ratio of 9:1 at the same temperature. For comparison, Al2024 aluminum powder was also hot pressed and extruded with the same parameters. Phase characterization was made by X-ray diffraction (XRD) using a Philips PW 1050 diffractometer with Co Kα radiation source operating at 40 kV and 40 mA. Scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDS) (Zeiss Gemini 1530) was used to investigate the microstructures and phase composition. The 3-dimensional reinforcement distribution was characterized via X-ray computed tomography (micro-CT) with a GE phoenix

f

Nanotom device operated at 120 kV, 100 μA and 750 ms detector timing. The obtained radiographic

oo

images with a spatial resolution of 3.08 μm were reconstructed using the VG Studio Max 2.2

pr

software. The density of the bulk samples was measured using the Archimedes principle. Tensile tests were performed at room temperature using an Instron 5869 testing machine with strain rate of 1

e-

× 10-4 s-1 . The specimens, fabricated from extruded rods, had a cylindrical dog-bone shape with

Pr

gauge length of 12.5 mm and 2.5 mm in diameter [32]. At least 3 samples were tested to ensure the repeatability of the results.

al

Tribological properties of unreinforced alloy and composites were examined by pin-on-disc wear test using a Nanovea tribometer. The pins were produced from extruded rods with a diameter of 3

rn

mm and length of ~25mm. The end face used to test was grinded with P4000 SiC paper to ensure a

Jo u

conformal contact [35]. X210Cr12 steel (C 1.9-2.2, Cr 11-13, Mn 0.2-0.6, Si 0.1-0.6, P and S ≤ 0.03, Fe balance, wt.%) with a hardness of 60 HRC and initial surface roughness Ra ≤ 3.2 μm was used as the rotating counterface. The wear tests were performed at a load of 15N, a sliding speed of 0.5 m/s and a distance 5000 m. The friction coefficient between specimen and disc was recorded simultaneously by the tribometer. Before and after test, the pin was cleaned in ethanol using an ultrasonic device, and weighed carefully utilizing a precise balance with an accuracy of 0.01 mg. The weight loss was converted to volume loss according to ASTM G99 via the known density of each sample, and the specific wear rate was calculated. Three samples were tested for each composition.

4

Journal Pre-proof

3 Results and discussion 3.1 Microstructure Fig. 1 shows the morphology of the composite powder mixtures with different glassy particle sizes. Reinforcement clusters cannot be observed and the glassy particles (light gray) are well-distributed among the aluminum powder (dark gray). Some large aluminum particles are slightly flattened although the milling conditions used were rather mild and cold welding did not occur. The Fe-based glassy particles mainly retain their as-atomized spherical shape, except for a few

oo

f

that fractured when the particle size increased to 72 μm.

The XRD patterns of the as-atomized Fe-based glassy powder, the composite powder, the hot

pr

extruded Al2024 unreinforced alloy and composites are presented in Fig. 2. The Fe-based glassy

e-

particles exhibit the broad diffraction maximum at 2θ = 52.5°, characteristic for the amorphous structure. After mixing with the Al2024 powder, the XRD pattern shows sharp Bragg peaks which

Pr

correspond to FCC aluminum superimposed on the broad maximum of the glassy phase. The XRD pattern of the hot extruded bulk composites display Bragg peaks of FCC Al along with a few

al

additional diffraction peaks corresponding to Al2 Cu and Al2 CuMg phases. The Al2 Cu and Al2 CuMg

rn

phases were precipitated from the Al2024 alloy during hot pressing and extrusion. No other peaks

Jo u

can be detected except for the above, suggesting that the amorphous state of the glassy particles was maintained in the hot extruded composites. The microstructure of the hot extruded composites with different glassy particle sizes is presented in Fig. 3 and 4. The SEM images show no detectable porosity, indicating a high density of the samples. Glassy particles are well-dispersed in the Al2024 matrix which are independent of the size. The inset in Fig. 3(a) shows a sharp interface without any visible reaction products between the matrix and glassy phase, which is consistent with the XRD results. Fig. 4 displays the micro-CT 3D views of the composites where the 3-dimensional distribution of the reinforcements can be clearly seen. Although the size of the glassy particles increases from 16 μm to 72 μm, all the composites have a homogenous distribution of glassy particles. In this work, the matrix to reinforcement particle size ratio is 2.65 to 0.58 (corresponding to the increase of the glassy particle size from 16 μm to 72 μm), which is located in the reported optimum range (1/3 to 3) [32, 36]. 5

Journal Pre-proof 3.2 Mechanical properties Fig. 5(a) shows the representative stress-strain curves of hot extruded Al2024 alloy and composites with different particle sizes. The corresponding tensile properties are summarized in Table 2. When the size of the glassy particle increases, the ultimate tensile strength (UTS) and fracture elongation of the composites gradually decrease while the yield strength (YS) shows insignificant change. All the composites show a remarkable improvement of yield strength when compared with the Al2024 alloy (from 181 MPa to about 215 MPa). Anomalous serrations are

oo

f

observed in the stress-strain curves for the Al2024 alloy and composites. Such effect was also reported in Markó et al. where Al2024 and Fe49.9 Co35.1Nb7.7B4.5Si2.8 metallic glass particles were

pr

utilized to fabricate composites [18]. This kind of discontinuous deformation usually appears in aluminum alloys with Mg as the primary alloying element (the 5××× series) [37]. The reason for

e-

such behavior in the present matrix composition is not yet clear and we assume that it may be the

Pr

result of the dynamic interactions between mobile solute atoms and dislocations [37]. Fig. 6 shows the tensile fracture morphology of the hot extruded Al2024 alloy and composites with particle size of

al

16 μm and 72 μm. The Al2024 unreinforced alloy presents small and homogenous dimples on the

rn

fracture surface and second phase particles (Al2 Cu or Al2 CuMg) in the center of the dimples (Fig. 6(b)), suggesting a typical ductile fracture mode. The dimples become shallower for larger particles

Jo u

in the fracture surface of composites with particle size of 16 μm and 72 μm, which is associated with the reduced ductility. In addition, particle fracture and interface debonding become noteworthy (Fig. 6(e)).

Many studies report that the yield strength of composites increases with a decreased reinforcement particle size, mainly because of the decreasing interparticle distance [19, 20, 38]. However, predictions also show that the stress-strain behavior of composites is only slightly dependent on the reinforcement particle size when it is large (e.g. >10 μm), and the mechanical behavior is dominated in this case by continuum plasticity (this concept considers load-sharing in composites but ignores dislocation effects). Dislocation strengthening dominates when particle size is small (e.g. <0.5 μm) and both the above mechanisms play a significant role on the deformation response of composites when the particle size is in the intermediate range [19]. In this research, the 6

Journal Pre-proof median particle size ranging from16 μm to 72 μm, which is in agreement with the theoretical predictions. Previous studies on pure aluminum reinforced with Zr-based glassy particles also reported that both compressive and tensile yield strength were not significantly affected when the particle size increased from 35 to 75 μm [32]. Actually, since a large number of second phases (Al2 Cu and Al2 CuMg) which are considerably smaller than the Fe-based glassy particles exist in the present Al2024 matrix (denoted by arrows in Fig. 3 (a) and Fig. 6(b)), the microstructural length scale which determines the deformation behavior of the composites is mainly the distance between

f

second phase particles. In other words, the influence of Fe-based particle size on yield strength is

oo

further impaired when its size is much larger than second phases in the matrix alloy.

pr

Since the Fe-based glassy particles are brittle and the Al2024 matrix is ductile, the former is not able to accommodate the large plastic strain of the matrix during deformation, and consequently,

e-

microcavities are nucleated at the particle/matrix interface or the brittle particles will break [39].

Pr

When the particle size is large, the formation of microcavities around the interface can be increased, easier for void growth and coalescence, resulting in interfacial separation (Fig. 6 (e) and (f)). There is

al

also a relationship between increasing particle size and tendency for particle fracture: the larger the particle size, the higher the proportion of broken particles at any given strain [19, 40]. The

rn

particle/matrix interfacial debonding and particle fracture lead to the decrease of flow stress, which

Jo u

lowers the tangent modulus, and results in earlier mechanical instability (the point of intersection of the true stress and tangent modulus curve in Fig. 5(b)). Secondly, the decrease of flow stress due to interface debonding and particle fracture can be larger than the increase in flow stress due to dislocation strengthening. Thus, the decrease of both ductility and ultimate tensile strength with increasing particle size (Fig. 5 and Table 2) can be rationalized. 3.3 Dry sliding behavior Fig. 7(a) shows the specific wear rate of hot extruded Al2024 alloy and composites with different glassy particle sizes. No significant difference of wear rate is observed between Al2024 alloy and composites with glassy particle size up to 49 μm (about 3 × 10-5 mm3 /mN under the present test conditions). The sharp decrease of wear rate (1.5 × 10-5 mm3 /mN) is found with the particle size of 72 μm. It is noteworthy that displaced metal was accumulated at the outer edge of the pin samples 7

Journal Pre-proof as shown in Fig. 7(b), which leads to an unrealistic mass loss (i.e. volume loss and specific wear rate) for the corresponding specimens. Nevertheless, one can readily find that the Al2024 alloy exhibits the largest amount of adhesive metal, followed by the composites with a particle size of 16 and 30 μm, and is negligible for the other specimens. The accumulation of displaced metal is ascribed to the soft and ductile of the samples, and the formation mechanism is thought to be similar with the wedge formation between sliding surfaces which occur in a variety of ductile metals [41]. When two flat metal surfaces are placed in contact under a normal load, a number of adhesive junctions are formed

f

at different places between them. The junctions do not break when the surface begin to slide, instead,

oo

they remain welded together and the relative motion of the sliding is accommodated by the plastic

pr

deformation of the metal near junctions, thus the plastic shearing of this metal takes place. The sheared metal transfers to the counterface or flows along the sliding direction and adheres to the front

e-

edge of the pin, while the excess transferred metal on the counterface will also be arrested by the rear

Pr

edge of the pin during next sliding, causing the accumulation of displaced metal around the pin edge. A schematic of the formation of displaced metal is shown in Fig. 8. Intrinsically, the formation of

al

displaced metal in Al2024 alloy and composite with smaller particle size may can also be regarded as occurrence of adhesion-initiated catastrophic wear [42]. Therefore, it can be found that all the

rn

composites have better wear resistance compared to the unreinforced Al2024 alloy, and the wear

Jo u

resistance increases with increasing glassy particle size. This agrees with most of the reported publications when micro-sized reinforcements were used. The worn surfaces and wear debris were further scrutinized to understand the wear mechanisms (Fig. 9). The Al2024 alloy exhibits worn surface with parallel scratch grooves together with large craters along the sliding direction (Fig. 9(a)), indicating the occurrence of both abrasive and adhesive wear. Asperities on the hardened steel counterface or hard particles (like oxides, as discussed later) in between the pin and disc plough or cut into the pin resulting in wear by the removal of small fragment of materials, typical feature related to abrasive wear [43]. Adhesion wear occurs because of adhesion at asperity contacts at interface. These contacts are sheared by sliding which induce severe plastic deformation and/or fracture near the subsurface region (up to several microns) in a softer material. Fragments then detach from the pin surface forming wear debris (see the large flake particle 8

Journal Pre-proof in Fig. 9(b)) [43, 44]. It should be noted that both the adhesive wear mentioned here and the aforementioned formation of displaced metal are originated from the adhesion at asperities, the difference is the adhesive junctions are assumed to be constantly broken and new ones created to replace them in the adhesive wear [41]. Another important wear mechanism is oxidative wear. The surface oxidation rate is significantly increased under sliding condition by asperity - asperity interactions, mechanical disturbances and an increase in temperature (both transient flash temperature or ambient temperature) [35]. Debris are formed by delamination of the oxide film when

f

its growth to a thickness of several micrometers. The formation of oxidation layer on the worn

oo

surface was confirmed by EDS (zone 1 in Fig. 9(a) and the corresponding mass fraction of main

pr

elements in Table 3), showing a large amount of iron and oxygen as well as some chromium. The oxygen content in wear debris (zone 3 in Fig. 9(b)) is remarkably higher compared to the worn

e-

surface, indicating that fine particles are predominately metal oxides. Although it is difficult to

Pr

distinguish which oxides come from spalling off of the oxide layer (since in abrasive wear, metallic particles after detachment may also be oxidized), the oxidation wear occurred undoubtedly. On the

al

other hand, it should be noted that the formation of oxide tribologica l layer reduces the shear strength of the interface and limits the number of direct metal – metal asperity occurring in adhesive wear,

rn

thus decreasing the wear rate to some extent [35, 45].

Jo u

Fig. 9(c) and (d) show worn surface and wear debris of the composites with particle size of 16 μm. Scratch grooves and a series of craters can also be observed, while the grooves becomes smaller (the width decreases from 7 μm for Al2024 alloy to 2 μm for the composites) since the increased hardness compared to unreinforced Al2024 sample. According to the Archard wear equation, the effect of hardness (H) on wear rate (Q) at a given normal load (W) can be expressed as follows [35]: Q=

𝐾𝑊 𝐻

where K is a dimensionless constant known as the wear coefficient. The higher the hardness (or yield strength) of the softer surface, the lower the wear rate. From the inset in Fig. 9(c), inhibition of metals removal around particle (shown by arrows) in sliding direction can be seen. Since glassy particles are much harder/wearable than the aluminum matrix, these hard particles protrude, inhibiting matrix removal in the following sliding. The above factors lead to increased wear 9

Journal Pre-proof resistance of composites than Al2024 alloy. The EDS examinations also indicate oxidative wear occurring in composites as shown in Table 3 (element content of zone 2 and 4 in Fig. 9(c) and (d)). In Fig. 9(d), there are some plate-like glassy particle wear debris (light gray), probably caused by deformation of glassy particles at high temperature. The metallic glass behaves like liquid when the temperature exceeds the glass transformation temperature. It is reported that flash temperature of several hundred Kelvin can be generated during sliding, e.g. 973 K is reached for steels at a sliding speed ~1 m/s [35].

f

Fig. 9(e) presents the worn surface of composites with 72 μm glassy particles. Although there

oo

are still traces of adhesive and abrasive wear, the craters are much smaller. The absence of large flake

pr

wear debris (Fig. 9(f)) corroborates the reduction of severe adhesion. Similarly, the grooves resulting from abrasives are discontinuous due to the interruption of large glassy particles. Fig. 9(e) also

e-

clearly shows many sites where particles inhibit matrix removal. The EDS of wear debris (zone 5 in

Pr

Fig. 9(f)) demonstrates significant differences compared to the Al2024 alloy and composite with the particle size of 16 μm. The content of aluminum decreases while the iron and chromium greatly

al

increase; this means an increment of wear debris comes from the steel disc. For composites incorporating larger particles, the evolution of surface topography in sliding process is considered to

rn

be useful to prevent softer aluminum matrix being further involved in the wear. A schematic

Jo u

illustration of the effect of particle size on wear damage is shown in Fig. 10. Both composites with the small and larger particles exhibit similar surface topography before wear test (by grinding to P4000 SiC paper), while differences emerge soon after sliding initiated. The small particles can be delaminated with matrix by adhesive wear and/or ploughed away by abrasive wear. In contrast, larger particles stand proud of the surface when surrounding matrix was delaminated or ploughed away. These particle protrusions carry the applied load and protect the wear of aluminum in following sliding process. At the same time, they abrade the steel disc, resulting in the formation of iron-rich wear debris. Fig. 11 displays the main element mapping on the worn surface of composites with particle size of 72 μm. The distribution of oxygen, iron and chromium can be seen, also indicating the occurrence of oxidative wear and the formation of tribological layer.

10

Journal Pre-proof It can also be seen from Fig. 7(a) that the average coefficient of friction keeps almost constant (range in 0.74 to 0.79) for Al2024 alloy and the composites. It is known that there are a large number of potential friction-affecting factors, e.g. contact geometry, relative motion, lubricant chemistry, applied force and temperature etc., and two materials exhibiting same friction coefficient can show quite different wear rate [46]. Adhesion is thought to be a major component in friction force during sliding [42], while it also confirmed that friction coefficient tends to be high when hard asperities work as abrasive ones against softer materials [47]. In this study, Al2024 alloy and composites with

f

smaller glassy particle size show severe adhesion, but in the composites with larger particle size, the

oo

hard glassy particles become protrusions and abrade the steel counterface (Fig. 9), which most likely

pr

be responsible for the nearly invariable friction coefficient in these materials.

e-

4 Conclusions

Pr

Al2024 alloy and Fe-based metallic glass powders with an optimum particle size ratio (in the range of 1/3 to 3) were utilized to prepare aluminum matrix composites through powder metallurgy.

al

The composites exhibited a dense structure and glassy particles were homogenously distributed in

rn

the three-dimensions, independent of the particle size. When the particle size is larger than 15 μm, the influence of particle diameter on yield strength of the composites is negligible. However, the

Jo u

ultimate tensile strength and ductility gradually decreased with increasing particle size since the particle/matrix interface separation and probability of particle fracture increased. The specific wear rate decreased with increasing particle size in dry sliding wear, in which the matrix was protected due to the evolution of surface topography.

Acknowledgements The authors thank H. Merker, N. Geiβler and B. Opitz for technical support, and Dr. J. Zeisig for stimulating discussion about the wear rate evaluation. T. He and T. Lu acknowledge the financial support of the China Scholarship Council (CSC).

11

Journal Pre-proof

References [1] S. Scudino, G. Liu, M. Sakaliyska, K.B. Surreddi, J. Eckert, Powder metallurgy of Al-based metal matrix composites reinforced with β-Al3 Mg2 intermetallic particles: Analysis and modeling of mechanical properties, Acta Mater., 57 (2009) 4529-4538. [2] J. Gu, S. Gu, L. Xue, S. Wu, Y. Yan, Microstructure and mechanica l properties of in-situ Al13 Fe4 /Al composites prepared by mechanical alloying and spark plasma sintering, Mater. Sci. Eng. A, 558 (2012) 684-691.

oo

f

[3] S. Scudino, Powder metallurgy of Al-based matrix composites reinforced with quasicrystalline particles: processing and mechanical properties A2 - Mitra, Rahul, in:

Intermetallic Matrix

pr

Composites, Woodhead Publishing, 2018, pp. 147-163.

[4] Y. Yuan, H. Hou, Y. Zhao, F. Yan, Characterization of aluminium matrix composites reinforced by

e-

Al–Cu–Fe-Cr quasicrystalline particles, Mater. Res. Express, 6 (2019) 076544.

Pr

[5] M.H. Lee, J.H. Kim, J.S. Park, J.C. Kim, W.T. Kim, D.H. Kim, Fabrication of Ni-Nb-Ta metallic glass reinforced Al-based alloy matrix composites by infiltration casting process, Scr. Mater., 50

al

(2004) 1367-1371.

rn

[6] P. Yu, K.B. Kim, J. Das, F. Baier, W. Xu, J. Eckert, Fabrication and mechanical properties of

1445-1450.

Jo u

Ni-Nb metallic glass particle-reinforced Al-based metal matrix composite, Scr. Mater., 54 (2006)

[7] K. Praveen Kumar, M. Gopi Krishna, J. Babu Rao, N.R.M.R. Bhargava, Fabrication and characterization of 2024 aluminium – High entropy alloy composites, J. Alloys Compd., 640 (2015) 421-427. [8] S. Zhou, X. Liu, Y. Xu, Microstructure, mechanical properties and tribological properties of NiAl composites reinforced by CrMnFeCoNi high-entropy alloy, Materials, 11 (2018) 1850. [9] Z.G. Wei, C.Y. Tang, W.B. Lee, Design and fabrication of intelligent composites based on shape memory alloys, J. Mater. Process. Technol., 69 (1997) 68-74. [10] W.P. Leser, J.A. Newman, J.D. Hochhalter, V.K. Gupta, F.G. Yuan, Embedded Ni–Ti particles for the detection of fatigue crack growth in AA7050, Fatigue. Fract. Eng. M., 39 (2016) 686-695.

12

Journal Pre-proof [11] N.E. Barta, I. Karaman, Embedded magnetic shape memory sensory particles in lightweight composites for crack detection, Mater. Sci. Eng. A, 751 (2019) 201-213. [12] A. Allue, P. Corte-León, K. Gondra, V. Zhukova, M. Ipatov, J.M. Blanco, J. Gonzalez, M. Churyukanova, S. Taskaev, A. Zhukov, Smart composites with embedded magnetic microwire inclusions allowing non-contact stresses and temperature monitoring, Compos. Part A - Appl. S., 120 (2019) 12-20. [13] M.M. Trexler, N.N. Thadhani, Mechanical properties of bulk metallic glasses, Prog. Mater Sci.,

f

55 (2010) 759-839.

oo

[14] R.B. Schwarz, P. Nash, Using Amorphous Phases in the Design of Structural Alloys, JOM, 41

pr

(1989) 27-31.

[15] D.V. Dudina, K. Georgarakis, Y. Li, M. Aljerf, A. LeMoulec, A.R. Yavari, A. Inoue, A

e-

magnesium alloy matrix composite reinforced with metallic glass, Compos. Sci. Technol., 69

Pr

(2009) 2734-2736.

[16] S. Khoramkhorshid, M. Alizadeh, A.H. Taghvaei, S. Scudino, Microstructure and mechanical

al

properties of Al-based metal matrix composites reinforced with Al84 Gd6 Ni7 Co3 glassy particles produced by accumulative roll bonding, Mater. Des., 90 (2016) 137-144.

rn

[17] Z. Wang, J. Tan, B.A. Sun, S. Scudino, K.G. Prashanth, W.W. Zhang, Y.Y. Li, J. Eckert,

Jo u

Fabrication and mechanical properties of Al-based metal matrix composites reinforced with Mg65 Cu20 Zn5 Y10 metallic glass particles, Mater. Sci. Eng. A, 600 (2014) 53-58. [18] D. Markó, K.G. Prashanth, S. Scudino, Z. Wang, N. Ellendt, V. Uhlenwinkel, J. Eckert, Al-based metal matrix composites reinforced with Fe49.9 Co35.1 Nb7.7 B4.5 Si2.8 glassy powder: Mechanical behavior under tensile loading, J. Alloys Compd., 615 (2014) S382-S385. [19] C.W. Nan, D.R. Clarke, The influence of particle size and particle fracture on the elastic/plastic deformation of metal matrix composites, Acta Mater., 44 (1996) 3801-3811. [20] M. Kouzeli, A. Mortensen, Size dependent strengthening in particle reinforced aluminium, Acta Mater., 50 (2002) 39-51.

13

Journal Pre-proof [21] V.V.B. Prasad, B.V.R. Bhat, Y.R. Mahajan, P. Ramakrishnan, Structure–property correlation in discontinuously reinforced aluminium matrix composites as a function of relative particle size ratio, Mater. Sci. Eng. A, 337 (2002) 179-186. [22] A. Slipenyuk, V. Kuprin, Y. Milman, V. Goncharuk, J. Eckert, Properties of P/M processed particle reinforced metal matrix composites specified by reinforcement concentration and matrix-to-reinforcement particle size ratio, Acta Mater., 54 (2006) 157-166. [23] A. Fathy, A. Sadoun, M. Abdelhameed, Effect of matrix/reinforcement particle size ratio (PSR)

f

on the mechanical properties of extruded Al-SiC composites, Int. J. Adv. Manuf. Technol., 73

oo

(2014) 1049-1056.

pr

[24] M. Leparoux, L. Kollo, H. Kwon, K. Kallip, N.K. Babu, K. AlOgab, M.K. Talari, Solid State

Eng. Mater., 20 (2018) 1800401.

e-

Processing of Aluminum Matrix Composites Reinforced with Nanoparticulate Materials, Adv.

Pr

[25] Y. Liang, Z. Ma, S. Li, S. Li, J. Bi, Effect of particle size on wear behaviour of SiC particulate-reinforced aluminum alloy composites, J. Mater. Sci. Lett., 14 (1995) 114-116.

al

[26] M. Kök, K. Özdin, Wear resistance of aluminium alloy and its composites reinforced by Al2 O3 particles, J. Mater. Process. Technol., 183 (2007) 301-309.

rn

[27] S. Kumar, V. Balasubramanian, Developing a mathematical model to evaluate wear rate of

Jo u

AA7075/SiCp powder metallurgy composites, Wear, 264 (2008) 1026-1034. [28] A.T. Alpas, J. Zhang, Effect of microstructure (particulate size and volume fraction) and counterface material on the sliding wear resistance of particulate-reinforced aluminum matrix composites, Metall. Mater. Trans. A, 25 (1994) 969-983. [29] S. Skolianos, T.Z. Kattamis, Tribological properties of SiCp-reinforced Al-4.5% Cu-1.5% Mg alloy composites, Mater. Sci. Eng. A, 163 (1993) 107-113. [30] M. Moazami-Goudarzi, F. Akhlaghi, Wear behavior of Al 5252 alloy reinforced with micrometric and nanometric SiC particles, Tribol. Int., 102 (2016) 28-37. [31] M. Roy, B. Venkataraman, V.V. Bhanuprasad, Y.R. Mahajan, G. Sundararajan, The effect of participate reinforcement on the sliding wear behavior of aluminum matrix composites, Metall. Trans. A, 23 (1992) 2833-2847. 14

Journal Pre-proof [32] T. He, O. Ertuğrul, N. Ciftci, V. Uhlenwinkel, K. Nielsch, S. Scudino, Effect of particle size ratio on microstructure and mechanical properties of aluminum matrix composites reinforced with Zr48 Cu36 Ag8 Al8 metallic glass particles, Mater. Sci. Eng. A, 742 (2019) 517-525. [33] N. Ciftci, N. Ellendt, E. Soares Barreto, L. Mädler, V. Uhlenwinkel, Increasing the amorphous yield of {(Fe0.6 Co0.4 )0.75 B0.2 Si0.05 }96Nb4 powders by hot gas atomization, Adv. Powder Technol., 29 (2018) 380-385. [34] N. Ciftci, N. Ellendt, G. Coulthard, E. Soares Barreto, L. Mädler, V. Uhlenwinkel, Novel

f

Cooling Rate Correlations in Molten Metal Gas Atomization, Metall. Mater. Trans. B, 50 (2019)

oo

666-677.

pr

[35] I. Hutchings, P. Shipway, Tribology: friction and wear of engineering materials, Butterworth-Heinemann, 2017.

e-

[36] A. Slipenyuk, V. Kuprin, Y. Milman, J.E. Spowart, D.B. Miracle, The effect of matrix to

Pr

reinforcement particle size ratio (PSR) on the microstructure and mechanical properties of a P/M processed AlCuMn/SiC p MMC, Mater. Sci. Eng. A, 381 (2004) 165-170.

al

[37] H. Halim, D.S. Wilkinson, M. Niewczas, The Portevin–Le Chatelier (PLC) effect and shear band formation in an AA5754 alloy, Acta Mater., 55 (2007) 4151-4160.

rn

[38] C. Wu, K. Ma, J. Wu, P. Fang, G. Luo, F. Chen, Q. Shen, L. Zhang, J.M. Schoenung, E.J.

Jo u

Lavernia, Influence of particle size and spatial distribution of B4 C reinforcement on the microstructure and mechanical behavior of precipitation strengthened Al alloy matrix composites, Mater. Sci. Eng. A, 675 (2016) 421-430. [39] M.A. Meyers, K.K. Chawla, Mechanical behavior of materials, Cambridge university press, 2008. [40] P.B. Prangnell, S.J. Barnes, S.M. Roberts, P.J. Withers, The effect of particle distribution on damage formation in particulate reinforced metal matrix composites deformed in compression, Mater. Sci. Eng. A, 220 (1996) 41-56. [41] M. Cocks, The formation of wedges of displaced metal between sliding metal surfaces, Wear, 8 (1965) 85-92.

15

Journal Pre-proof [42] D. Markov, D. Kelly, Mechanisms of adhesion-initiated catastrophic wear: pure sliding, Wear, 239 (2000) 189-210. [43] D. Jeyasimman, R. Narayanasamy, R. Ponalagusamy, V. Anandakrishnan, M. Kamaraj, The effects of various reinforcements on dry sliding wear behaviour of AA 6061 nanocomposites, Mater. Des., 64 (2014) 783-793. [44] B. Bhushan, Introduction to tribology, John Wiley & Sons, 2013. [45] A. Abdollahi, A. Alizadeh, H.R. Baharvandi, Dry sliding tribological behavior and mechanical

f

properties of Al2024–5 wt.%B4 C nanocomposite produced by mechanical milling and hot

oo

extrusion, Mater. Des., 55 (2014) 471-481.

pr

[46] P.J. Blau, The significance and use of the friction coefficient, Tribol. Int., 34 (2001) 585-591.

Jo u

rn

al

Pr

e-

[47] K. Kato, Wear in relation to friction - a review, Wear, 241 (2000) 151-157.

16

pr

oo

f

Journal Pre-proof

e-

Fig. 1 Morphology of the powder mixtures with different glassy particle sizes: (a) 16 μm, (b) 30 μm,

Jo u

rn

al

Pr

(c) 49 μm and (d) 72 μm.

Fig. 2 XRD patterns of powders and as-extruded samples.

17

pr

oo

f

Journal Pre-proof

e-

Fig. 3 SEM images of the hot extruded composites with different glassy particle sizes: (a) 16 μm, (b)

Jo u

rn

al

Pr

30 μm, (c) 49 μm and (d) 72 μm.

Fig. 4 Micro-CT 3D views of the hot extruded composites with different glassy particle sizes.

18

f

Journal Pre-proof

oo

Fig. 5 Mechanical properties of Al2024 alloy and the composites with different particle sizes: (a)

pr

representative stress-strain curves and the inset shows the variation of strength and ductility with increasing glassy particle size, (b) the true stress and tangent modulus as a function of strain (the

Jo u

rn

al

Pr

e-

stress data was smoothed for calculating the tangent modulus).

Fig. 6 SEM images of the tensile fracture surface: (a) and (b) Al2024 unreinforced alloy, (c) and (d) the composites with particle size of 16 μm, (e) and (f) 72 μm.

19

Journal Pre-proof

Fig. 7 Specific wear rate and coefficient of friction for the Al 2024 alloy and composites with

Jo u

rn

al

Pr

e-

pr

oo

f

different particle size (a) and (b) macroscopic morphology of the samples after wear test.

Fig. 8 Schematic of forming displaced metal at the outer edge of the pin: (a) the distortion of the pin and disc surfaces after a very short distance of sliding, (b) plastic shearing of the adhesion junction and sheared metal adheres to the front edge of the pin, (c) arrest of excess transferred metal on the disc surface at the rear edge of the pin.

20

oo

f

Journal Pre-proof

pr

Fig. 9 Worn surface and wear debris of (a) and (b) Al 2024 alloy and composites with particles sizes

Jo u

rn

al

Pr

e-

of (c) and (d) 16 μm and (e) and (f) 72 μm.

Fig. 10 Schematic illustration of particle size on wear damage process: (a) small particles and (b) larger particles.

21

oo

f

Journal Pre-proof

Fig. 11 EDS mapping of main elements on worn surface of the composites with particle size of 72

Jo u

rn

al

Pr

e-

pr

μm.

22

Journal Pre-proof

Table 1 Chemical composition of the Al2024 aluminum alloy powder.

Cu 4.40

Mg 1.42

Mn 0.45

Fe 0.2

Si <0.1

Al Bal.

oo

f

Element wt.%

e-

UTS (MPa) 354±11.2 374±7.5 360±4.9 356±5.4 342±6.2

al

Pr

YS (MPa) 181±4.4 218±8.9 216±8.6 215±3.8 217±4.4

Fracture strain (%) 15.7±4.7 9.9±2.0 8.4±1.1 7.9±0.3 5.9±0.4

Jo u

rn

Particle size (μm) Al2024 16 30 49 72

pr

Table 2 Tensile properties of hot extruded Al2024 alloy and composites with different particle sizes.

Table 3 Main elements mass fraction (wt.%) of EDS analysis of the zones in Fig. 9.

Zone

Al

Fe

Cr

O

Co

Cu

Mg

1

47.32

14.28

2.02

22.39

-

2.78

1.07

2

25.94

24.54

2.28

29.72

5.59

1.69

0.57

3

20.81

18.98

2.33

36.33

-

1.41

0.59

4

16.72

21.84

2.00

35.5

4.76

1.37

0.45

5

7.53

36.93

4.69

37.56

2.32

0.76

0.19

23

Jo u

rn

al

Pr

e-

pr

oo

f

Journal Pre-proof

24

Journal Pre-proof

Declaration of Interest Statement

Jo u

rn

al

Pr

e-

pr

oo

f

The authors declare no conflict of interest regarding the publication of this article.

25

Journal Pre-proof Highlights 1. Matrix to reinforcement particle size ratio ranges from 1/3 to 3 was used. 2. 3D homogenous distribution of glassy particles independent of particle size. 3. Insignificant change of tensile yield strength with particle size. 4. Ultimate tensile strength and ductility decrease with increasing particle size.

Jo u

rn

al

Pr

e-

pr

oo

f

5. Smaller particle size leads to lower wear resistance.

26

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

Figure 11