fabrication of al/diamond particles functionally graded materials
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Journal of Physics Conference Series
OPEN ACCESS
Fabrication of AlDiamond Particles FunctionallyGraded Materials by Centrifugal Sintered-CastingMethodTo cite this article Yoshimi Watanabe et al 2013 J Phys Conf Ser 419 012002
View the article online for updates and enhancements
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Fabrication of AlDiamond Particles Functionally Graded
Materials by Centrifugal Sintered-Casting Method
Yoshimi Watanabe1 Masafumi Shibuya and Hisashi Sato
Department of Engineering Physics Electronics and Mechanics
Nagoya Institute of Technology Gokiso-cho Showa-ku Nagoya 466-8555 Japan
E-mail yoshiminitechacjp
Abstract The continuous graded structure of functionally graded materials (FGMs) can be
created under a centrifugal force Centrifugal sintered-casting (CSC) method proposed by the
authors is one of the fabrication methods of FGM under centrifugal force This method is
a combination of the centrifugal sintering method and centrifugal casting method In this study
Aldiamond particle FGM was fabricated by the proposed method
1 Introduction
The continuous graded structure of the functionally graded materials (FGMs) can be created by a
centrifugal force As one of fabrication methods of FGM under the centrifugal force centrifugal
mixed-powder method was developed [1 2] However the mixed powder moves along the flow of
the molten matrix metal when the molten metal is poured into the spinning mold To overcome this
problem novel FGM fabrication method centrifugal sintered-casting (CSC) method is proposed The
schematic illustration of CSC method is shown in figure 1 At first ring-shaped metal-matrix preform
including dispersion particles is produced by centrifugal sintering Powder mixture of dispersion
particles and matrix metal particles is inserted into a spinning mold as shown in figure 1 (a)
Subsequently the powder mixture is sintered under the centrifugal force as shown in figure 1 (b)
Then the molten matrix metal is poured into the fabricated preform by centrifugal casting as shown in
figure 1 (c) As a result the molten matrix metal penetrates into the space between the particles by
the pressure due to the centrifugal force At the same time matrix metal particles are melted by the
heat from molten matrix Finally an FGM ring with dispersion particles such as abrasive grains
distributed on its surface can be obtained as shown in figure 1 (d) In this study Aldiamond particle
FGM has been fabricated by the CSC method
Figure 1 The schematic illustration of the centrifugal sintered-casting (CSC) method
1 To whom any correspondence should be addressed
FGM 2012 IOP PublishingJournal of Physics Conference Series 419 (2013) 012002 doi1010881742-65964191012002
Published under licence by IOP Publishing Ltd 1
2 Experimental Procedure
Pure Al particles (purity 9999 diameter 106 to 180 m) pure Mg particles (purity 995 mean
diameter 180 m) Al-15massSi particles (mean diameter 125 m) and diamond particles (270 to
325 mesh) were used as primary materials Three types of mixed powder with pure Al Al-05Mg
and Al-15Si particles are prepared and they are named as P1 P2 and P3 samples respectively The
mixed powder was set in the cylindrical mold having rotation axis with 20 mm in diameter and 30 mm
in length respectively Then the mixed powder was sintered in the spinning cylindrical mold under
the centrifugal force of 280 G at 655 oC 640
oC and 570
oC for P1 P2 and P3 samples respectively
for 3 h in vacuum Here G is the ratio of centrifugal force to gravity (G number) The centrifugal
sintering conditions of each fabricated preform are listed in table 1
Table 1 Summary of the centrifugal sintering
Pure Al ingot and obtained cylindrical preform were placed in compact vacuum centrifugal casting as
shown in figure 2 The Al ingot was melted by heating coil and then molten Al was poured into the
mold with the preform by applied centrifugal force of 34 G or 78 G at casting temperature of 900 -
1100 oC Table 2 summarizes the centrifugal casting conditions with fabricated preforms For ideal
processing centrifugal direction in centrifugal casting should correspond to the one in centrifugal
sintering However this centrifugal casting machine was used as a convenient means because of
machine performance in this study The microstructural observations of the fabricated preforms and
cast samples were carried out with a scanning electron microscope (SEM) Area fractions of diamond
abrasive grains in Al matrix were evaluated from SEM photographs
Figure 2 Schematic illustrations of compact vacuum centrifugal machine (left) and mold (right) The
shape of products by this machine is rod
Table 2 Summary of the centrifugal casting
Preform sample name P1 P2 P3
Amount of matrix particles
Al (g) 435 432 Mg (g) 002
Al-15Si (g) 425 Amount of diamond particles (g) 063
Volume fraction of diamond (vol) 10 Sintering temperature (
oC) 655 640 570
G number 280
Cast sample name C1 C2 C3 C4
Used preform sample P3 Amount of Al ingot (g) 35
Casting temperature (oC) 900 1200 1100
G number 34 78 Atmosphere Vacuum Ar
FGM 2012 IOP PublishingJournal of Physics Conference Series 419 (2013) 012002 doi1010881742-65964191012002
2
3 Results and Discussion
Upper and lower figures of figure 3 (a) show the macro photograph and SEM micrograph of P1
sample respectively It is seen from these figures pure Al particles cannot be sintered even though
the sintering was carried out at high temperature (5 oC lower than melting point of Al) This is
because the Al particles are covered by Al oxide and higher sintering temperature is necessary for
sintering of the Al oxide To avoid this phenomenon Mg particles were added into the mixed powder
because it has strong reduction ability and P2 sample was fabricated The results of P2 sample are
shown in figure 3 (b) Although intermetallic compound was formed good sintering of P2 sample
was not found Alternatively Al-15Si alloy particles with lower melting point were used and macro
photograph of P3 perform and its SEM micrograph are shown in figure 3 (c) Ring-shaped Al-
15Sidiamond particles preform has been successfully fabricated using centrifugal sintering method
It is also found that homogeneous distribution of diamond particles was observed in the preform It is
interesting to note here that the microstructure of P3 sample still consists of the spherical-shaped Al
particles similar to those of primary Al-15Si particles without sintering However from magnified
SEM photograph it is found that these spherical-shaped Al has been connected each other Therefore
it is expected that perform of P3 sample is good for application of CSC method
Figure 3 Macro photographs of performs (upper) and their SEM micrographs (lower) (a) (b) and
(c) are P1 P2 and P3 samples respectively
Since the Al-15Sidiamond particles preform can be successfully fabricated using centrifugal
sintering method P3 sample will be used for centrifugal casting experiment Figures 4 upper (a) to
(d) show the cross sectional views of C1 to C4 samples respectively SEM photographs showing
microstructures around outer surface of C1 to C4 samples are also shown in figures 4 lower (a) to (d)
respectively Solid samples could not be obtained for the C1 and C2 samples which were fabricated
under vacuum condition with casting temperature of 900 oC or 1200
oC respectively as shown in
figures 4 upper (a) and (b) In our previous study [3] cooling rate distribution of the centrifugal
casting using the compact vacuum centrifugal casting machine shown in figure 2 is estimated by Al-
Al2Cu eutectic lamella structure It was shown that the casting atmosphere as well as casting
temperature and G number have affected the cooling rate distribution Since local cooling rate
strongly influences the local microstructure of the cast centrifugal casting is carried out under Ar gas
condition and the results are shown in figures 4 (c) and (d) It is seen that the solid samples could be
fabricated under Ar gas condition Moreover as seen in figure 4 lower (d) diamond particles are
distributed at only outer surface of C4 sample and volume fraction of diamond particles is 11 vol as
expected Therefore it is concluded that the CSC method is useful to fabricate the rod or ring shaped
FGM 2012 IOP PublishingJournal of Physics Conference Series 419 (2013) 012002 doi1010881742-65964191012002
3
FGMs with diamond particles located at outer surface of rod-shaped sample These rod or ring shaped
FGMs dispersed with diamond particles on its outer surface can be used as grading wheels for drilling
of carbon fiber reinforced plastic (CFRP) [4]
Figure 4 Macro photographs of cast samples (upper) and their SEM micrographs (lower) (a) C1 (b)
C2 (c) C3 and (d) C4 samples
4 Conclusions In this study Aldiamond particle FGM has been fabricated by the centrifugal sintered-casting (CSC)
method which is combination of sintering method and casting under the centrifugal force First three
types of performs are fabricated under the centrifugal force from mixed powder of pure Al Al-Mg and
Al-15Si alloy particles with diamond particles Among them it is found that preform can be
obtained from mixed powder of Al-15Si alloy particles with diamond particles Using this type of
preform FGM was fabricated by casting under the centrifugal force It is found that the diamond
particles are distributed at only outer surface of casting In this way Aldiamond particles FGM can
be successfully fabricated by CSC method This method has advantage of the good control ability of
diamond distribution
Acknowledgments
This research was supported by Regional Innovation Cluster Program (Global Type) ldquoTokai Region
Nanotechnology Manufacturing Clusterrdquo from the Ministry of Education Culture Sports Science and
Technology (MEXT) of Japan One of the authors YW acknowledges the financial support from The
Light Metal Educational Foundation Inc of Japan
References
[1] Watanabe Y Inaguma Y Sato H and Miura-Fujiwara E 2009 Materials 2 2510
[2] Watanabe Y and Sato H 2011 Review Fabrication of Functionally Graded Materials under a
Centrifugal Force Nanocomposites with Unique Properties and Applications in Medicine and
Industry ed J Cuppoletti (Rijeka Shanghai and New York InTech) chapter 7 pp 133-150
[3] Watanabe Y Hattori Y and Sato H 2012 unpublished data
[4] Watanabe Y Miura-Fujiwara E Sato H Takekoshi K Tsuge H Kaga T Bando N Yamagami
S Kurachi K and Yokoyama H 2011 Inter J Mater Prod Tech 42 29
FGM 2012 IOP PublishingJournal of Physics Conference Series 419 (2013) 012002 doi1010881742-65964191012002
4
Fabrication of AlDiamond Particles Functionally Graded
Materials by Centrifugal Sintered-Casting Method
Yoshimi Watanabe1 Masafumi Shibuya and Hisashi Sato
Department of Engineering Physics Electronics and Mechanics
Nagoya Institute of Technology Gokiso-cho Showa-ku Nagoya 466-8555 Japan
E-mail yoshiminitechacjp
Abstract The continuous graded structure of functionally graded materials (FGMs) can be
created under a centrifugal force Centrifugal sintered-casting (CSC) method proposed by the
authors is one of the fabrication methods of FGM under centrifugal force This method is
a combination of the centrifugal sintering method and centrifugal casting method In this study
Aldiamond particle FGM was fabricated by the proposed method
1 Introduction
The continuous graded structure of the functionally graded materials (FGMs) can be created by a
centrifugal force As one of fabrication methods of FGM under the centrifugal force centrifugal
mixed-powder method was developed [1 2] However the mixed powder moves along the flow of
the molten matrix metal when the molten metal is poured into the spinning mold To overcome this
problem novel FGM fabrication method centrifugal sintered-casting (CSC) method is proposed The
schematic illustration of CSC method is shown in figure 1 At first ring-shaped metal-matrix preform
including dispersion particles is produced by centrifugal sintering Powder mixture of dispersion
particles and matrix metal particles is inserted into a spinning mold as shown in figure 1 (a)
Subsequently the powder mixture is sintered under the centrifugal force as shown in figure 1 (b)
Then the molten matrix metal is poured into the fabricated preform by centrifugal casting as shown in
figure 1 (c) As a result the molten matrix metal penetrates into the space between the particles by
the pressure due to the centrifugal force At the same time matrix metal particles are melted by the
heat from molten matrix Finally an FGM ring with dispersion particles such as abrasive grains
distributed on its surface can be obtained as shown in figure 1 (d) In this study Aldiamond particle
FGM has been fabricated by the CSC method
Figure 1 The schematic illustration of the centrifugal sintered-casting (CSC) method
1 To whom any correspondence should be addressed
FGM 2012 IOP PublishingJournal of Physics Conference Series 419 (2013) 012002 doi1010881742-65964191012002
Published under licence by IOP Publishing Ltd 1
2 Experimental Procedure
Pure Al particles (purity 9999 diameter 106 to 180 m) pure Mg particles (purity 995 mean
diameter 180 m) Al-15massSi particles (mean diameter 125 m) and diamond particles (270 to
325 mesh) were used as primary materials Three types of mixed powder with pure Al Al-05Mg
and Al-15Si particles are prepared and they are named as P1 P2 and P3 samples respectively The
mixed powder was set in the cylindrical mold having rotation axis with 20 mm in diameter and 30 mm
in length respectively Then the mixed powder was sintered in the spinning cylindrical mold under
the centrifugal force of 280 G at 655 oC 640
oC and 570
oC for P1 P2 and P3 samples respectively
for 3 h in vacuum Here G is the ratio of centrifugal force to gravity (G number) The centrifugal
sintering conditions of each fabricated preform are listed in table 1
Table 1 Summary of the centrifugal sintering
Pure Al ingot and obtained cylindrical preform were placed in compact vacuum centrifugal casting as
shown in figure 2 The Al ingot was melted by heating coil and then molten Al was poured into the
mold with the preform by applied centrifugal force of 34 G or 78 G at casting temperature of 900 -
1100 oC Table 2 summarizes the centrifugal casting conditions with fabricated preforms For ideal
processing centrifugal direction in centrifugal casting should correspond to the one in centrifugal
sintering However this centrifugal casting machine was used as a convenient means because of
machine performance in this study The microstructural observations of the fabricated preforms and
cast samples were carried out with a scanning electron microscope (SEM) Area fractions of diamond
abrasive grains in Al matrix were evaluated from SEM photographs
Figure 2 Schematic illustrations of compact vacuum centrifugal machine (left) and mold (right) The
shape of products by this machine is rod
Table 2 Summary of the centrifugal casting
Preform sample name P1 P2 P3
Amount of matrix particles
Al (g) 435 432 Mg (g) 002
Al-15Si (g) 425 Amount of diamond particles (g) 063
Volume fraction of diamond (vol) 10 Sintering temperature (
oC) 655 640 570
G number 280
Cast sample name C1 C2 C3 C4
Used preform sample P3 Amount of Al ingot (g) 35
Casting temperature (oC) 900 1200 1100
G number 34 78 Atmosphere Vacuum Ar
FGM 2012 IOP PublishingJournal of Physics Conference Series 419 (2013) 012002 doi1010881742-65964191012002
2
3 Results and Discussion
Upper and lower figures of figure 3 (a) show the macro photograph and SEM micrograph of P1
sample respectively It is seen from these figures pure Al particles cannot be sintered even though
the sintering was carried out at high temperature (5 oC lower than melting point of Al) This is
because the Al particles are covered by Al oxide and higher sintering temperature is necessary for
sintering of the Al oxide To avoid this phenomenon Mg particles were added into the mixed powder
because it has strong reduction ability and P2 sample was fabricated The results of P2 sample are
shown in figure 3 (b) Although intermetallic compound was formed good sintering of P2 sample
was not found Alternatively Al-15Si alloy particles with lower melting point were used and macro
photograph of P3 perform and its SEM micrograph are shown in figure 3 (c) Ring-shaped Al-
15Sidiamond particles preform has been successfully fabricated using centrifugal sintering method
It is also found that homogeneous distribution of diamond particles was observed in the preform It is
interesting to note here that the microstructure of P3 sample still consists of the spherical-shaped Al
particles similar to those of primary Al-15Si particles without sintering However from magnified
SEM photograph it is found that these spherical-shaped Al has been connected each other Therefore
it is expected that perform of P3 sample is good for application of CSC method
Figure 3 Macro photographs of performs (upper) and their SEM micrographs (lower) (a) (b) and
(c) are P1 P2 and P3 samples respectively
Since the Al-15Sidiamond particles preform can be successfully fabricated using centrifugal
sintering method P3 sample will be used for centrifugal casting experiment Figures 4 upper (a) to
(d) show the cross sectional views of C1 to C4 samples respectively SEM photographs showing
microstructures around outer surface of C1 to C4 samples are also shown in figures 4 lower (a) to (d)
respectively Solid samples could not be obtained for the C1 and C2 samples which were fabricated
under vacuum condition with casting temperature of 900 oC or 1200
oC respectively as shown in
figures 4 upper (a) and (b) In our previous study [3] cooling rate distribution of the centrifugal
casting using the compact vacuum centrifugal casting machine shown in figure 2 is estimated by Al-
Al2Cu eutectic lamella structure It was shown that the casting atmosphere as well as casting
temperature and G number have affected the cooling rate distribution Since local cooling rate
strongly influences the local microstructure of the cast centrifugal casting is carried out under Ar gas
condition and the results are shown in figures 4 (c) and (d) It is seen that the solid samples could be
fabricated under Ar gas condition Moreover as seen in figure 4 lower (d) diamond particles are
distributed at only outer surface of C4 sample and volume fraction of diamond particles is 11 vol as
expected Therefore it is concluded that the CSC method is useful to fabricate the rod or ring shaped
FGM 2012 IOP PublishingJournal of Physics Conference Series 419 (2013) 012002 doi1010881742-65964191012002
3
FGMs with diamond particles located at outer surface of rod-shaped sample These rod or ring shaped
FGMs dispersed with diamond particles on its outer surface can be used as grading wheels for drilling
of carbon fiber reinforced plastic (CFRP) [4]
Figure 4 Macro photographs of cast samples (upper) and their SEM micrographs (lower) (a) C1 (b)
C2 (c) C3 and (d) C4 samples
4 Conclusions In this study Aldiamond particle FGM has been fabricated by the centrifugal sintered-casting (CSC)
method which is combination of sintering method and casting under the centrifugal force First three
types of performs are fabricated under the centrifugal force from mixed powder of pure Al Al-Mg and
Al-15Si alloy particles with diamond particles Among them it is found that preform can be
obtained from mixed powder of Al-15Si alloy particles with diamond particles Using this type of
preform FGM was fabricated by casting under the centrifugal force It is found that the diamond
particles are distributed at only outer surface of casting In this way Aldiamond particles FGM can
be successfully fabricated by CSC method This method has advantage of the good control ability of
diamond distribution
Acknowledgments
This research was supported by Regional Innovation Cluster Program (Global Type) ldquoTokai Region
Nanotechnology Manufacturing Clusterrdquo from the Ministry of Education Culture Sports Science and
Technology (MEXT) of Japan One of the authors YW acknowledges the financial support from The
Light Metal Educational Foundation Inc of Japan
References
[1] Watanabe Y Inaguma Y Sato H and Miura-Fujiwara E 2009 Materials 2 2510
[2] Watanabe Y and Sato H 2011 Review Fabrication of Functionally Graded Materials under a
Centrifugal Force Nanocomposites with Unique Properties and Applications in Medicine and
Industry ed J Cuppoletti (Rijeka Shanghai and New York InTech) chapter 7 pp 133-150
[3] Watanabe Y Hattori Y and Sato H 2012 unpublished data
[4] Watanabe Y Miura-Fujiwara E Sato H Takekoshi K Tsuge H Kaga T Bando N Yamagami
S Kurachi K and Yokoyama H 2011 Inter J Mater Prod Tech 42 29
FGM 2012 IOP PublishingJournal of Physics Conference Series 419 (2013) 012002 doi1010881742-65964191012002
4
2 Experimental Procedure
Pure Al particles (purity 9999 diameter 106 to 180 m) pure Mg particles (purity 995 mean
diameter 180 m) Al-15massSi particles (mean diameter 125 m) and diamond particles (270 to
325 mesh) were used as primary materials Three types of mixed powder with pure Al Al-05Mg
and Al-15Si particles are prepared and they are named as P1 P2 and P3 samples respectively The
mixed powder was set in the cylindrical mold having rotation axis with 20 mm in diameter and 30 mm
in length respectively Then the mixed powder was sintered in the spinning cylindrical mold under
the centrifugal force of 280 G at 655 oC 640
oC and 570
oC for P1 P2 and P3 samples respectively
for 3 h in vacuum Here G is the ratio of centrifugal force to gravity (G number) The centrifugal
sintering conditions of each fabricated preform are listed in table 1
Table 1 Summary of the centrifugal sintering
Pure Al ingot and obtained cylindrical preform were placed in compact vacuum centrifugal casting as
shown in figure 2 The Al ingot was melted by heating coil and then molten Al was poured into the
mold with the preform by applied centrifugal force of 34 G or 78 G at casting temperature of 900 -
1100 oC Table 2 summarizes the centrifugal casting conditions with fabricated preforms For ideal
processing centrifugal direction in centrifugal casting should correspond to the one in centrifugal
sintering However this centrifugal casting machine was used as a convenient means because of
machine performance in this study The microstructural observations of the fabricated preforms and
cast samples were carried out with a scanning electron microscope (SEM) Area fractions of diamond
abrasive grains in Al matrix were evaluated from SEM photographs
Figure 2 Schematic illustrations of compact vacuum centrifugal machine (left) and mold (right) The
shape of products by this machine is rod
Table 2 Summary of the centrifugal casting
Preform sample name P1 P2 P3
Amount of matrix particles
Al (g) 435 432 Mg (g) 002
Al-15Si (g) 425 Amount of diamond particles (g) 063
Volume fraction of diamond (vol) 10 Sintering temperature (
oC) 655 640 570
G number 280
Cast sample name C1 C2 C3 C4
Used preform sample P3 Amount of Al ingot (g) 35
Casting temperature (oC) 900 1200 1100
G number 34 78 Atmosphere Vacuum Ar
FGM 2012 IOP PublishingJournal of Physics Conference Series 419 (2013) 012002 doi1010881742-65964191012002
2
3 Results and Discussion
Upper and lower figures of figure 3 (a) show the macro photograph and SEM micrograph of P1
sample respectively It is seen from these figures pure Al particles cannot be sintered even though
the sintering was carried out at high temperature (5 oC lower than melting point of Al) This is
because the Al particles are covered by Al oxide and higher sintering temperature is necessary for
sintering of the Al oxide To avoid this phenomenon Mg particles were added into the mixed powder
because it has strong reduction ability and P2 sample was fabricated The results of P2 sample are
shown in figure 3 (b) Although intermetallic compound was formed good sintering of P2 sample
was not found Alternatively Al-15Si alloy particles with lower melting point were used and macro
photograph of P3 perform and its SEM micrograph are shown in figure 3 (c) Ring-shaped Al-
15Sidiamond particles preform has been successfully fabricated using centrifugal sintering method
It is also found that homogeneous distribution of diamond particles was observed in the preform It is
interesting to note here that the microstructure of P3 sample still consists of the spherical-shaped Al
particles similar to those of primary Al-15Si particles without sintering However from magnified
SEM photograph it is found that these spherical-shaped Al has been connected each other Therefore
it is expected that perform of P3 sample is good for application of CSC method
Figure 3 Macro photographs of performs (upper) and their SEM micrographs (lower) (a) (b) and
(c) are P1 P2 and P3 samples respectively
Since the Al-15Sidiamond particles preform can be successfully fabricated using centrifugal
sintering method P3 sample will be used for centrifugal casting experiment Figures 4 upper (a) to
(d) show the cross sectional views of C1 to C4 samples respectively SEM photographs showing
microstructures around outer surface of C1 to C4 samples are also shown in figures 4 lower (a) to (d)
respectively Solid samples could not be obtained for the C1 and C2 samples which were fabricated
under vacuum condition with casting temperature of 900 oC or 1200
oC respectively as shown in
figures 4 upper (a) and (b) In our previous study [3] cooling rate distribution of the centrifugal
casting using the compact vacuum centrifugal casting machine shown in figure 2 is estimated by Al-
Al2Cu eutectic lamella structure It was shown that the casting atmosphere as well as casting
temperature and G number have affected the cooling rate distribution Since local cooling rate
strongly influences the local microstructure of the cast centrifugal casting is carried out under Ar gas
condition and the results are shown in figures 4 (c) and (d) It is seen that the solid samples could be
fabricated under Ar gas condition Moreover as seen in figure 4 lower (d) diamond particles are
distributed at only outer surface of C4 sample and volume fraction of diamond particles is 11 vol as
expected Therefore it is concluded that the CSC method is useful to fabricate the rod or ring shaped
FGM 2012 IOP PublishingJournal of Physics Conference Series 419 (2013) 012002 doi1010881742-65964191012002
3
FGMs with diamond particles located at outer surface of rod-shaped sample These rod or ring shaped
FGMs dispersed with diamond particles on its outer surface can be used as grading wheels for drilling
of carbon fiber reinforced plastic (CFRP) [4]
Figure 4 Macro photographs of cast samples (upper) and their SEM micrographs (lower) (a) C1 (b)
C2 (c) C3 and (d) C4 samples
4 Conclusions In this study Aldiamond particle FGM has been fabricated by the centrifugal sintered-casting (CSC)
method which is combination of sintering method and casting under the centrifugal force First three
types of performs are fabricated under the centrifugal force from mixed powder of pure Al Al-Mg and
Al-15Si alloy particles with diamond particles Among them it is found that preform can be
obtained from mixed powder of Al-15Si alloy particles with diamond particles Using this type of
preform FGM was fabricated by casting under the centrifugal force It is found that the diamond
particles are distributed at only outer surface of casting In this way Aldiamond particles FGM can
be successfully fabricated by CSC method This method has advantage of the good control ability of
diamond distribution
Acknowledgments
This research was supported by Regional Innovation Cluster Program (Global Type) ldquoTokai Region
Nanotechnology Manufacturing Clusterrdquo from the Ministry of Education Culture Sports Science and
Technology (MEXT) of Japan One of the authors YW acknowledges the financial support from The
Light Metal Educational Foundation Inc of Japan
References
[1] Watanabe Y Inaguma Y Sato H and Miura-Fujiwara E 2009 Materials 2 2510
[2] Watanabe Y and Sato H 2011 Review Fabrication of Functionally Graded Materials under a
Centrifugal Force Nanocomposites with Unique Properties and Applications in Medicine and
Industry ed J Cuppoletti (Rijeka Shanghai and New York InTech) chapter 7 pp 133-150
[3] Watanabe Y Hattori Y and Sato H 2012 unpublished data
[4] Watanabe Y Miura-Fujiwara E Sato H Takekoshi K Tsuge H Kaga T Bando N Yamagami
S Kurachi K and Yokoyama H 2011 Inter J Mater Prod Tech 42 29
FGM 2012 IOP PublishingJournal of Physics Conference Series 419 (2013) 012002 doi1010881742-65964191012002
4
3 Results and Discussion
Upper and lower figures of figure 3 (a) show the macro photograph and SEM micrograph of P1
sample respectively It is seen from these figures pure Al particles cannot be sintered even though
the sintering was carried out at high temperature (5 oC lower than melting point of Al) This is
because the Al particles are covered by Al oxide and higher sintering temperature is necessary for
sintering of the Al oxide To avoid this phenomenon Mg particles were added into the mixed powder
because it has strong reduction ability and P2 sample was fabricated The results of P2 sample are
shown in figure 3 (b) Although intermetallic compound was formed good sintering of P2 sample
was not found Alternatively Al-15Si alloy particles with lower melting point were used and macro
photograph of P3 perform and its SEM micrograph are shown in figure 3 (c) Ring-shaped Al-
15Sidiamond particles preform has been successfully fabricated using centrifugal sintering method
It is also found that homogeneous distribution of diamond particles was observed in the preform It is
interesting to note here that the microstructure of P3 sample still consists of the spherical-shaped Al
particles similar to those of primary Al-15Si particles without sintering However from magnified
SEM photograph it is found that these spherical-shaped Al has been connected each other Therefore
it is expected that perform of P3 sample is good for application of CSC method
Figure 3 Macro photographs of performs (upper) and their SEM micrographs (lower) (a) (b) and
(c) are P1 P2 and P3 samples respectively
Since the Al-15Sidiamond particles preform can be successfully fabricated using centrifugal
sintering method P3 sample will be used for centrifugal casting experiment Figures 4 upper (a) to
(d) show the cross sectional views of C1 to C4 samples respectively SEM photographs showing
microstructures around outer surface of C1 to C4 samples are also shown in figures 4 lower (a) to (d)
respectively Solid samples could not be obtained for the C1 and C2 samples which were fabricated
under vacuum condition with casting temperature of 900 oC or 1200
oC respectively as shown in
figures 4 upper (a) and (b) In our previous study [3] cooling rate distribution of the centrifugal
casting using the compact vacuum centrifugal casting machine shown in figure 2 is estimated by Al-
Al2Cu eutectic lamella structure It was shown that the casting atmosphere as well as casting
temperature and G number have affected the cooling rate distribution Since local cooling rate
strongly influences the local microstructure of the cast centrifugal casting is carried out under Ar gas
condition and the results are shown in figures 4 (c) and (d) It is seen that the solid samples could be
fabricated under Ar gas condition Moreover as seen in figure 4 lower (d) diamond particles are
distributed at only outer surface of C4 sample and volume fraction of diamond particles is 11 vol as
expected Therefore it is concluded that the CSC method is useful to fabricate the rod or ring shaped
FGM 2012 IOP PublishingJournal of Physics Conference Series 419 (2013) 012002 doi1010881742-65964191012002
3
FGMs with diamond particles located at outer surface of rod-shaped sample These rod or ring shaped
FGMs dispersed with diamond particles on its outer surface can be used as grading wheels for drilling
of carbon fiber reinforced plastic (CFRP) [4]
Figure 4 Macro photographs of cast samples (upper) and their SEM micrographs (lower) (a) C1 (b)
C2 (c) C3 and (d) C4 samples
4 Conclusions In this study Aldiamond particle FGM has been fabricated by the centrifugal sintered-casting (CSC)
method which is combination of sintering method and casting under the centrifugal force First three
types of performs are fabricated under the centrifugal force from mixed powder of pure Al Al-Mg and
Al-15Si alloy particles with diamond particles Among them it is found that preform can be
obtained from mixed powder of Al-15Si alloy particles with diamond particles Using this type of
preform FGM was fabricated by casting under the centrifugal force It is found that the diamond
particles are distributed at only outer surface of casting In this way Aldiamond particles FGM can
be successfully fabricated by CSC method This method has advantage of the good control ability of
diamond distribution
Acknowledgments
This research was supported by Regional Innovation Cluster Program (Global Type) ldquoTokai Region
Nanotechnology Manufacturing Clusterrdquo from the Ministry of Education Culture Sports Science and
Technology (MEXT) of Japan One of the authors YW acknowledges the financial support from The
Light Metal Educational Foundation Inc of Japan
References
[1] Watanabe Y Inaguma Y Sato H and Miura-Fujiwara E 2009 Materials 2 2510
[2] Watanabe Y and Sato H 2011 Review Fabrication of Functionally Graded Materials under a
Centrifugal Force Nanocomposites with Unique Properties and Applications in Medicine and
Industry ed J Cuppoletti (Rijeka Shanghai and New York InTech) chapter 7 pp 133-150
[3] Watanabe Y Hattori Y and Sato H 2012 unpublished data
[4] Watanabe Y Miura-Fujiwara E Sato H Takekoshi K Tsuge H Kaga T Bando N Yamagami
S Kurachi K and Yokoyama H 2011 Inter J Mater Prod Tech 42 29
FGM 2012 IOP PublishingJournal of Physics Conference Series 419 (2013) 012002 doi1010881742-65964191012002
4
FGMs with diamond particles located at outer surface of rod-shaped sample These rod or ring shaped
FGMs dispersed with diamond particles on its outer surface can be used as grading wheels for drilling
of carbon fiber reinforced plastic (CFRP) [4]
Figure 4 Macro photographs of cast samples (upper) and their SEM micrographs (lower) (a) C1 (b)
C2 (c) C3 and (d) C4 samples
4 Conclusions In this study Aldiamond particle FGM has been fabricated by the centrifugal sintered-casting (CSC)
method which is combination of sintering method and casting under the centrifugal force First three
types of performs are fabricated under the centrifugal force from mixed powder of pure Al Al-Mg and
Al-15Si alloy particles with diamond particles Among them it is found that preform can be
obtained from mixed powder of Al-15Si alloy particles with diamond particles Using this type of
preform FGM was fabricated by casting under the centrifugal force It is found that the diamond
particles are distributed at only outer surface of casting In this way Aldiamond particles FGM can
be successfully fabricated by CSC method This method has advantage of the good control ability of
diamond distribution
Acknowledgments
This research was supported by Regional Innovation Cluster Program (Global Type) ldquoTokai Region
Nanotechnology Manufacturing Clusterrdquo from the Ministry of Education Culture Sports Science and
Technology (MEXT) of Japan One of the authors YW acknowledges the financial support from The
Light Metal Educational Foundation Inc of Japan
References
[1] Watanabe Y Inaguma Y Sato H and Miura-Fujiwara E 2009 Materials 2 2510
[2] Watanabe Y and Sato H 2011 Review Fabrication of Functionally Graded Materials under a
Centrifugal Force Nanocomposites with Unique Properties and Applications in Medicine and
Industry ed J Cuppoletti (Rijeka Shanghai and New York InTech) chapter 7 pp 133-150
[3] Watanabe Y Hattori Y and Sato H 2012 unpublished data
[4] Watanabe Y Miura-Fujiwara E Sato H Takekoshi K Tsuge H Kaga T Bando N Yamagami
S Kurachi K and Yokoyama H 2011 Inter J Mater Prod Tech 42 29
FGM 2012 IOP PublishingJournal of Physics Conference Series 419 (2013) 012002 doi1010881742-65964191012002
4
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