metal lo graphic preparation of mmc

8/3/2019 Metal Lo Graphic Preparation of MMC

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P.Merle et al. MMC-Assess – Thematic Network

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P .Mer le e t a l .




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C O N T E N T

AA6061/ Al2O3 /10-22p...................................................................................................2

A359/SiC/22p ..................................................................................................................2

AA2XXX / SiC / 25p .......................................................................................................4

AlSi7/SiC/(50+16)p-bimodal .........................................................................................5

Dispal...............................................................................................................................6

AA 357 / C-KC139 /UD or laminates...........................................................................8

AA1099 / Al2O3 Nextel 610 / 50f-UD..........................................................................9

AlZn6Mg / Al2O3 Altex/UD50f .................................................................................10

Carbon fiber reinforced magnesium alloys ..............................................................11

Magnesium/ C-T300 /50f-UD......................................................................................12

Micrographs of C/Mg-composites with Al-content in the magnesium matrixand without...................................................................................................................13

Micrographs of C/Mg-composites with Al2O3 particles as spacers.....................14

Cu-C (SFRM)// vol. 44% ..............................................................................................15

Cu-C (CFRM)// vol 40, 50,60% ...................................................................................15

Stainless Steel AISI 316 / 10-20 Vol.% Al2O3 ...........................................................16

Stainless Duplex Steel (UNS 31803) + 30 w.% Cr3C2 ..............................................17

Titan-alloys / continuous SiC fibre ............................................................................19

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AA6061/ Al2O3 /10-22p

A359/SiC/22p

T1,T4 or T6 condition.

POLISHING CONDITIONS

• Automatic polishing. MECAPOL P320 machine with rotating polishing disk +PERE rotating

specimen holder

• Polishing cloths and diamond pastes PRESI (http://www.presi.com)

Table 1:Polishing stages of AA6061/ Al2O3 /10-22p and A359/SiC/22p

Stage

N°Support Abrasive

Force*

(daN)

Disc

Rotating

speed (rpm)

Specimen

Rotating speed

(rpm)

Time

(min)Lubricant

1 paper SiC P400 6 150 100 1 water

2 paper SiC P800 6 150 100 1 water

3 paper SiC 1200 6 150 100 1 water

4

Polishin

g cloth

RAM

diamond

paste 6?m

LD33

1spray/45

sec

6 150 100 5

GH

(2drop /

5s)

5

Polishin

g cloth

RAM

diamond

paste 3?m

LD33

1spray/45

sec

6 150 100

1

+

30”

GH

(2drop /

5s)

6

Polishin

g cloth

SUPRA

Suspensio

n SPM

1/3 SPM+

2/3 H2O

1drop/sec

6 150 100 3 ///

* Pressure of 0,15 MPa for typical 32 mm diameter polish

Fig.1:AA6061/ Al 2O3 /10p (Duralcan W6A10A)

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Fig.2: AA6061/ Al 2O3 /22p (Duralcan W6D22A)

Fig.3: A359/SiC/22p (Duralcan F3S.20S)

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AA2XXX / SiC / 25p


• Manual polishing with rotating disk (? 300mm)• All grinding and polishing products purchased from Struers (http://www.struers.com)

Table 2:Polishing stages of AA2XXX / SiC / 25p

Stage N° Support AbrasiveDisc Rotating

speed (rpm)

Time

(min)Lubricant

1 paper SiC 180 300 1 water


3 paper SiC 500 300 1 water G r i n d i n g


1

Polishing

cloth

DP-Plan

diamond paste

6?m SYNXI150 2-3

DP-Blue

(DEPIF)

(1drop / 3s)

2

Polishing

cloth DP-

MOL

diamond paste

3?m SYNTE150 2-3

DP-Blue

(DEPIF)

(1drop / 3s) P o l i s h i n g

3

Polishing

cloth OP-

Chem

OP-S

Suspension150 3-4 ///

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AlSi7/SiC/(50+16)p-bimodal


• Polishing and grinding by Planopol-3 with Pedemax-2 (STRUERS)

Table 3:Polishing stages of AlSi7/SiC/(50+16)p-bimodal

Stage

Nr. Support

Abrasi

vePressure

Disc Rotating

Speed

(rpm)

Specimen

Rotating

Speed

Time

(min)Lubricant

1Diamond

disc

Piano

220F=170N 150 110

to

plainWater

2 Largo-disc 15µm F=170N 150 110 8-10min

Diamond-suspension

3

Polishing

Cloth

PAN

15µm F=170N 150 1105-6

min

Diamond-

suspension

4

Polishing

Cloth

DUR

6µm F=170N 150 110 6minDiamond-

suspension

5

Polishing

Cloth

MOL

3µm F=170N 150 110 6minDiamond-

suspension

6

Polishing

Cloth

OP-CHEM

OPS or

OPUF=65N 150 110 2min

100ml OPS

+1ml H2O2

+1ml

Ammoniak

Fig.4: AlSi7/SiC/(50+16)p-bimodal

FOR MORE INFORMATION

Heidemarie Knoblich, [email protected]

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Dispal

DISPAL M1xx (M = reactive milling); AA1085 + submicron Al4C3/Al2O3

DIS PAL M2xx (M = reactive milling); AlSi(12-20) + submicron Al4C3/Al2O3

DISPAL A2xx (A = RS-powder by spraying); AlSi(12-40) + further alloying elements

DIS PAL S2xx (S = spray compaction); AlSi(12-40) + further alloying elementsDISPAL S7xx (S = spray compaction); AlZn(6-15) + further alloying elements


• Automatic polishing with RotoPol-31 + RotoForce-4 top (rotating polishing disk (? 200 or

300 mm) and rotating specimen holder of ? 100mm)

• Polishing cloths: Struers (http://www.struers.de)

• Diamond pastes Wirtz-Bühler (http://www.buehlerltd.com), Fig.1

Table 4:Polishing stages of Dispal

Stage N° Support Abrasive

Disc Rotat

ing speed

(rpm)

Force*

[N]

Time

[min] Lubricant

1 SiC 80 120 0.25 water

2 SiC 220 90 0.25 water

3 SiC 800 90 0.25 water

4 SiC 1200 90 0.25 water G r i n d i n g

5

SiC-Paper

on MD-

Fuga

SiC 2400

150

90 0.25

1 Polishingcloth

MD-DAC

diamond paste 6µm

90 5 Struers blue

2

Polishing

cloth MD-MOL

diamond paste 3

µm 60 5

Struers

red

3

Polishing

cloth MD-MOL

diamond paste 1

µm 60 5

Struers

red P o l i s h i n g

4Polishing

cloth MD-NAP

Mastermet-

Polish suspension

Fa. Wirtz Buehler(SiO2; 0,06 µm)

150

60 2

* Pressure of 0,15 MPa for typical 32 mm diameter polish

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Fig.5:DISPAL S250 (AlSi20Fe5Ni2, spray compacted and extruded, LT)

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AA 357 / C-KC139 /UD or laminates


• Cutting under water using a diamond cut-off wheel.• Polishing with rotating (? 230mm) polishing plate. Polishing cloths and diamond pastes :

PRESI (http://www.presi.com)

STRUERS (http://www.struers.com),

LAM PLAN (http://www.lamplan.fr),

TRIEFUS France (28011 CHARTRES CEDEX, Tel : 02-37-24-40-40)

Table 5:Polishing stages of AA 357 / C-KC139 /UD or laminates

Stage

N°Support Abrasive Supplier

Disc Rotating

speed (rpm)

Time

(min)Lubricant

1 paper SiC 320 PRESI 250 1-2 water



4 Flocked

cloth PSF

(TRIEFUS)

diamond

paste

6?m

LAM

PLAN

250-300 1-3 alcohol

5 Woven

cloth 432

(LAM

PLAN)

diamond

paste

3?m

LAM

PLAN

250-300 1-3 alcohol

6 Flocked

cloth TF-R(PRESI)

Diamon

d paste0.25 ?m

LAM

PLAN

250-300 1-3 alcohol

Cleaning with alcohol in an ultrasonic bath and drying after stages 3, 4, 5, 6

Fig.6:AA 357 / C-KC139 /UD or laminates

FOR MORE INFORMATIONS

[email protected]

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AA1099 / Al2O3 Nextel 610 / 50f-UD


• Automatic polishing with rotating polishing disk ( ? 200mm) and rotating specimen holder(? 100mm)

• Grinding, polishing cloths and diamond pastes of

Table 6:Polishing stages of AA1099 / Al2O3 Nextel 610 / 50f-UD

Stage

N°Support Abrasive

Pres-

sure

(bar)

Disc

Rotation

(rpm)

Specimen

Rotation

(rpm)

Time

(min)Lubricant

1 SiC 320 1 flat

2 SiC 600 1 1

3 SiC 12001

14

Paper1

Dia-

mond

disc 2

SiC 4000 1

PIANO

1202

0.6 1 150110

2

water

5Polishing

cloth

RAM 1

LARGO

disc 2

diamond paste

6?m DESY 1

9µm 20.6 150 110 3-5

PM 1

(1drop / 3s)

suspension 2

6Polishing cloth

RAM 1

DAC 2

diamond paste 3?m

DESY 1 0.6 150 1103-5

PM 1

(1drop / 3s)

suspension 2

7

Polishing cloth

SUPRA1

MD-Chem 2

Suspension

25%SPM 1

+75%H2O;

OPS or OPU 2

0.6 150 110 1-2

As above 1 or

100ml OPS 2

+1ml H2O

+1ml NH3

8 1Polishing cloth

HS 1As above 1 0.4 150 110 1 water

1 PRESI (http://www.presi.com), 2 STRUERS (http://www.struers.de)

Fig.7:AA1099 / Al2O3 Nextel 610 / 50f-UD

FOR MORE INFORMATION:

1 [email protected]; 2 [email protected]

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AlZn6Mg / Al2O3 Altex/UD50f


• Automatic polishing with rotating polishing disk (? 300mm) and rotating specimen holder(? 160mm)



Table 8:Polishing stages of AlZn6Mg / Al2O3 Altex/UD50f

Stage

N°

Support Abrasive Pressure

(bar)

Disc Rotating

speed (rpm)

Specimen

Rotating speed

(rpm)

Time

(min)

Lubricant

1 paper SiC 180 1 - 5 300 150 until

flat

water

2 Largo °

Honey-

comb

disc

diamond

suspensi

on 9?m

1 - 5 300 150 3 Dialub sw

3 Texmet

W *

diamond

suspensi

on 3?m

1 - 5 150 150 3 Dialub sw

4 Polishin

g cloth F

*

Masterm

et II *

1 - 5 150 150 2.1 water


[email protected]

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Carbon f iber reinforced magnesium alloys

• Fiber: Tenax HTA 5331, Toray T300J, Toray T800H, Torray T1000

Fiber coating: TiN and uncoated

• Matrix: cp-Mg, AM20, AM50, AZ91


• Manuel polishing with a very low pressure

• The same preparation conditions like mentioned in the table below are used for the

combination of all fiber matrix types listed above:

Table 9:Polishing stages of Carbon fiber reinforced magnesium alloys

Stage

No Support Abrasive Pressure

Disc Rotating

speed (rpm)

Time

(min)Lubricant

1 Paper SiC 320 Low 300 1 Ethanol






7 Polishing

Cloth

MOL*

Dp

suspen-

sion 3

µm

(Samte*)

Low 300 5-10 Struers Lubricant red*

+ blue*

* Products of Struers (www.struers.de)

Comment : In the case of Al2O3 particles as spacers for producing graded carbon fibre

reinforced magnesium alloys, the metallographic preparation stays the same


[email protected]

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Magnesium/ C-T300 /50f-UD


• Automatic polishing. MECAPOL P320 machine with rotating polishing disk +PERE rotatingspecimen holder

• Polishing cloths and diamond pastes PRESI (http://www.presi.com)

Table 10:Polishing stages of Magnesium/ C-T300 /50f-UD

Stage

N°

Support Abrasive Force*

(daN)

Disc Rotating

speed (rpm)

Specimen

Rotating speed

(rpm)

Time

(min)

Lubricant

1 paper SiC P240 6 150 100 2 EXXSOL

D80

2 paper SiC P600 6 150 100 2 EXXSOLD80

3 paper SiC 1200 6 150 100 2 EXXSOL

D80

4 Polishin

g cloth

RAM

diamond

paste

6?m

PM

6 150 100 5 EXXSOL

D80 (1drop

/ 2s)

5 Polishin

g cloth

RAM

diamond

paste

3?m

LD33

6 150 100 3 EXXSOL

D80 (1drop

/ 2s)

** Pressure of 0,15 MPa for typical 32 mm diameter polish

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Micrographs of C/Mg-composites with Al-content in the

magnesium matrix and without

The two SEM micrographs show composites with a Tenax HTA 5331 carbon fibre (similar to

Toray T300J) as reinforcement and two different magnesium matrix alloys. On the left picture

micrograph you see the fibres in a pure magnesium matrix (cp-Mg). On the right micrograph

the fibers are infiltrated in a magnesium matrix with an aluminum content of 5% (AM50). To

make the fiber/matrix-interface better visible the matrix has been e tched for 15 seconds with 2%

HNO3. On the right picture micrograph plate shape Al2MgC2 precipitates can be seen at the

fiber/matrix-interface.

Fig.7: Tenax HTA5331/cp-Mg (SEM) Tenax HTA5331/AM50 (SEM)

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Micrographs of C/Mg-composites with Al2O3 particles as spacers

The two SEM micrographes show composites with a pure magnesium matrix (cp-Mg) andToray T300J fibres as reinforcement. The Al2O3 particles are used as spacers to get a graded

fibre volume fraction. On the left micrograph on the bottom there are no Al2O3 particles and

the composite has a fiber volume fraction of about 60%. Only on top of this micrograph a few

Al2O3 particles (white) are visible. One the right micrograph the fiber volume fraction is about

30% and a lot of Al2O3 are visible in white color.

Fig.7: T300J/cp-Mg composite with a very low content of Al2O3 particles on top of the

micrograph (SEM)

Fig.8: T300J/cp-Mg composite with high content lot of Al2O3 particles (SEM)

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Cu-C (SFRM)// vol. 44%

Cu-C (CFRM)// vol 40, 50,60%


• Polishing and grinding by hand. The time for grinding depends on the surface morphology

which was determined by a visual control of the surface.

Table 10:Polishing stages of Cu-C (SFRM)// vol. 44% and u-C (CFRM)// vol 40, 50,60%

Stage

N°Support

Abrasi

ve

Pressure

(bar)

Disc Rotating

speed (rpm)

Specimen

Rotating speed

(rpm)

Time

(min)Lubricant

1 paper SiC 320 - ~750 - dep. water

2 paper SiC

1200

- ~750 - dep. water

3 paper SiC

2400

- ~750 - dep. water

4 paper SiC

4000

- ~750 - dep. water

5 Polishing

with felts

3µ

and/or

1µm

- ~750 - dep. alcohol

Fig.9: Cu-C-SFRM (x-y-direction) Cu-C-SFRM (z-direction)

100 µm

100 µm


[email protected]

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16/20

Stainless Steel AISI 316 / 10-20 Vol.% Al2O3


• Manual polishing with rotating polishing disk (? 250mm in stages 1-5 and ? 200mm instages 6-8). Duration of each stage - polishing until apparent scratches from the previous

stage has been disappeared (Table 1. and Fig. 1.).

• Abrasive papers: Buehler (http://www.buehlerltd.com/)

• Polishing cloths and diamond pastes: Struers (http://www.struers.com/)

Table 11:Polishing stages of the AISI 316 + 20 Vol.% Al 2O3 PRM MMC.

Stage

No.Support Abrasive

Disc Rotating

speed (rpm)Lubricant

1 paper SiC 60 300 water2 paper SiC 320 300 water

3 paper SiC 400 300 water



6polishing cloth

DP-Moldiamond paste 3? m 70 etanol + glycerin

7polishing cloth

DP-Napdiamond paste 1? m 70 etanol + glycerin

8polishing cloth

DP-Nap

magnesium oxide

(MgO)70 water

Fig. 10:Polished microstructure of AISI 316 + 20 Vol.% Al2O3 PRM MMC (200x).


[email protected],[email protected]

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Stainless Duplex Steel (UNS 31803) + 30 w.% Cr3C2


• Manual polishing with rotating polishing disk (? 250mm in stages 1-5 and ? 200mm

in stages 6-8). Duration of each stage - polishing until apparent scratches from the

previous stage has been disappeared, Table 1.

• Polished microstructure, Fig. 1.

• • Abrasive papers: Buehler (http://www.buehlerltd.com/)

• • Polishing cloths and diamond pastes: Struers (http://www.struers.com/)

ETCHING

Etching solution Aqua regia + glycerin. Etched microstructure, Fig. 2.

Table 12:Polishing stages of composite sample.Stage

No.

Support Abrasive Disc Rotating

speed (rpm)

Lubricant






6 polishing cloth

DP-Mol

diamond paste 3?m 70 etanol + glycerin

7 polishing clothDP-Nap diamond paste 1?m 70 etanol + glycerin

8 polishing cloth

DP-Nap

magnesium oxide

(MgO)

70 water

Fig. 11: Polished microstructure of Duplex Stainless Steel+30 w.% Cr3C2 PRM MMC (200x).

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Fig. 12:Polished+etched microstructure of Duplex Stainless Steel+30 w.% Cr3C2 PRM MMC (200x).


[email protected],[email protected]

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Titan-alloys / continuous SiC fibre

CUTTING CONDITIONS

• low speed precision saw• resin bonded diamond wheel, thickness 0.6 mm, diamond grain size ca. 126 µm


• Automatic polishing device, rotating disk (diameter 300 mm), rotating specimen holder

(diameter 140 mm)



Table 13:Polishing stages of Titan-alloys / continuous SiC fibre

Stage

No.

Support Abrasive Lubri-

cant

Load

(N)

Disc

Rotating

Speed

(rpm)

Specim

en

Rotatin

g

Speed

(rpm)

Time

(min)

1 diamond

pad

Ni-

bonded

diamond

grain

size

20 µm

water hand 150 2

2 SiC-paper

SiC 800 water hand 150 1

3 SiC-

paper

SiC 1200 water hand 150 1

4 synthetic

woven

silk

polishin

g

cloth

diamond

grain

size

3 µm

alcoholic

suspensi

on

90 150 140 6

5 synthetic

leather

polishin

g

cloth

SiO2

0,04 µm

colloidal

silica

suspensi

on

pH 9.8

40 150 140 1

ETCHING, ALTERNATING WITH POLISHING, STAGE 5

100 ml water, 15 ml nitric acid (65 %), 10 ml hydrofluoric acid (40 %) for several seconds at

room temperature

MORE INFORMATION

[email protected]

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Fig. 13: cross section of a metal matrix composite Ti (Timetal 834)/ SiC (SCS-6) fibre

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21/20

MMC-Assess Publications

Volume 1: Glossary of Terms sp ecific to Metal M atrix Compo sit es

Volume 2: Thermal Treatm ents of A ge-hardenable Metal M atrix Compos ites

Volume 3: Metallographic Preparation of M etal M atrix Compos ites

Volume 4: X-R ay Computed Tomography on M etal Mat rix Composit es

Volume 5: Qualit y control and nondestructiv e tests in metal mat rix composit es

Volum e 6: Machining guidelines of Al/SiC parti culate MM C

Volume 7: Thermophy sical Properties of M etal M atrix Compos ites

Volume 8: Guidelines for joining of m etal m atrix composit es

Volume 9: Bomding and interface format ion in M etal M atrix Compo sites

Copyright: MMC-Assess Consortium, August 2000Content: P.Merle

Design: P.Prader

Contact: Insitut e of M aterials Science and Testing – Vienna Univ ersity of Technology

[email protected]: http://mmc-assess.tuwien.ac.at/

metal lo graphic preparation of mmc

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