FEMS EUROMAT 2023
Lecture
05.09.2023
Aluminium matrix composites for lightweight components
LL

Lucia Lattanzi (Ph.D.)

Jönköping University

Lattanzi, L. (Speaker)¹; Awe, S.²; Jansson, P.³; Rudenstam, C.⁴; Westergård, R.⁵; Jarfors, A.E.¹
¹School of Engineering - Jönköping University; ²Automotive Components Floby AB; ³Comptech i Skillingaryd; ⁴Husqvarna AB, Huskvarna (Sweden); ⁵Gränges Finspång AB
Vorschau
18 Min. Untertitel (CC)

Aluminium-based metal matrix composites (MMCs) can successfully substitute cast iron in the production of automotive components, like brake discs, clutches and pistons. Not limited to automotive, these materials are promising for similar components that require good wear resistance and mechanical stability at elevated temperatures and would benefit from the lightweight feature of the aluminium matrix. The aluminium-based MMCs provide good tribological performance and suitable thermophysical properties combined into a lightweight solution. The two main challenges lie in the high-temperature mechanical properties and the recyclability of the composite at the products’ end-of-life. Transition metals like nickel (Ni) and copper (Cu) are known to improve the thermal stability of aluminium alloys. In addition, Ni and Cu are not on the 2020 critical raw materials list by the European Commission. Maintaining a suitable mechanical response at elevated temperatures is one critical requirement for automotive components like brake discs and pistons. The project focuses on characterising Al-Si-based MMCs reinforced with 20 wt.% of SiC particles. The composites were produced by squeeze casting with 3 wt.% of Ni and 0.5 wt.% of Cu to the matrix alloy. The performance is compared to a current commercial solution developed for light brake discs, with a maximum operating temperature of 420 °C. The present study aims at increasing this temperature to 470 °C. The addition of Ni determined the formation of Al3Ni as part of the ternary eutectic Al-Si-Al3Ni. The amount of Cu did not determine the precipitation of Cu-based phases. Compression tests were conducted at room temperature and up to 470 °C, with different strain rates from 0.001/s to 1/s. The peak stress increased by 60 % at 350 °C with adding Ni and by 90 % at 470 °C, compared to the reference composite without Ni. The presence of Cu determined a further 10 % increase at 350 °C, stabilising the mechanical response at higher temperatures. Ni is a promising element for improving the maximum operating temperature of the currently available composite. Cu presents issues related to eco-toxicity and corrosion resistance; thus, it is a relevant addition for applications without restrictions or concerns in these aspects and that target temperatures up to 350 °C.

Abstract

Abstract

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