| The study presented in this thesis focuses on developing castable, precipitation-strengthened Al--B4C metal matrix composites (MMCs) for high temperature applications.;In the second part, Sc and Zr were introduced into Al-15vol.% B 4C composites presaturated by Ti, and eight experimental composites with different Sc and Zr levels were prepared via a conventional casting technique. It was found that Sc was involved in the interfacial reactions with B 4C that partially consume Sc. The Sc addition yielded considerable precipitation strengthening in the as-cast and peak aged conditions. To achieve an equivalent strengthening effect of Sc in binary Al-Sc alloys, approximately double the amount of Sc is required in Al-B4C composites. On the contrary, no major Zr reaction products were found at the interfaces and the major part of Zr remained in the matrix for the precipitation strengthening. The combination of Sc and Zr enhanced sthe precipitation strengthening. Two kinds of nanoscale precipitates, Al3Sc and Al3(Sc, Zr), were found in the as-cast microstructure and contributed to the increase in the matrix hardness.;In the third part, all the experimental composites were isothermally aged at 300, 350, 400 and 450°C after a homogenization/solution treatment. Results demonstrate that the addition of Sc generated a considerable precipitation hardening of the matrix of the composites for all aging temperatures applied. The precipitation hardening effect increased when increasing the Sc content and decreased with increase in aging temperature. The combination of alloying Sc and Zr in Al-B4C composites produced a remarkable synergistic effect. The addition of Zr provided not only a strength increase at peak aging but also an improvement of thermal stability. The composites with a high Zr:Sc ratio (≥1) showed excellent thermal stability of the strength up to 400°C. The overaging in these materials was delayed by ∼100°C compared with the Zr-free composites at the same Sc level. The precipitate volume fraction, the average radius and the size distribution of nanoscale Al3Sc and Al3(Sc,Zr) precipitates during the aging process were measured. The Al3(Sc,Zr) precipitates generally showed a much better coarsening resistance than the Al3Sc precipitates.;In the fourth part, two experimental composites with 0.4wt.% Sc and 0.4wt.% Sc plus 0.24wt.% Zr 0were selected to examine the mechanical properties during long-term exposure (2000h) at elevated temperatures from 250 to 350°C. For long-term thermal stability, the mechanical properties of the Sc and Zr containing composite were stable up to 300°C, while the composite containing only Sc exhibited a good softening resistance up to 250°C. At higher temperatures the strengths of both composites decreased with prolonged annealing time. The reduction of the composites' mechanical properties during long-time annealing at higher temperatures was dominated by the precipitate coarsening.;In the first part, B4C plates were immersed in liquid aluminum alloyed with Sc, Zr and Ti to investigate the interfacial reactions between B4C and liquid aluminum The influences of Sc, Zr and Ti on the interfacial microstructure in terms of individual and combined additions were examined. Results reveal that all three elements reacted with B4C and formed interfacial layers that acted as a diffusion barrier to limit the decomposition of B4C in liquid aluminum. The interfacial reactions and the reaction products in each system were identified. With the combined addition of Sc, Zr and Ti, most of the Ti was found to enrich at the interface, which not only offered appropriate protection of the B4C but also reduced the consumption of Sc and Zr at the interface.;Finally, two experimental composites with 0.58wt.% Sc and 0.58wt.% Sc plus 0.24wt.% Zr, were respectively hot-rolled to a 2 mm thick sheet with a total reduction of 93%. Results indicate that the Sc- and Zr-containing composites possessed a good hot rolling processability. (Abstract shortened by UMI.)... |
