Densification Study of Cu-Al-SiC Composite Powders Prepared by Mechanical Milling

Abstract

This work involves the preparation of Cu-Al-SiC composite powders by a high-energy milling process and the study of their densification behavior by cold compaction. The goal of the milling process is to get embedded the ceramic particles in the metal matrix to enhance the distribution of the metal and ceramic phases in the compacts, an important condition to derive in isotropic properties of consolidated materials. For comparison purposes, compressibility tests of a Cu-5Al matrix prepared by high-energy milling were performed; while additions of 1, 5 and 10 vol.% SiC were added to the matrix. It was found that the high-energy milling process leads to Cu-Al-SiC composite powders with a homogeneous distribution of the reinforcement in the matrix. Compressibility essays showed that densification of the powders decreased with SiC content; a densification of 73.7% was obtained for composites with 10% SiC compared to 76.0% for samples with 1% SiC at the maximum load applied. Milling time reduced the plastic deformation capacity of the matrix leading to fracture of the cold welded aggregates; the fracture process was accelerated by the addition of the hard reinforcement particles. Thus, morphology of the powders changed from laminar, to fine fragments and coarse aggregates, affecting the compaction behavior.