Ultrasonic nanowelding of SiC microparticles on Al surface

doi:10.1016/j.apsusc.2012.02.094

Applied Surface Science

Volume 258, Issue 15, 15 May 2012, Pages 5786-5789

https://doi.org/10.1016/j.apsusc.2012.02.094 Get rights and content

Abstract

Ultrasonic nanowelding technique was used to coat silicon carbide (SiC) particles on aluminium (Al) substrate. Both sparse SiC particles and dense particle coating layers were fabricated on Al surface. Detailed analysis shows that SiC particles are bonded and compacted well with the Al surface after the ultrasonic nanowelding process, but no structural transformation and chemical combination at the interface between SiC and Al were observed. The samples of the SiC coatings nanowelded on Al surface possess high hardness, and bigger SiC particle size results in higher hardness values. Corrosion tests reveal that the corrosion resistant properties of Al are improved with the nanowelded SiC coatings.

Highlights

► Ultrasonic nanowelding was developed to coat SiC particles on Al surface. ► SiC particles were bonded and compacted well with the Al substrate. ► The microhardness and anticorrosion properties were improved after nanowelding.

Introduction

Aluminium and its alloys have been widely used in aeronautical, chemical, and transportation industries due to their low density and high specific strength [1]. However, the easy worn and corrosion of its surface is a serious problem for many applications, which cause material waste and equipment failure. Hence, there is an interest in improving surface properties of Al through various surface modifications such as electrophoretic deposition [2], plasma spraying [3], [4], and laser cladding [5], [6]. Electrophoretic deposition offers advantages of uniform coatings [7]; however, the adhesion between coatings and substrates is usually poor and limits the application. Plasma spraying and laser cladding are capable of coating a thick-film in short operating time with many pores and cracks on the coatings. Most of the above mentioned methods involve depositing ceramics particles like SiC, Al₂O₃, and B₄C as the enhanced coatings on the surface of Al [8]. SiC particles, among these ceramics, are the most promising material due to their high hardness and excellent corrosion resistance. Although great progress has been made, other methods should be explored to improve surface properties of Al with good adhesion, low cost and uniformity.

A simple ultrasonic nanowelding technique [9] was developed for bonding nanomaterials on metal electrodes. The bonds formed were measured to be mechanically strong and the performance was demonstrated to be not depending on the specific kind of nanocomponent or metal electrodes. Moreover, it is hopeful that the ultrasonic welding area can be scaled up so that multiple bondings on a substrate can be achieved in a single step, under one single press vibrating at a specific ultrasonic frequency. In this paper, the simple ultrasonic nanowelding method has been used to bond SiC particles on Al substrate, and the surface properties of Al welded with different particle sizes are studied using structural and mechanical analyses.

Section snippets

Experimental

SiC particles with average diameter of 2 μm, 5 μm and 10 μm were used in the experiments. Cleaned Al plates with purity of 99.99% and thickness of 500 μm were used as substrates. SiC particles were laid on Al surface by screen printing method. The binder was mixed with 20 wt.% terpineol, 70 wt.% isopropyl alcohol and 10 wt.% ethylcellulose, and prepared on hot plates. SiC particles and the binder (in the weight ratio of 1:2) were stirred in the paste-stirring machine to form a paste. The paste was

Results and discussion

Fig. 1 shows typical SEM images of the welded sample with different SiC sizes. For comparison, half of the sample with 2 μm SiC was welded. As shown in Fig. 1a, the ultrasonic welding produces an apparent welded zone due to the vibration of the welding head. In the unwelded zone, SiC particles loosely lay on the surface of Al substrate (Fig. 1b). Inside the welded zone (Fig. 1c), SiC particles and Al substrate are compacted and bonded together to form a new welded surface. Almost all particles

Conclusions

Ultrasonic nanowelding technique was used to weld SiC particles on Al substrate. The microhardness and anticorrosion properties were improved because of the dense welded surface. Detailed analysis shows no structural transformation and chemical combination at the interface between SiC and Al. It should be mentioned that ultrasonic nanowelding experiments have also been performed and resulted in excellent surface properties at SiC coated Ti and Ti alloy. This work demonstrated that ultrasonic

Acknowledgements

This work was supported by National Nature Science Foundation of China (Nos. 50730008 and 51005145), Innovation Program of Shanghai Municipal Education Commission (No. 12ZZ163), and Xuzhou Science and Technology Program No. XZZD1001.

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Ultrasonic nanowelding of SiC microparticles on Al surface

Abstract

Highlights

Introduction

Section snippets

Experimental

Results and discussion

Conclusions

Acknowledgements

J. Mater. Process. Technol.

J. Eur. Ceram. Soc.

Mater. Sci. Eng. A

Surf. Coat. Technol.

Surf. Coat. Technol.

Wear

Carbon