Development of Carbon Fiber Reinforced Stellite Alloy Based Composites for Tribocorrosion ...

203 Pages·2013·9.63 MB·English

Development of Carbon Fiber Reinforced Stellite Alloy
Based Composites for Tribocorrosion Applications
by
Alireza Khoddamzadeh
B. Eng., M.A.Sc. Materials
A thesis submitted to the Faculty of Graduate and Postdoctoral Affairs
in partial fulfilment of the requirements
for the degree of
Doctor of Philosophy
in
Mechanical Engineering
Ottawa-Carleton Institute for
Mechanical and Aerospace Engineering
Department of Mechanical and Aerospace Engineering
Carleton University
Ottawa, Ontario, Canada
June, 2012
Copyright ©2012
Alireza Khoddamzadeh
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Abstract
This thesis reports the design and development of two classes of new composite
materials, which are low-carbon Stellite alloy matrices, reinforced with either chopped
plain carbon fiber or chopped nickel-coated carbon fiber. The focus of this research is on
obviating the problems related to the presence of carbides in Stellite alloys by
substituting carbides as the main strengthening agent in Stellite alloys with the
aforementioned carbon fibers. Stellite 25 was selected as the matrix because of its very
low carbon content (0.1 wt%) and thereby relatively carbide free microstructure. The
nickel coating was intended to eliminate any chance of carbide formation due to the
possible reaction between carbon fibers and the matrix alloying additions. The composite
specimens were fabricated using the designed hot isostatic pressing and sintering cycles.
The fabricated specimens were microstructurally analyzed in order to identify the main
phases present in the specimens and also to determine the possible carbide formation
from the carbon fibers. The material characterization of the specimens was achieved
through density, hardness, microhardness, corrosion, wear, friction, and thermal
conductivity tests. These novel materials exhibit superior properties compared to existing
Stellite alloys and are expected to spawn a new generation of materials used for high
temperature, severe corrosion, and wear resistant applications in various industries.
Acknowledgements
I would like to express my sincere gratitude to my thesis supervisors, Professor
R. Liu and Professor M. Liang, for their continuous support throughout this research.
I wish to thank my NRC co-supervisor Dr. Q. Yang, Dr. X. J. Wu, T. Benak, A.
Merati and N. Powell for their generous help.
I also wish to thank Dr. M. X. Yao of Kennametal Stellite for technical guidance
through the progress of the project.
I am also grateful to D. Morphy, D. Chow, R. MacNeil, and M. Genest for their
assistance in my laboratory work at the National Research Council Canada (NRC).
Deepest thanks to my family and especially my parents who are a source of
unwavering love and encouragement and my friends for their energetic support.
Table of Contents
Abstract ....... iii
Acknowledgements.....................................................................................................................iv
Table of Contents..........................................................................................................................v
List of Tables................................................................................................................................x
List of Figures.............................................................................................................................xii
Nomenclature...........................................................................................................................xvii
List of Acronyms......................................................................................................................xix
Chapter 1: Introduction................................................................................................................1
1.1 Background of Present Research.....................................................................................1
1.1.1 Synopsis of Stellite Alloys.........................................................................................1
1.1.2 Chemical Compositions of Stellite Alloys..............................................................2
1.1.3 Carbide Related Issues in Stellite Alloys................................................................3
1.1.4 Fabrication of Stellite Alloys....................................................................................5
1.2 Plan of Present Research...................................................................................................6
1.2.1 Objectives...................................................................................................................6
1.2.2 Tasks and Methodologies.........................................................................................6
1.3 Organization of the Thesis..............................................................................................10
Chapter 2: Literature Review.....................................................................................................12
2.1 Superalloys........................................................................................................................12
2.1.1 Fundamentals and Classification............................................................................12
2.1.2 Properties and Application.......................................................................................13
2.2 Cobalt-Based Superalloys................................................................................................14
2.2.1 Elemental Cobalt.......................................................................................................14
2.2.2 History and Characteristics......................................................................................17
2.2.3 Main Groups.............................................................................................................19
2.3 Stellite Alloys....................................................................................................................19
2.3.1 Chemical Constituents.............................................................................................19
2.3.2 Machinability and Application...............................................................................23
2.3.3 Tribocorrosion Properties.......................................................................................24
2.3.4 Processing Methods.................................................................................................28
2.4 Composite Materials........................................................................................................29
2.4.1 Types of Composite Materials................................................................................29
2.4.2 Metal Matrix Composites.......................................................................................30
2.4.3 Carbon Fibre Reinforced MMCs............................................................................33
Chapter 3: Specimen Fabrication................................. 37
3.1 Raw Materials..................................................................................................................37
3.1.1 Matrix Material.........................................................................................................37
3.1.2 Reinforcement Material...........................................................................................38
3.2 Mixture of Powders..........................................................................................................41
vi
3.2.1 Chemical Composition of the Composites...........................................................41
3.2.2 Powder Blending......................................................................................................42
3.3 Fabrication Process.........................................................................................................42
3.3.1 Hot Isostatic Pressing...............................................................................................42
3.3.2 Preparation of Containers.......................................................................................43
3.3.3 Differential Scanning Calorimetry.........................................................................44
3.3.4 Design of HIPing/Sintering Cycle.........................................................................47
Chapter 4: Material Characterization.......................................................................................50
4.1 Microstructural Analysis.................................................................................................50
4.1.1 Objectives.................................................................................................................50
4.1.2 Surface Preparation..................................................................................................51
4.1.3 Apparatus..................................................................................................................53
4.1.4 Carbide Volume Fraction Analysis........................................................................54
4.2 Density Measurement.....................................................................................................55
4.3 Corrosion Test..................................................................................................................56
4.4 Hardness Test...................................................................................................................58
4.4.1 Macrohardness..........................................................................................................58
4.4.2 Microhardness...........................................................................................................59
4.5 Wear and Friction Tests..................................................................................................60
4.5.1 Sliding Wear.............................................................................................................60
4.5.2 Test Parameters........................................................................................................61
4.5.3 Data Collection........................................................................................................61
vii
4.6 Thermal Conductivity.....................................................................................................63
4.6.1 Background...............................................................................................................63
4.6.2 Methodology..........................................................................................;.................63
Chapter 5: Eperimental Results................................................................................................65
5.1 Plain Carbon Fibre Reinforced Composites.................................................................65
5.1.1 Microstructure...........................................................................................................65
5.1.2 Density......................................................................................................................68
5.1.3 Corrosion Resistance...............................................................................................68
5.1.4 Hardness....................................................................................................................70
5.1.5 Friction and Wear Resistance.................................................................................71
5.2 Ni-Coated Carbon Fibre Reinforced Composites........................................................74
5.2.1 Microstructure...........................................................................................................74
5.2.2 Density......................................................................................................................75
5.2.3 Corrosion Resistance...............................................................................................76
5.2.4 Hardness....................................................................................................................76
5.2.5 Friction and Wear Resistance.................................................................................77
5.3 Supporting Tests Results.................................................................................................79
5.3.1 Microhardness...........................................................................................................79
5.3.2 Thermal Conductivity..............................................................................................80
Chapter 6: Discussion................................................................................................................82
6.1 Carbide Volume Fraction..............................................................................................82
viii
6.2 Beneficial Effects of Carbon Fibres...............................................................................84
6.3 Effects of Nickel Coating................................................................................................94
Chapter 7: Conclusions and Future Work................................................................................96
7.1 Conclusions......................................................................................................................96
7.2 Cotributions.....................................................................................................................101
7.3 Future Work....................................................................................................................102
References ..............................................................................................................................104
Tables ..............................................................................................................................117
Figures .............................................................................................................................128