Rolled FeCoNiCrRn/Al-2024Al Composite Panel for Strength and Ductility
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Solution Overview
Problem
Traditional particle-reinforced aluminum matrix composites (AMCs) exhibit low ductility and local instantaneous breakability, limiting their application range, while also facing challenges in forming effective interfaces with aluminum matrices, which affects their mechanical properties.
Innovation Solution
A rolled (FeCoNiCrRn/Al)-2024Al composite panel is fabricated by adding FeCoNiCrRn medium-entropy alloy particles as a reinforcing phase to a 2024 aluminum alloy matrix, utilizing hot-roll bonding and microwave sintering to create a stable interface with a FeCoNiCrAl FCC structure, enhancing both strength and toughness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional non-metallic particle reinforcement is used in aluminum matrix composite, then high strength and abrasion resistance are achieved, but effective interface formation with aluminum matrix becomes difficult and brittleness increases
Solution Approach 1:
The patent uses medium-entropy alloy particles (FeCoNiCrAl) as reinforcement instead of traditional non-metallic particles. This composite reinforcement phase combines multiple metallic elements in specific atomic ratios to achieve both high strength and good interfacial compatibility with the aluminum matrix, resolving the contradiction between strength and interface stability.
Solution Approach 2:
The patent optimizes the atomic ratios of Fe, Co, Ni, Cr, and Al elements in the medium-entropy alloy particles, controlling them within specific ranges (e.g., Al: 30-50 at%, Fe: 10-20 at%). This parameter optimization ensures the reinforcement phase achieves high strength while maintaining good wettability and stability with the aluminum matrix.
2Reliability
If medium-entropy alloy particles are used as reinforcement, then excellent interface wettability and stable interface are formed, but the sintering temperature and inherent brittleness of metal-based reinforcing phase are limited
Solution Approach 1:
The patent optimizes the composition parameters of the medium-entropy alloy, specifically controlling the Al content at 30-50 at% and adding small amounts of Y (0.1-5 at%) and R (0.1-5 at%). This compositional parameter optimization lowers the sintering temperature requirement while maintaining interface stability and preventing excessive brittleness.
Solution Approach 2:
The patent introduces Y and R elements in small amounts to specifically improve the interfacial properties and reduce brittleness of the medium-entropy alloy particles. These local compositional adjustments address the brittleness issue without compromising the overall interface stability achieved by the medium-entropy alloy structure.
3Strength
If traditional particle-reinforced AMC is used, then high strength is achieved, but low ductility and local instantaneous breakability severely limit application range
Solution Approach 1:
The patent uses medium-entropy alloy particles with a specific multi-element composition (FeCoNiCrAl system) as reinforcement. This composite reinforcement phase provides both high strength and improved ductility compared to traditional non-metallic particles, as the metallic nature of the reinforcement allows for better plastic deformation and energy absorption.
Solution Approach 2:
The patent optimizes the atomic ratios of the medium-entropy alloy elements, particularly controlling the balance between strengthening elements (Fe, Co, Ni) and ductility-enhancing elements (Al, Y, R). This parameter optimization ensures the composite achieves both high strength and improved ductility, expanding its application range.
4Strength
If FeCoNiCrRn medium-entropy alloy particles are added to aluminum matrix, then high strength and toughness are achieved, but the complexity of controlling multiple element ratios increases
Solution Approach 1:
The patent defines specific atomic ratio ranges for each element in the medium-entropy alloy (Al: 30-50 at%, Fe: 10-20 at%, Co: 10-20 at%, Ni: 10-20 at%, Cr: 5-15 at%, Y: 0.1-5 at%, R: 0.1-5 at%). These parameter specifications simplify the composition control by providing clear ranges rather than requiring precise single-value control, thus reducing complexity while maintaining high strength and toughness.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The composite panel achieves improved mechanical properties, including high strength, toughness, and fatigue crack growth resistance, while maintaining light weight and low cost, addressing the limitations of traditional AMCs by combining the benefits of medium-entropy alloys and 2024 aluminum alloys.
Implementation Method 1
the excellent interface wettability between a metal-based reinforcement and an aluminum alloy matrix makes a stable and effective interface formed between the reinforcement particles and the aluminum matrix
Implementation Method 2
subjecting a 2024Al aluminum alloy plate and the FeCoNiCrRn/Al aluminum matrix composite as raw materials to hot-roll bonding to obtain the rolled (FeCoNiCrRn/Al)-2024Al composite panel
Data Source
AI summary
Disclosed are a rolled (FeCoNiCrRn/Al)-2024Al composite panel and a preparation method therefor. The preparation method involves taking pure aluminum as a matrix, adding an FeCoNiCrRn medium-entropy alloy with a high strength and toughness as an reinforcing phase to prepare an FeCoNiCrRn/Al composite material, then laminating the FeCoNiCrRn/Al composite material with aluminum alloy 2024, and preparing the (FeCoNiCrRn/Al)-2024Al composite board by means of hot-rolling recombination, which solves the problem that high-strength aluminum matrix composites (AMCs) are prone to instantaneous breakability and low ductility, thereby improving the overall performance of the material. The present disclosure adopts microwave sintering (MWS) to fabricate a medium-entropy alloy-reinforced AMC, and adopts hot-roll bonding to fabricate the (FeCoNiCrRn/Al)-2024Al metal composite panel. The composite panel fabricated by the present disclosure has excellent comprehensive mechanical properties, and has high application values for promoting the application of modern lightweight and high-efficiency industrial materials in aerospace, new energy vehicles, and the like.