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Discussion of ceramic bar reinforced TWIP steel composite structure

  • Guo-jin Sun EMAIL logo , Wang Qi and Hou Miaoyu
Published/Copyright: December 8, 2022
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Science and Engineering of Composite Materials
From the journal Science and Engineering of Composite Materials Volume 29 Issue 1

Abstract

A ceramic–steel composite structure which consists of Si3N4 ceramic bars and twinning-induced plasticity (TWIP) steel matrix was prepared using lost foam casting method. Microstructural analysis indicated that the ceramic bars and TWIP steel matrix can form favorable and tight interface. A comparison of mechanical properties between the composite structure and TWIP steel matrix was made. Results show that the bending strength increased from 388 to 805 MPa compared with TWIP steel matrix. The influence of annealing heat treatment on the bending strength of this new type of composite structure was also discussed.

Keywords: composite structure; Si3N4 ceramic bar; TWIP steel; annealing heat treatment

Composite structures or materials which combine the advantages of two or more material properties have been used in many areas, such as wear resistance parts, heat resistance parts or special vehicle protections [1,2,3,4]. Metal matrix composites whose reinforcements and matrix are ceramics and metals offer more benefits thanks to higher stiffness, improved strength and better wear resistance compared to the unreinforced metal [5,6,7,8]. Oxides (e.g., ZrO2 and Al2O3), nitrides (e.g., Si3N4 and TiN) and carbides (e.g., TiC and VC) [9,10] ceramics are the common materials proposed to be used as reinforcement in metal based composites. Specifically, nitride ceramics have shown their suitability as reinforcements in steel and iron matrices due to their high hardness, low density, high melting temperature and high corrosion resistance [11].

Recently, some researchers have focused on metal matrix composites on the basis of steel matrix which exhibits special deformation properties. Nowadays, researchers continuously pay attention to the ceramic reinforced steel with the hope to improve the plastic deformation capacity. For example, steels with transformation-induced plasticity (TRIP steels) properties were processed with zirconia acting as particle reinforcements [12,13]. TRIP-steel matrix shows a high ductility and strain hardening capability [14], especially under compressive loading conditions. Particle reinforcements can improve the mechanical properties of steel matrix [15], which leads to a possible application of the materials in crash absorber components [12,16]. Simple changes in the chemical compositions of TRIP steel matrix trigger another important deformation mechanism, namely, mechanical twinning. Also, steels with twinning-induced plasticity (TWIP) effect exhibits excellent strain hardening properties and ductility [17]. Therefore, TWIP steels reinforced by Si3N4 ceramic bars are of interest at present.

It is generally accepted that with the increase in ceramic volume fraction, the wear resistance rises with the decrease in density, but there exists a limit value of reinforcement volume fraction for normal particle reinforced composite. Therefore, several excellent works have carried out research on the combination of monolithic ceramic with metals which can offer more efficient, lightweight and wear resistant structures [18–21]. For example, Sanusi et al. investigated a ceramic–steel composite structure and pointed out that ceramic–steel composite was much more effective in protection performance than medium carbon steel [22]. Ishchenko et al. studied a two-layer metal–ceramic composite which showed a high resistance to the penetration of the steel impactor [23]. Baumgart et al. prepared ceramic particles reinforced TWIP steel with different ceramic range from 0 to 10 vol%, and the results showed that TWIP matrices were much more damage-tolerant [24].

As mentioned above, addition of ceramics often provide a mechanical enhance of steel and many previous work also concentrated on ceramic reinforced steel matrix composites or structures. In fact, it should be noted that most of the reinforcement size in steel composites ranges from nanometers to micrometers in the purpose of ensuring the mechanical or microstructural properties. A few examples have been reported about ceramic bars reinforced TWIP steel composite structures. So, the objective of this study is to investigate the feasibility of processing this new type of TWIP steel matrix composite structure whose reinforcement is silicon nitride ceramic bars. The possibility of further improving the mechanical properties through a simple annealing heat treatment will be discussed here.

1 Experimental procedures

A set of commercially available silicon nitride (Si3N4) ceramic bars with a size of Φ5 mm × 95 mm were chosen as the reinforcements. Lost foam casting method is widely used to fabricate metal matrix composites or other locally reinforced composites because of the low cost and high efficiency. So, lost foam casting is adopted here to fabricate the composite structure. As shown in Figure 1, after polished and cleaned in alcohol, ceramics were inserted into the foam mold pattern which is made of polystyrene with a density of 0.03 g cm−3. Then, the foam mold patterns were coated and dried at 45°C for 24 h. The foam mold patterns were coated and dried for no less than 3 times in order to form a coating which is about 3 mm thick. Then, foam patterns were fixed in sand box whose size is 1 m × 1 m × 2 m. After filling with silica sand of 40–20 mesh size, the sand box is facilitated by a four-point clamping for 5 min at horizontal vibration. A 30 mm × 200 m × 400 m TWIP steel matrix without ceramics were also prepared for the mechanical properties and microstructure analysis.

Figure 1 Schematic picture of composite foam pattern.
Figure 1

Schematic picture of composite foam pattern.

The TWIP steel matrix has the composition of Fe–20Mn–0.6C and is prepared by intermediate frequency furnace using medium carbon steel, low carbon ferro-manganese and casting iron as raw materials. First, the medium carbon steel and casting steel were melted and held at 1,600°C for about 5 min. Then, low carbon ferro-manganese was added into the melt and soaked for 10 min during which aluminum deoxidation is used to avoid the burning of manganese alloying element. Finally, the melt is poured into the foam pattern at 1,600°C.

After being solidified, the castings were removed from the sand box. The inner macrostructure assessment was performed through non-destructive computerized tomography (CT) techniques. Annealing process which is shown in Figure 2 was carried out in a box heat treatment furnace based on previous experimental results [25]. The heating rate was 5°C min−1 and the cooling mode was air cooling. Scanning electron microscope (SEM) and optical microscopy (OM) were used to investigate the microstructure of composite structures. The mechanical properties were characterized through three points bending test at a rate of 2 mm min−1 on a MST testing machine. Bending specimens of reinforcement unit with a cross section size of 12 mm × 12 mm were machined from the composite structure. As illustrated in Figure 3, the ceramic bar is located in the center of the bending sample.

Figure 2 Annealing heat treatment process.
Figure 2

Annealing heat treatment process.

Figure 3 Schematic diagram of bending specimens.
Figure 3

Schematic diagram of bending specimens.

2 Results and discussion

Non-destructive CT and SEM results are shown in Figures 4 and 5. Non-destructive CT photo of composite structure in Figure 4(b) reveals that there are no cracks, cavities, inclusions or other types of macroscopic imperfections in the TWIP steel matrix. The ceramics have been fully integrated into TWIP matrix steel. The SEM and Back electron image (BEI) results at the interface are shown in Figure 4(c) and (d) from which a perfect interface between ceramic bar and TWIP steel matrix could be observed. There exists a long crack which should be formed during the specimen preparing process due to uncontrollable factors. Energy dispersive scanning (EDS) results in Figure 5 show that alloying element diffusion phenomena exists at the interface. From the results of Figures 4 and 5, it can be concluded that the ceramic bars and TWIP steel matrix can form a favorable and tight interface.

Figure 4 (a) Photograph of TWIP steel composite structure and (b) non-destructive CT photo of composite structure. (c) SEM microstructure, and (d) BEI of interface between ceramic bar and TWIP steel matrix.
Figure 4

(a) Photograph of TWIP steel composite structure and (b) non-destructive CT photo of composite structure. (c) SEM microstructure, and (d) BEI of interface between ceramic bar and TWIP steel matrix.

Figure 5 (a) SEM microstructure of interface, (b) Fe and (c) Si alloying elements distribution at interface.
Figure 5

(a) SEM microstructure of interface, (b) Fe and (c) Si alloying elements distribution at interface.

Bending curves and specimens after bending test are shown in Figure 6. As shown in Figure 6(a), an increase in strength and plasticity is demonstrated in the ceramic–steel composite compared with the TWIP steel matrix without ceramic bars. The bending strength of TWIP steel matrix is 388 MPa, while it reaches 805 MPa after combining with ceramics. This can be related to the strengthening effect of ceramic bars. Clamp displacement during bending test, which can be considered as a character of plasticity of TWIP steel matrix, is about 3 mm, while for the composite structure, it is about 6.8 mm. For TWIP steel matrix, after bending test, the specimen fractures completely, while only a short crack is formed in the composite structure even though bearing much more plastic deformation, as shown in Figure 6(b). Both the strength and plasticity of ceramic–steel composite structure are improved notably compared with the TWIP steel matrix under the same conditions.

Figure 6 Bending curves (a) and specimens after bending test (b).
Figure 6

Bending curves (a) and specimens after bending test (b).

A simple annealing heat treatment whose temperature and holding time are 500°C and 60 min respectively is selected to verify that it is possible to further improve the mechanical properties of this ceramic–steel composite structure. After heat treatment, bending test under the same conditions are used again to characterize the mechanical properties, and the results are shown in Figure 7. From Figure 7, it can be inferred that the bending strength of composite structure increased from 805 to 1,023 MPa while the clamp displacement increased from 6.8 to 9.6 mm after annealing heat treatment.

Figure 7 Bending strength of composite structure before and after heat treatment.
Figure 7

Bending strength of composite structure before and after heat treatment.

The increase in mechanical properties of ceramic–steel composite structure after annealing heat treatment can be attributed to the mechanical enhancement of TWIP steel matrix [25]. Even though annealing heat treatment has little effect on the ceramic bars, the mechanical properties of TWIP steel matrix are improved significantly. After annealing heat treatment, fine carbide particles were formed on the austenite matrix which has great influence on the mechanical properties of TWIP steels. As shown in Figure 8(a) and (b), the grain size of TWIP steel matrix before and after annealing heat treatment has no significant changes because the annealing temperature was not high enough. But there were precipitate particles to be observed after annealing heat treatment which enhanced the mechanical properties of TWIP steel matrix, as shown in Figure 8(c) and (d).

Figure 8 OM microstructure under casting (a) and annealing (b) conditions. Precipitation distribution under casting (c) and annealing (d) conditions.
Figure 8

OM microstructure under casting (a) and annealing (b) conditions. Precipitation distribution under casting (c) and annealing (d) conditions.

The SEM and EDS results of TWIP steel matrix after annealing heat treatment are shown in Figure 9. EDS results indicate that the particles have abundant carbon, manganese and ferro which may be (Fe, Mn)3C precipitations. So the strength of TWIP steel matrix is enhanced after annealing heat treatment because of precipitation strengthening effect. This is consistent with the previous works [26,27]. Usually, the plasticity decreases with the increase in strength, but the plasticity of TWIP steel matrix is improved. This can be attributed to the decrease in stacking-fault energy (SFE) which plays an important role in the mechanical-induced twinning behavior of matrix. Considerable research efforts have been devoted to the influence of SFE on the mechanical properties of TWIP steel. Frommeyer et al. investigated the influence of SFE on the twinning behavior of TWIP steels and found that twinning occurred when the SFE was about 25 mJ m−2 [28]. Han and Hong reported that mechanical twinning occurs when the SFE ＜ 60 mJ m−2 [29]. For the present TWIP steel matrix, the SFE value is about 20–40 mJ m−2. After annealing heat treatment, the value of SFE decreases because of carbide precipitation. So the mechanical-induced twinning behavior could occur more easily [28,29]. The different twinning effects of TWIP steel matrix after tensile under casting and annealing conditions are shown in Figure 10. In Figure 10, it can be seen that more mechanical twins were formed after annealing heat treatment. Both the strength and plasticity of TWIP steel matrix are modified after annealing heat treatment. So the mechanical properties of this ceramic reinforced TWIP composite structure are improved because of the modification of TWIP steel matrix.

Figure 9 SEM microstructure of TWIP steel matrix and EDS analysis results of precipitations.
Figure 9

SEM microstructure of TWIP steel matrix and EDS analysis results of precipitations.

Figure 10 Twinning morphology of TWIP steel matrix before (a) and after (b) annealing heat treatment.
Figure 10

Twinning morphology of TWIP steel matrix before (a) and after (b) annealing heat treatment.

3 Conclusion

In this study a new type of ceramic bar reinforced TWIP steel composite structure which displayed competitive mechanical properties were investigated. The following conclusions can be made from the aforementioned investigations:

  1. TWIP steel combined with a size of φ 5 mm × 95 mm Si3N4 ceramic bars was successfully prepared through lost foam casting process.

  2. A favorable and tight interface was formed between the ceramic bars and TWIP steel in the composite structure.

  3. The bending strength of composite structure is 805 MPa which is much higher than that of TWIP matrix (only 388 MPa). After annealing at 500°C for 60 min, the bending strength of composite structure increased once more from 805 to 1,023 MPa.

  4. Annealing at 500°C for 60 min is a useful process for the modification of this new type composite structure.

  1. Funding information: This study was financially supported by the Key Scientific and Technological Projects in Henan Province (No. 182102210262) and the Fund Project of Henan Institute of Technology, China (KQ1823).

  2. Conflict of interest: Authors state no conflict of interest.

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Received: 2022-10-16
Accepted: 2022-11-13
Published Online: 2022-12-08

© 2022 the author(s), published by De Gruyter

This work is licensed under the Creative Commons Attribution 4.0 International License.

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https://doi.org/10.1515/secm-2022-0173
Keywords for this article
composite structure; Si3N4 ceramic bar; TWIP steel; annealing heat treatment
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