超声激励下铝基碳化硅复合材料变形机理和力学性能研究

铝基碳化硅（SiCp/Al）是一种重要的金属基复合材料，被广泛应用于汽车、航空航天、精密仪器以及光学仪器等制造领域。但由于材料的硬脆性和内部结构的异质性给高效低损伤加工带来了挑战。目前，SiCp/Al使用传统加工技术时往往出现损伤增多以及表面完整性差的问题，因此开发新型SiCp/Al加工技术对于提高该材料质量和生产效率至关重要。超声振动辅助加工已被广泛应用于各种金属材料，其通过引入高频动态载荷以改变材料的力学行为并改善加工性能。然而，不同SiC含量的SiCp/Al复合材料在超声振动作用下的变形机理、微观组织演化以及力学性能变化尚不清晰，限制了超声振动辅助技术在复合材料构件高效低损伤制造中的应用。

本论文旨在研究SiCp/Al复合材料（20%~45%SiC体积含量）和6061铝合金在高频动态载荷条件下的力学响应行为和微观组织演化规律。通过设置超声加载环境进行超声压缩实验，并与常规准静态加载实验平行对照，获得了材料的宏观变形特性；进一步采用纳米压痕技术对材料不同加载模式后的力学性能变化进行表征，并采用SEM、EBSD和TEM等表征方法对其微观组织演化过程进行分析，揭示了不同SiC含量SiCp/Al的动态变形机制。研究结果表明：超声压缩显著提高了SiCp/Al的最大塑性应变量，同时大幅降低了变形应力。在高频动态载荷下，不同SiC含量的SiCp/Al复合材料变形应力从准静态的700 MPa左右显著降低至75 MPa～92 MPa。同时，45％SiC含量的SiCp/Al塑性极限在高频动态载荷下几乎提升了1倍，且无任何宏观裂纹或断裂。当SiC体积含量超过30％时，由于硬质界面对超声加载应力波的增强作用，SiCp/Al在超声加载后的纳米压痕硬度会显著超过常规加载，表现出更强的残余硬化效应。系统分析了超声加载对SiCp/Al变形区域的位错扩散、晶粒细化、再结晶等微观组织演化的促进作用，基于此揭示了高频动态载荷下SiCp/Al的低应力塑性软化变形机理。在此基础上，设计了超声辅助模压成型方案，验证了SiCp/Al室温下的微结构快速、低应力成型的可行性。本研究为颗粒增强复合材料的超声辅助高效加工和性能调控提供了理论依据，并为复合材料的微结构成型提供了新的技术途径。

Aluminum-based silicon carbide (SiCp/Al) is an important metal matrix composite widely utilized in manufacturing sectors such as automotive, aerospace, precision instruments, and optical devices. However, its material brittleness and internal structural heterogeneity pose challenges for efficient and low-damage processing. Currently, traditional processing techniques often lead to increased damage and poor surface integrity when applied to SiCp/Al, highlighting the critical importance of developing novel processing techniques to enhance material quality and production efficiency. Ultrasonic vibration-assisted processing has been extensively employed in various metal materials, leveraging high-frequency dynamic loads to alter material mechanical behavior and improve processing performance. However, the deformation mechanisms, microstructural evolution, and mechanical property changes of SiCp/Al composites with different SiC contents under ultrasonic vibration remain unclear, thereby limiting the application of ultrasonic vibration-assisted techniques in the efficient and low-damage manufacturing of composite components.

This thesis aims to investigate the mechanical response behavior and microstructural evolution of SiCp/Al composite materials (with SiC volume fractions ranging from 20% to 45%) and 6061 aluminum alloy under high-frequency dynamic loading conditions. A series of ultrasonic compression experiments were conducted using a designed ultrasonic loading device, and parallel conventional quasi-static loading experiments were performed to obtain the materials' macroscopic deformation characteristics. Furthermore, nanoindentation techniques were employed to characterize the mechanical property changes of the materials under different loading modes. SEM, EBSD, and TEM characterization methods were utilized to analyze the microstructural evolution process, revealing the dynamic deformation mechanisms of SiCp/Al composite materials with different SiC contents. The findings indicate that ultrasonic compression significantly increases the maximum plastic strain of SiCp/Al composite materials while greatly reducing the deformation stress. Under high-frequency dynamic loading, the deformation stress of SiCp/Al composite materials with different SiC contents decreases significantly from around 700 MPa under quasi-static loading to 75 MPa to 92 MPa, which is only about 1/10 of the deformation stress under traditional quasi-static loading. Meanwhile, the plastic limit of SiCp/Al composite with 45% SiC content almost doubles under high-frequency dynamic loading, with no macroscopic cracks or fractures observed. When the SiC volume fraction exceeds 30%, due to the enhanced effect of the hard interface on the stress wave of ultrasonic loading, the nanoindentation hardness of SiCp/Al after ultrasonic loading significantly exceeds that of traditional loading, demonstrating a stronger residual hardening effect. The thesis systematically analyzes the promotion effect of ultrasonic loading on the microstructural evolution of SiCp/Al, including dislocation diffusion, grain refinement, and recrystallization in the deformation region. Based on this, the low-stress plastic softening deformation mechanism of SiCp/Al under high-frequency dynamic loading is revealed. Based on these findings, an ultrasonic-assisted molding scheme is designed, verifying the feasibility of rapid and low-stress forming of SiCp/Al at room temperature. This study provides theoretical basis for the ultrasonic-assisted efficient processing and performance regulation of particle-reinforced composite materials and offers new technical approaches for the microstructure formation of composite materials.

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