Investigation of thermal residual stresses in layered composite using the finite element method and X-ray diffraction

Research paper by S. Ho, E. J. Lavernia

Indexed on: 01 Dec '97Published on: 01 Dec '97Published in: Metallurgical and Materials Transactions B


A SiC particulate-reinforced 2024Al matrix composite was fabricated using a spray atomization and codeposition process to produce a layered macrostructure. The thermal macro- and microresidual stresses that develop in this layered 2024Al/SiC composite during cooling from the codeposition temperature to ambient temperature were studied using thermoelastoplastic finite element analysis. The calculated residual stresses from finite element method were compared with those obtained from X-ray diffraction (XRD), and good agreement was observed between them. The macroresidual stress distribution was very distinct for the Al and the SiC-rich layers. The macroradial stress was tensile in the Al layers and compressive in the SiC-rich layers. The macroaxial stress was found to be compressive in the vicinity of the center region of the spray-deposited material and to have mostly a continuous distribution in the Al and the SiC-rich layers. The magnitude of the macroaxial stress was noted to decrease with increasing deposition thickness from the bottom. In addition, the spray-deposited material exhibited the highest macro-von Mises’ stress around the outer edge of the deposited material. The microradial stress was in a compressive state in the SiC particulate and in the Al matrix in the vicinity of the SiC particulate. The SiC particulate exhibited compressive microhoop stress, whereas the Al matrix exhibited tensile microhoop stress. The micro-von Mises’ stress was of the highest value at the interface between the SiC particulate and the Al matrix.