Determination and Relaxation of Residual Stress in 2024 Al-30 vol.% Magnesium Borate Whisker Composites

Residual stresses in 30 vol.% magnesium borate whisker-reinforced 2024 aluminum matrix composites have been determined by a nanoindentation method which takes into consideration pile-up and sink-in effects on indentation contact depth. Owing to the thermal mismatch and the large difference in elasticity modulus between the Al matrix and MBO whiskers, tensile residual stress was introduced to Al matrix material during fabrication. It was found that the solution treatment reduced the tensile residual stress by producing interfacial component and dislocations in the composites. Cryogenic cooling released the stress via reversing the tensile residual stress to compression in the matrix, which was more effective than solution treatment to release the tension stress in the composites. The combination of the solution treatment and the cryogenic cooling provided the most effective procedure to release the residual stress in the composites, which reduced the tensile residual stress from 232.6 to 56.5 MPa, i.e., 76% reduction. Meanwhile, no cracks were observed in the composite when processed with such sudden thermal shocking.