6

PROCESSING

bundle of cylindrical capillary tubes (Martins et al. 1988; Maxwell et al. 1990). Other analyses, initially proposed in Japan and the United Kingdom, model the preform as a continuum (Clyne et al. 1985; Fukunaga and Goda 1985a; Fukunaga and Goda 1984; Fukunaga and Goda 198Sb; Fukunaga et al. 1983; Fukunaga and Kuriyama 1982; Fukunaga and Ohde 1982; Nagata and Matsuda 1981). In this approach, analysis is based on consideration of a differential volume element AV, which contains pores, metal, and reinforcement elements such as fibers or particles, and is schematically represented in Figure 1.2. Within AV, parameters such as fraction solid metal g,, fiber volume fraction Vf or temperature Tare uniform. Velocities of the fluid phase vi and solid phase v, are also averaged over AV. In most cases, preform deformation is neglected, so the solid phase is assumed to be stationary (v, = 0). However, it is necessary to take the solid velocity into account when preform deformation occurs during infiltration (Sommer 1992). The continuum approach is generally legitimate given the small size of the reinforcements (typically 1 to 20 km in diameter) compared to preform dimensions. Using this continuum approach, Nagata and Matsuda illustrated the possibility of infiltrating preforms having initial temperatures below the metal liquidus (Nagata and Matsuda 1981). Fukunaga and Goda proposed an explanation for the case of pure aluminum: a layer of solidified metal forms around the fibers, allowing for flow of liquid metal around it (Fukunaga and Goda 1984). More recently, the role and interaction of transport phenomena influencing infiltration kinetics and composite microstructure have been investigated

and analyzed quantitatively (Lacoste and Dank 1991; Lacoste et al. 1991; Mortensen et al. 1989; Mortensen and Michaud 1991; Mortensen and Wong 1990). The basic governing equations of these continuum models in general form will now be discussed. Vfi V , and V , are the local volume fraction of reinforcement, , pores, and metal, respectively, such that Vf + V, + V = 1. If a fraction of the metal g, solidifies during infiltration, and V,f represents the local fraction solid in the composite, including reinforcement and solidified g,V,. For a given alloy and metal, then V,f = Vf reinforcement, the following laws govern.

1.1.2*1 F1uid F1ow

F1ow of liquid metal though A v generally fOllom the Forscheimer equation:

f - VP

[pVm(l - gs)K-'

+BprnGG21(v,

- vs)

(1-1)

where f is the local volumetric value of the gravitational, centrifugal, or electromagnetic force applied to AV, P the average pressure in AV, and p the viscosity of the liquid metal, which is a function of the metal temperature and composition. K, the local permeability tensor of the preform, and B are functions of V , and of the morphology and volume fraction of the solidified metal (Beavers and Sparrow 1969; Coulaud et al. 1988). pm is the metal density, assumed here to be the same in the solid and liquid state. When the relevant Reynolds number is below a critical value near one:

Figure 1.2. Schematic representation of a volume element AV, containing liquid metal, solid metal, fibers, and pores.