Advancing sintering and matrix-reinforcement interaction in Al/AlN metal matrix composites through use of novel AlN reinforcement

Abstract

Demand for energy-efficient transportation has led to increased use of lightweight aluminium alloys due to their exceptional strength-to-weight. Meanwhile, aluminium-based metal matrix composites (MMCs) are being developed to enhance wear resistance and strength. However, traditional ceramic reinforcements often have poor bonding with the matrix, compromising performance. Here, we demonstrate the use of a novel ex-situ AlN reinforcement powder to enhance sintering and interfacial bonding for powder metallurgy preparation of Al/AlN MMCs. We compared two series of Al/AlN MMCs featuring 10 vol.% ex-situ AlN reinforcement, one prepared using commercial AlN powder, and the other using our novel AlN reinforcement prepared by low temperature direct nitridation of Al powder. Metallic Al contained in the synthesized reinforcement significantly improved interfacial adhesion between matrix and reinforcement and enhanced densification during sintering. This resulted in a substantial improvement in tensile mechanical properties, with an 11.5% increase in ultimate tensile strength and almost five-fold improvement in ductility compared to composites prepared using the conventional ceramic AlN reinforcement. This study provides a strategy for powder metallurgy production of advanced Al/AlN MMCs with superior physical and mechanical properties.