Enhanced strength and toughness of carbon fiber reinforced aluminum matrix composite prepared via novel indirect extrusion method

Abstract

The fabrication of large-sized, high-performance CF/Al composites presents significant challenges for the aerospace industry. This study introduces a novel indirect extrusion (IE) method for the high-quality production of CF/Al composites. The study investigates the infiltration mechanism of the alloy liquid during the IE process, highlights the technique's advantages, and systematically analyzes the mechanical properties and failure mechanisms of CF/Al composites. Results show that the aluminum liquid initially fills the interlayers and subsequently penetrates the fiber bundles, effectively shortening the infiltration distance. At a casting temperature of 800°C and an infiltration pressure of 40 MPa, the composite exhibits excellent forming quality and microstructural integrity. Compared to direct extrusion (DE) CF/Al composites, IE-CF/Al composites show significant improvements in compressive strength (16.72 %), flexural strength (16.87 %), fracture toughness (43.18 %), and work of fracture (90.61 %). The interlayer alloy and increased fiber spacing in IE-CF/Al composites enhance energy absorption capacity and reduce the risk of brittle fracture. This process lays a solid foundation for the high-quality production and application of CF/Al composites.