Abstract
In situ nitridation of pre-compacted aluminium flakes is shown to be a key to lightweight composites for many engineering applications such as more efficient and cost-effective construction vehicles. This new composite has the mechanical properties of high-strength streels while being ∼3.4 times lighter. This composite was produced by: (i) compaction of micrometric Al flakes into porous blanks, (ii) partial melting through rapid heating to 870 K in N2 and (iii) annealing of the pre-melted blanks at 750 K in N2, where different Al flake deoxidisers were used to control a sufficiently low level of H2O/O2 activating in situ nitridation. The nitrided composites contained stellar dendrites composed of Al, AlN and γ-Al2O3, in which the ceramic fraction increases over the nitridation stage. The traces of H2O in the N2 atmosphere were found to be beneficial for strengthening, due to oxidation and suppression of the composite dendrites from overgrowing and segregation.
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