Spray-atomized and codeposited 6061 Al/SiCp composites

Abstract

Spray atomization and codeposition processes have received considerable attention for the synthesis of discontinuously reinforced metal-matrix composites. This methodology involves the mixing of reinforcements and matrix under thermal conditions such that the matrix contains both solid and liquid phases. In principle, such an approach avoids the extreme thermal excursions, with concomitant degradation in interfacial properties and extensive macrosegregation, normally associated with casting processes. Furthermore, this approach also eliminates the need to handle fine reactive particulates normally associated with powder metallurgical processes. To investigate the utility of this process for the preparation of metal-matrix composites, several silicon carbide particulate-reinforced 6061 Al composites were prepared. The spray-atomized and codeposited materials exhibited attractive combinations of strength, elastic modulus and elongation, although further work is needed to optimize their properties.