In this research, the effects of nanodiamond (ND) addition at different loadings on the compressive and wear properties of the interpenetrating phases hybrid aluminum/alumina (Al/Al2O3) composite were investigated. The samples were fabricated in a two-step process. First, the Al2O3-ND preforms were fabricated via the replica method. Second, the squeeze casting route was employed to infiltrate the molten pure Al. The ceramic preforms were made by immersing a polyurethane foam with 17 ppi pores in a slurry containing α-Al2O3 powder (1 μm), ND particles (0–10 vol%), and natural egg white. After sintering at 1500 °C for 4 h, the preheated preforms were infiltrated with molten Al. The microstructural evaluations of the preforms and composites revealed a proper distribution of the ND particles in the preform, as well as the formation of the ND agglomerates at higher volume percentages. Also, the hardness of the samples enhanced with an increase in the ND loading, reaching a maximum of 263.8 Vickers for the 10 vol% ND-loaded composite. The compressive strength of the samples enhanced up to 3 vol% ND addition and then decreased due to the agglomeration. The wear test results indicated that the best behavior was related to the 3 vol% ND-loaded composite. Embedding the 3 vol% ND decreased the weight rate and friction coefficient of the interpenetrating phases hybrid Al/Al2O3 composite by 16 % (from 8.2396×10−3 to 6.9269×10−3 mm3/m) and 12 % (0.8165 to 0.7238), respectively. The study of the worn surfaces of the samples after wear testing revealed that the dominant wear mechanisms were abrasive and adhesive for the higher and lower volume fractions of the ND, respectively.
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