In situ (Al3Zr + Al2O3np)/2024Al metal matrix composite with novel reinforcement distributions fabricated by reaction hot pressing

In situ hybrid (Al3Zr + Al2O3np)/2024Al metal matrix composites with unique controlled reinforcement distributions were fabricated using low energy ball milling and reactive hot pressing. The reaction system between 2024Al and ZrO2 was studied using differential thermal analysis (DTA). In situ formed aluminium oxide (Al2O3) and zirconium tri-aluminide (Al3Zr) with varying morphology and sizes were produced under different fabricating conditions. Al3Zr with varying morphologies such as particle, plate and flakes were observed. With a total 10 vol.% of reinforcements, the composite containing a three-dimensional network of closely spaced in situ synthesized Al3Zr and Al2O3 particles had a YS of 175 MPa and a UTS of 261 MPa, effectively strengthening the 2024Al matrix. The effect of different sintering conditions on the microstructure and tensile properties of the composite was systematically investigated. Crown Copyright (c) 2013 Published by Elsevier B.V. All rights reserved.