Composite Materials Infiltrated by Aluminium Alloys Based on Porous Skeletons from Alumina, Mullite and Titanium Produced by Powder Metallurgy Techniques

The infiltration technology with reinforcement in the form of porous skeletons fabricated with powder metallurgy methods has been presented in relation to the general characteristics of metal alloy matrix composite materials. The results of our own investigations are presented pertaining to four alternative technologies of fabrication of porous, sintered skeletons, and their structure and their key technological properties are presented. Porous skeletons made of Al2O3 aluminium are sintered reactively using blowing agents or are manufactured by ceramic injection moulding (CIM) from powder. Porous skeletons made of 3Al2O3⋅2SiO2 mullite are achieved by sintering a mixture of halloysite nanotubes together with agents forming an open structure of pores. Titanium porous skeletons are achieved by selective laser sintering (SLS). The structure and properties of composite materials with an aluminium alloy matrix—mainly EN AC-AlSi12 and also EN AC-AlSi7Mg0.3 alloys—reinforced with the so manufactured skeletons are also described. A unique structure of the achieved composite materials, together with good mechanical properties and abrasive wear resistance at low density, ensured by an aluminium alloy matrix, are indicating broad application possibilities of such composites

TEM Study of the Microstructure of an Alumina/Al Composite Prepared by Gas-Pressure Infiltration

Ceramic injection moulding and gas-pressure infiltration were employed for the manufacturing of alumina/AlSi10Mg composites. Porous ceramic preforms were prepared by mixing alumina powder with a multi-binder system and injection moulding the powder polymer slurry. Then, the organic part was removed through a combination of solvent and thermal debinding, and, finally, the materials were sintered at different temperatures. Degrading the binder enabled open canals to form. The sintering process created a porous ceramic material consisting of alumina without any residual carbon content. During infiltration, the liquid metal filled the empty spaces (pores) effectively and formed a three-dimensional network of metal in the ceramic. The microstructure and properties of the manufactured materials were examined using high-resolution transmission electron microscopy, porosimetry, and bending strength testing. Microscopy observations showed that the fabricated composite materials are characterised by a percolation type of microstructure and a lack of unfilled pores. The research confirmed the diversified nature of the connection at the particle–matrix interface. It was observed that the interphase boundary was characterised by the lack of a transition zone between the components or a continuous transition zone, with the thickness not exceeding 30 nm. Thanks to their increased mechanical properties and low density, the obtained composites could be used in the automotive industry as a material for small piston rings and rods, connecting rods, or even gears