COMPOSITES

SCIENCE AND
TECHNOLOGY
Composites Science and Technology 67 (2007) 737–745
www.elsevier.com/locate/compscitech

Alloying effects on microstructure and mechanical properties of

high volume fraction SiC-particle reinforced Al-MMCs made
by squeeze casting infiltration
a,*
Olivier Beffort , Siyuan Long b, Cyril Cayron c, Jakob Kuebler d, Philippe-André Buffat e

a
Empa, Materials Science and Technology, CH-3602 Thun, Switzerland
b
College of Mechanical Engineering, Chongqing University, Chongqing 400044, China
c
Commissariat à l’Energie Atomique, CEA, F-38054 Grenoble Cedex 9, France
d
Empa, Materials Science and Technology, CH-8600 Duebendorf, Switzerland
e
Swiss Federal Institute of Technology, EPFL-CIME, CH-1015 Lausanne, Switzerland

Received 22 March 2006; accepted 28 April 2006

Available online 19 June 2006

Abstract

The mechanical properties of high volume fraction SiC-particle reinforced Al-based metal matrix composites (MMCs) produced by
means of pressurized liquid metal infiltration (squeeze casting) are shown to be triggered by matrix alloying and heat treatment proce-
dures. It is distinguished between the effect of those alloying elements that only act on matrix strengthening, leaving the interface unaf-
fected, and those alloying elements that interact with both (i.e. Mg). Among the first category a further sub-division is made between
pure solid solution and precipitation hardening elements (i.e. Zn and Cu, ZnMg, respectively). In particular, this study addresses the
effect of alloying and age hardening for AlCu3 and AlZn6Mg1 as well as the specific role of Mg additions to Al/SiC MMCs on interface
microstructure formation, mechanical properties and fracture mode. For instance, it is shown that single additions of Mg catalyse the
formation of Al4C3 whereas additions of Cu as well as (Zn + Mg) provide opportunities to enhance the composites’ strength.
 2006 Elsevier Ltd. All rights reserved.

Keywords: A. Metal matrix composites (MMCs); B. Mechanical properties; B. Microstructure; B. Interface; B. Fracture; E. Liquid metal infiltration
(LMI)

1. Introduction stiffness and strength as well as low thermal distortion

and good damage tolerance are required, such as in sport-
Particle reinforced Al/SiC metal matrix composites ing goods, automotive engineering, aerospace industry,
(MMCs) with high SiC loadings (e.g. 50–75 vol%) feature high accuracy mechanical engineering or defense technol-
attractive mechanical and thermophysical properties [1]. ogy [3,4].
Owing to a high thermal conductivity coupled with a low The synthesis of high volume fraction Al/SiC MMCs is
thermal expansion coefficient, this type of MMC has now usually based on the principle of liquid metal infiltration,
found widespread application in high performance which may either rely on wetting for reactive pressureless
power-and microelectronics for thermal management and infiltration, or on the application of an external pressure
packaging purposes [2]. On the other hand, high volume by a gas in an autoclave or by the mechanical action of a pis-
fraction Al/SiC MMCs show as well a high potential for ton in die- or squeeze casting [5]. Reactive pressureless infil-
structural applications in sectors where low weight, high tration and gas pressure infiltration are basically isothermal
processes involving extended contact between the ceramic
*
Corresponding author. Tel.: +41 33 228 3041; fax: +41 33 228 4490. and the liquid metal phases at high temperatures. Typically,
E-mail address: olivier.beffort@empa.ch (O. Beffort). the contact time is of several minutes and several hours, and

0266-3538/$ - see front matter  2006 Elsevier Ltd. All rights reserved.
doi:10.1016/j.compscitech.2006.04.005
738 O. Beffort et al. / Composites Science and Technology 67 (2007) 737–745

the temperature about 700 C and above 900 C for gas ble composite compositions as well as for the use of specific
pressure infiltration and reactive pressureless infiltration, alloy compositions to tailor the composite properties to the
respectively. To prevent the formation of Al4C3 which is needs of particular applications. In fact, the present authors
prone to form under such conditions following the chemical have shown that attractive properties in terms of elastic mod-
reaction between liquid Al and SiC (Eq. (1)), Si is usually ulus, bending and fatigue strength and fracture toughness
added to the Al matrix to an amount such as to provide coupled with high wear resistance can be achieved for an
for the thermodynamic equilibrium between the phases Al/SiC composite containing 60 vol% of SiC particles in an
involved, thus annihilating the driving force for the reaction age hardenable AlCu4Mg1Ag matrix alloy [15]. However,
to proceed; for reactive pressureless infiltration the critical there is a persisting lack of basic understanding concerning
Si content may be as high as 20 wt% [6–9]. the isolated effect of selected alloying elements on micro-
structure and interface formation on the one hand and on
4Al + 3SiC ! Al4 C3 + 3Si ð1Þ
mechanical properties and fracture mechanisms on the other
Another practise consists in adding Mg (less than 10 wt%) hand. The present study aims at providing a contribution to
to the Al matrix, or in some cases to the SiC preform. The the clarification of these aspects for Al/SiC MMCs, relying
purposes of Mg additions are manyfold: on the use of the squeeze casting process and selected matrix
alloy additions.
(i) enhance the wetting behaviour with the SiC particles
(particularly important for pressureless infiltration) 2. Experimental
[10–12];
(ii) the formation of spinel (MgAl2O4) or MgO at the 2.1. Matrix alloying elements selection and ceramic particles
interface of oxidized SiC (Eqs. (2a) and (2b)), thus
protecting the SiC particles from reaction with Al In order to minimize the effect of impurities, high purity
according to Eq. (1) [13,14]; Al (99.99 wt%) was used as a matrix alloy, and except for
(iii) enhance the interfacial bonding [4]; the Al50Cu50 master alloy used as a Cu source, all alloying
(iv) strengthening of the Al matrix (by solid solution elements were added in elementary form at a purity mini-
hardening) [4]. mum of 99.9 wt%. Cu, Mg and Zn were selected as alloying
elements and they were added isolatedly or in combination
(Zn + Mg) to the Al matrix. The alloying elements selec-
2Al + 5Mg + 2SiO2 ! MgAl2 O4 + 2Mg2 Si ð2aÞ tion has been based on the following criteria:
4Mg + SiO2 ! 2MgO + Mg2 Si ð2bÞ
(i) Mg acts solely as solid solution hardening element; at
As a matter of fact, for pressureless and gas pressure infil- contents below 4 wt% it does not form any interme-
tration of Al/SiC composites the matrix chemistry has to tallic phase with Al. Mg is prone to react with SiC
be adapted to the process requirements, usually involving and its surface oxide SiO2, if present (Eqs. (2a) and
Si and Mg additions as the principal alloying elements. (2b)), thus influencing the interfacial bonding
The high Si contents added to preclude the formation of strength. The addition of Mg is expected to increase
Al4C3 lead to the precipitation of AlSi eutectic and in some the Al matrix strength and to enhance interfacial
cases also to primary Si in the Al matrix and/or at the SiC bonding between Al and SiC.
interface. Moreover, when Mg is added, MgAl2O4, MgO, (ii) Zn acts as a solid solution hardening element, as does
Mg2Si or Al2O3 are prone to form, isolatedly or in combi- Mg; however, on a comparative concentration scale,
nation. Such interfacial reactions, however, are known to Zn is less effective than Mg in this respect. Zn does
cause degradation of the SiC particles and to be detrimen- not react neither with Al nor with SiC to form any
tal to the composites’ mechanical properties (e.g. [4]). The intermetallic phases. The addition of Zn is expected
matrix composition being widely imposed by the process to increase the Al matrix strength while leaving the
needs, there is very limited room for influencing the com- interface unaffected.
posite mechanical (and physical) properties by means of (iii) Cu additions lead to the formation of semi-coherent
matrix alloying. matrix precipitates of the type Al2Cu (h 0 ) upon solu-
In this respect, the squeeze casting infiltration process tion treatment and artificial ageing. As an alloying
provides some opportunities, as it involves comparatively element in the Al matrix, Cu should not significantly
low infiltration temperatures (about 700–750 C, depending interact with the SiC particles (note, however, that
on matrix alloy composition), fast infiltration and rapid SiC will be dissolved in liquid copper!). The addition
solidification, i.e. short contact time between the liquid metal of Cu is expected to increase the Al matrix strength
and the ceramic reinforcement phase (typically 20–60 s, after T6 heat treatment, while leaving the interface
depending on the volume of the casting) and high applied unaffected, provided that the Cu-rich intermetallics
pressures (typically 500–1000 bar) [5,16]. Such process con- that are prone to form upon solidification and subse-
ditions considerably widen the flexibility in terms of matrix quent cooling can be dissolved successfully by solu-
chemical composition, allowing for the synthesis of metasta- tion heat treatment.
 O. Beffort et al. / Composites Science and Technology 67 (2007) 737–745 739

(iv) Combined addition of both Mg and Zn leads to the (TEM, Philips CM20T, 200 kV, EDX). The fracture sur-
formation of metastable, nano-dispersed matrix pre- faces were analyzed by SEM.
cipitates of the type Zn2Mg (g 0 ). Additionally, Mg The 4-point bending test was used for measurement of
is prone to influence interfacial bonding, as described the strength according to EN 843-1 standard, the elastic
in (i). The combined addition of both Mg and Zn is modulus according to EN 843-2 standard and the fracture
expected to increase the Al matrix strength after T6 toughness according to the SEVNB method using notched
heat treatment and to enhance interfacial bonding specimens. For comparison, the elastic modulus was mea-
between Al and SiC. sured as well using the impulse excitation test (IET)
(v) High purity (hp) Al (99.99 wt%) serves as the refer- method according to ASTM C 1259 standard. The respec-
ence matrix material to assess the effects of the above tive figures for the mechanical properties were obtained
listed alloying elements systems on matrix strength from averaging over five measurement values. The age
and interfacial bonding. hardening behaviour was measured by Brinell hardness
measurements (HB30).
The concentration of the alloying elements was selected
within the solubility limits such as to avoid the precipita- 3. Results
tion of primary phases and intermetallic compounds which
could not be re-dissolved (and re-precipitated as hardening 3.1. Age hardening
phases) by subsequent solid state heat treatments. The
matrix compositions, the effect of the alloying elements Following solid solution treatment and artificial ageing
and the corresponding heat treatments are given in Table 1. according to the specifications of Table 1, the hardness of
The SiC particles selected were of the type F500 HD, both precipitation hardenable composites AlCu3/SiC/60p
green a from Norton, with a mean particle diameter of and AlZn6Mg1/SiC/60p was increased by about 10% and
12.5 lm; they were added in a volume fraction of 60%, cor- 20%, respectively, in the peak aged T6 condition compared
responding to the tap packed density of this particle type. to the as-cast F condition. The respective hardness values
as well as those of the other composite systems are given
2.2. Processing in Table 2.

The SiC particles were tap-packed into steel casings with 3.2. Microstructure and interfaces
a graphite-based coating, preheated under Ar atmosphere
at 750 C and pressure infiltrated (by squeeze casting) with 3.2.1. Scanning electron microscopy (SEM)
the melt superheated to 100 C above liquidus of the The infiltrated composite samples feature a dense and
respective matrix (alloy). Upon infiltration, a maximum pore free microstructure with a homogeneous SiC particle
process pressure of 1400 bar was established and main- distribution, as depicted in Fig. 1a. No formation of pri-
tained for 2 min, to ensure pressurized solidification of
the casting, which was achieved typically after less than Table 2
Mechanical properties of the AlXX/SiC/60p composites
60 s. Further process details are provided elsewhere [16].
Composite samples of 100 · 100 · 10 mm3 from which Matrix alloy Temperature r4-pt.ra EIET E4pt. Hardness
(MPa) (GPa) (GPa) (HB30)
specimens were machined for characterization were
obtained after dehousing. Al99.99 F 477.2 ± 16.5 209.1 199.7 163
AlMg4 F 502.8 ± 27.4 199.4 202.1 243
AlZn6 F 493.7 ± 20.1 204.8 199.1 175
2.3. Characterization AlCu3 F 493.9 ± 63.1 207.4 207.2 223
AlCu3 T6 563.7 ± 56.3 205.3 205.4 247
The microstructure was investigated by optical micros- AlZn6Mg1 F 532.8 ± 25.5 207.7 206.0 226
copy, scanning electron microscopy (SEM, Zeiss DSM AlZn6Mg1 T6 562.0 ± 19.8 211.7 210.4 285
a
962, 20 kV, EDX) and transmission electron microscopy Ultimate 4-point rupture stress.

Table 1
Alloy compositions (wt%), heat treatments and alloying effects
Alloy Heat treatmenta Conditionb Effectc
Al99.99 (hpAl) – F Reference
AlMg1, AlMg4 – F SSH, IFR
AlZn6 – F SSH
AlCu3 500 C/2 h + 520 C/2 h + # + 170 C/10 h F&T6 PH
AlZn6Mg1 480 C/2 h + #+ 120 C/24 h F&T6 SSH, IFR
a
100 h RT natural ageing following quenching (#) prior to artificial ageing.
b
F: as-cast, T6: peak aged.
c
SSH: solid solution hardening; PH: precipitation hardening; IFR: interfacial reaction susceptibility.
740 O. Beffort et al. / Composites Science and Technology 67 (2007) 737–745

Fig. 1. (a) SiC particle distribution (overview), (b) interface in AlCu3/SiC/60p-F (Al2Cu segregations in as-cast condition) and (c) same as (b) in T6
condition (i.e. solution and peak ageing treatment).

mary intermetallic phases and segregations is observed in 3.2.2. Transmission electron microscopy (TEM)
any of the composite systems investigated, except for com- The composite systems hpAl/SiC/60p, AlMg1/SiC/60p
posite AlCu3/SiC/60p-F where interfacial segregation of a and AlMg4/SiC/60p were subjected to TEM investigations,
Cu rich phase is evident, as shown in Fig. 1b. EDX mea- with particular focus on the interface microstructure for-
surements on this phase yielded a composition close to that mation. In contrast to composite hpAl/SiC/60p which does
of stoichiometric Al2Cu. After solution heat treatment and not display any interfacial reaction products or segrega-
subsequent peak ageing (T6 condition) this phase has tions, the addition of Mg clearly leads to the formation
widely disappeared (Fig. 1c), even though traces scarcely of both Al4C3 and Mg2Si (identification by selected area
persist. diffraction pattern SADP and energy dispersive X-ray
EDX analysis), as illustrated in Fig. 2. The extent of the

Fig. 2. TEM and SADP of interfacial reaction products in AlMg4/SiC/60p (F condition). (a) Al4C3, (b) Mg2Si.
 O. Beffort et al. / Composites Science and Technology 67 (2007) 737–745 741

reaction is clearly more pronounced for high Mg additions

than for lower ones (4 versus 1 wt%). On the other hand,
no evidence of Al2O3, MgO or MgAl2O4 was found.

3.3. Mechanical properties

There is no obvious effect of Al matrix alloying and T6

heat treatment on the elastic modulus of the composites;
the values scatter between 200 and 210 GPa and generally
the results obtained from both measurement methods, i.e.
IET and 4-point bending, match quite well, with, however,
a minor discrepancy of about 5% for hpAl/SiC/60p. The
effective values are given in Table 2.
In contrast to the elastic modulus, the composites’ hard-
ness is clearly influenced by the effect of both Al matrix
alloying and T6 heat treatment. Compared to the unal-
loyed reference composite, the addition of 4 wt% of Mg
raises the hardness from 163 to 243 HB30, i.e. by about
50%, while the addition of 6 wt% of Zn does not signifi-
cantly increase the hardness. In the as-cast condition, the
effect on hardness increase for the addition of 3 wt% of Fig. 3. Schematic stress–strain behaviour of the different AlXX/SiC/60p
Cu and for the combined addition of 6 wt% of Zn and composites (type I: Al99.99/SiC/60p and AlZn6/SiC/60p, type II: AlMg4/
1 wt% of Mg is similar; in both cases composite hardness SiC/60p, AlCu3/SiC/60p-F&T6 and AlZn6Mg1/SiC/60p-F, and type III:
is increased by nearly 40%. The hardness response of AlZn6Mg1/SiC/60p-T6).
AlZn6Mg1/SiC/60p to T6 heat treatment, however, is
clearly superior to that of AlCu3/SiC/60p. AlZn6Mg1/
SiC/60p-T6 yields a hardness of 285 HB30, which is the plastic deformation and, hence, total strain to failure are
highest value measured in this study (cf. Table 2). negligible in this case (type III mode).
Similarly, bending strength is found to be influenced by The fracture toughness was measured for Al99.99/SiC/
both matrix chemistry and heat treatment condition; the 60p and AlZn6/SiC/60
p p; the values obtained are 9.17 and
age hardenable AlCu3/SiC/60p and AlZn6Mg1/SiC/60p 8.14 MPa m, respectively.
composites yield the highest bending strength values in
the peak aged T6 condition; compared to the unalloyed ref- 3.4. Fractography
erence composite, the strength increases from about 480 to
560 MPa. On the other hand, the effect of isolated addition Regarding the fracture surface of the 4-point bending
of the elements Mg, Zn and Cu does not significantly test specimens, two fracture modes have been distinguished
improve the as-cast composite bending strength. The effec- for the investigated composite systems:
tive 4-point bending strength values are given in Table 2.
Noticeable differences concerning the stress–strain (i) matrix shear failure with isolated cleaved SiC parti-
response during 4-point bending were observed among cles, as depicted in Fig. 4a;
the composite systems, as schematically depicted in (ii) SiC-cleaving (intrinsic fracture) induced failure, as
Fig. 3. For Al99.99/SiC/60p and AlZn6/SiC/60p pro- depicted in Fig. 4b.
nounced plastic deformation, i.e. deviation from the linear
elastic behaviour, begins at 20–25% of the ultimate rupture In the as-cast condition, all the investigated composite
stress and the slope of the stress–strain curves becomes systems tend to obey the first failure mode, whereas the
increasingly flatter until final failure; the total strain to rup- peak aged composite systems, AlCu3/SiC/60p-T6 and
ture of these composites is comparatively high (type I AlZn6Mg1/SiC/60p-T6, rather obey the second rupture
mode). For AlMg4/SiC/60p, AlCu3/SiC/60p (F&T6) and mechanism. In the first case, the fracture surface appear-
AlZn6Mg1/SiC/60p (F) plastic deformation also starts ance is quite rough, which is in sharp contrast to the com-
quite early (approximately at 30% of the ultimate rupture paratively flat fracture surface topography observed for the
stress), but these composite systems undergo pronounced second failure mode. Even though crack propagation in-
strain hardening until final failure, which leads to higher between the closely packed SiC particles proceeds adjacent
rupture stresses but also clearly lower strains than for the to the interfaces, as exemplarily depicted in Fig. 4c, effec-
two previous composite systems (type II mode). tive interfacial debonding between the matrix alloy and
AlZn6Mg1/SiC/60p-T6, finally, shows a nearly perfect lin- the SiC particles has not been observed in any case. Some
ear-elastic behaviour up to the rupture stress, with a minor remaining thin matrix material layer is always found to
deviation starting at about 50% of the total rupture stress; adhere to the SiC particles’ surface.
742 O. Beffort et al. / Composites Science and Technology 67 (2007) 737–745

Fig. 4. (a) Fractography of Al99.99/SiC/60p, (b) fractography of AlCu3/SiC/60p-T6, and (c) crack propagation path in AlZn6Mg1/SiC/60p-F.

4. Discussion aspects have to be considered as well [17]. As a matter of

fact, the thermal conditions inherent to the squeeze casting
Despite comparable hardness, the bending strength is process are transient rather than isothermal and thermody-
lower for AlMg4/SiC/60p than for AlCu3/SiC/60p-T6. This namic equilibrium usually is not achieved. This is the rea-
is ascribed to the embrittling effect of the reaction products son why it is possible to synthesize hpAl/SiC composites
Al4C3 and Mg2Si formed at the interface in the Mg-con- free of Al4C3 by squeeze casting, as already stated by Lee
taining composite. Since no evidence of such reaction is et al. in an earlier study [8] and confirmed by the findings
found in the unalloyed reference composite, it is obvious of the present investigation. This phenomenon may be
that under the particular conditions of the squeeze casting explained by the fact that the Si equilibrium is reached
assisted liquid metal infiltration process, the formation of locally in the intimate vicinity of the SiC surface during
Al4C3 is triggered by additions of Mg; 1 wt% has been the infiltration step within a couple of seconds and subse-
found to be sufficient to catalyse the reaction. quently frozen upon solidification, thus preventing dilution
Under isothermal infiltration conditions, during pro- by further diffusion of Si into the matrix. The closed pack-
cessing of hpAl/SiC, SiC usually dissolves in molten Al ing density of the SiC particles and the resulting narrow
to form atomic C and Si. As dissolution proceeds, the con- matrix channels between the individual SiC particles (e.g.
centration (i.e. the activity) of both C and Si increases in Fig. 4c) are prone to favour this effect by minimizing the
the Al matrix. However, the solubility of C in liquid Al is concentration gradients, i.e. the Si diffusion driving force,
very low and so is the equilibrium concentration of C with in these areas. Romero and Arsenault [18] reported on iso-
both SiC and the reaction product Al4C3 (Eq. (1)). For a thermal annealing of hot-pressed 1100-Al/SiC composites
given temperature, the formation of Al4C3 will go ahead at 680 C for 10 h without formation of Al4C3. They attrib-
to keep the carbon content at its thermodynamic equilib- uted these findings to local concentrations of dissolved Si at
rium concentration, until the Si equilibrium concentration the Al/SiC interface sufficiently high (theoretically up to
in the Al matrix has been reached. To counteract this reac- 18 wt% at 680 C) such as to prevent the carbide forma-
tion scheme, it is a common practise to initially add the tion. However, at temperatures above 700 C the interface
respective critical Si content to the matrix alloy [6–9]. How- was seen to react quite rapidly and to be covered with a
ever, to better understand the relationship between micro- thick layer of Al4C3, which was ascribed to the consider-
structural features and process conditions, a pre-requisite ably higher theoretical equilibrium Al4C3 content at
for process and materials optimisation, thermodynamic 700 C (0.004 mol% after 30 min at 700 C versus
considerations on their own are not sufficient and kinetic 0.0001 mol% after 10 h at 680 C). Hence, the short contact
 O. Beffort et al. / Composites Science and Technology 67 (2007) 737–745 743

time of the constituents in the liquid Al phase and the rapid the composite AlZn6Mg1/SiC/60p. As a matter of fact, in
subsequent composite solidification (less than 1 min upon the as-cast condition this latter composite yields a higher
infiltration start), which are both inherent to the squeeze bending strength than composite AlMg4/SiC/60p, despite
casting process, do not provide thermodynamic and kinetic the lower hardness value. Such a behaviour may be
conditions in favour of Al4C3 formation. ascribed to the lack of embrittling interfacial reaction prod-
In contrast, when Mg is added to the Al matrix, Al4C3 is ucts in the Zn containing composite system, which, how-
found to form as well in squeeze cast composites. This ever, remains to be confirmed by TEM analysis for this
effect obviously is linked to the simultaneous appearance particular case.
of Mg2Si. In fact, Si released from dissolution of SiC in Eventually it is noted that no evidence of neither Al2O3,
(liquid) Al is instantaneously trapped by Mg to form the MgO nor MgAl2O4 has been found in the present investi-
silicide (Eq. (3)). Consequently, the Si activity is reduced gation. Therefrom it is concluded that there are no signifi-
and its concentration in the Al matrix will not raise until cant amounts of SiO2 on the surface of our SiC particles.
the Mg has completely been consumed, thus suppressing Indeed, the SiC powder supplier gives the figure of
the barrier to Al4C3 formation. The simultaneous observa- 0.12 wt% for SiO2 contamination, and even after oxidizing
tion of Al4C3 and Mg2Si in the Mg containing composite in air at 900 C for 1 h the SiO2 thickness has been reported
samples implies that reactions (1) and (3) (Eqs. (1) and to be only about 25 nm [20].
(3)) are actually coupled, resulting in the global reaction Young’s modulus primarily depends on the elastic prop-
according to Eq. (4). erties and the respective volume fractions of the compos-
2Mg + Si ! Mg2 Si ð3Þ ites’ constituents and is thus expected to be independent
on matrix alloying and heat treatment. Neglecting the
4Al + 6Mg + 3SiC ! Al4 C3 + 3Mg2 Si ð4Þ minor effect of alloying on the matrix elastic properties
Even though Mg is quite a common alloying element in Al/ and simplifying that the reinforcement volume fraction is
SiC composites (e.g. [4,10–14]), to the authors knowledge, the same in all the composite systems investigated here,
its indirect effect on the formation of Al4C3 has not been comparable Young’s moduli should be expected for the dif-
revealed before. ferent composite systems. In fact, this is what we observe
Both interfacial Al4C3 and Mg2Si are prone to cause and the experimental values fit within the lower and upper
composite embrittlement and the comparatively low bend- elastic modulus bounds proposed by Hashin and Shtrick-
ing strength of AlMg4/SiC/60p may be ascribed to this man [21] (Fig. 5).
effect. In an earlier study [19] the present authors have In contrast to the Young’s modulus, bending strength is
shown that Zn additions to an AlMg matrix in turn will clearly influenced by matrix alloying and heat treatment
trap Mg to form MgZn2 (g 0 ), thus preventing the formation (Table 2) and, in particular, the stress–strain curve has been
of Mg2Si (and MgO). This mechanism may be effective in found to develop differently for specific composite systems,

500
Ashby upper bound
450 Ashby lower bound
Hashin-Shtrickman upper bound
400 Hashin-Shtrickman lower bound
Al99.99/SiCp
AlMg4/SiCp
350
Elastic Modulus, [GPa]

AlZn6/SiCp
AlCu3/SiCp-F
300 AlCu3/SiCp-T6
AlZn6Mg1/SiCp-F
AlZn6Mg1/SiCp-T6
250

200

150

100
squeeze cast AlXX/SiCp-MMCs
50

0
0 0.2 0.4 0.6 0.8 1
SiC particle volume fraction

Fig. 5. Elastic modulus of the different AlXX/SiC/60p composites in comparison with the bounds proposed by Hashin and Shtrickman [21] and Ashby
[22], with EAl = 70, mAl = 0.33 and ESiC = 450 GPa, mSiC = 0.15 and vr-SiC = 0.6.
744 O. Beffort et al. / Composites Science and Technology 67 (2007) 737–745

as depicted in Fig. 3. For high purity Al and AlZn6 the alumina particles instead of commercial grinding quality
matrix flow stress is low and plastic deformation quite pro- ‘‘reactive’’ SiC-particles leads to clearly higher fracture
nounced. The matrix rupture stress being lower than both toughness values.
the interfacial bonding strength and the SiC particles’
cleavage stress, this eventually leads to the type I stress–
strain curve and the associated fracture pattern (Fig. 4a). 5. Conclusions
Failure also occurs by inter-particulate matrix shearing
for composites AlMg4/SiC/60p, AlCu3/SiC/60p-F and When using squeeze casting assisted pressurization for
AlZn6Mg1/SiC/60p-F. However, these composite systems the infiltration of SiC particle preforms with high purity
feature embrittling interfacial second phases for the first Al, the formation of Al4C3 is widely prevented, owing to
two composites on the one hand and pronounced strain the peculiarities of the squeeze casting process which does
hardening and limited plastic deformation on the other not provide favourable thermodynamic and kinetic condi-
hand; this finally results in the type II stress–strain curve. tions for the associated reaction to proceed.
In T6 condition, the combined effect of matrix precipita- However, under identical process conditions, additions
tion hardening and internal constraints imposed by the of Mg lead to the formation of both Al4C3 and Mg2Si. Si
SiC particles favour the development of plain-strain condi- which is released from the direct reaction between Al and
tions in the matrix phase with increasing stress, and the SiC reacts with Mg to form Mg2Si; this reaction, in turn,
matrix rupture stress becomes of the same order of magni- decreases the Si activity and, thus favours the formation
tude than the SiC particles’ cleavage stress. At a critical of Al4C3 in squeeze cast AlMg/SiCp composites. Any
stress level, first isolated SiC particles begin to fracture as potential positive effect of enhanced interfacial bonding
a consequence of the SiC particles’ Weibull distribution strength due to the Mg addition on mechanical properties
on the one hand, or due to local interfacial embrittlement is counterbalanced by the embrittling effect of the interfa-
caused by residual interfacial reaction, precipitation or seg- cial reaction products.
regation, on the other hand. Intragranular cleavage of the No evidence of oxides or oxygen containing phases has
SiC particles gives rise to local stress concentrations in the been found, meaning that the SiC particles did not contain
adjacent composite matrix zones. Such stress concentra- any significant amounts of SiO2 at the origin.
tions cannot be relaxed by matrix yielding in the In contrast to the composite flow stress, the elastic mod-
AlZn6Mg1/SiC/60p-T6 composite due the generally very ulus of AlXX/SiCp composites is not significantly influ-
limited strain hardening capacity of AlZnMg-alloys in the enced by matrix alloying and heat treatment; instead, it is
peak-aged condition. This finally leads to collective intra- dictated by the SiC volume fraction and its values of
granular SiC failure (Fig. 4b) and the associated type III 200–210 GPa fall within the bounds proposed by Hashin
stress–strain curve. Principally, AlCu3/SiC/60p-T6 displays and Shtrickman.
a similar failure mode and fracture pattern; in this latter The best compromise between maximum bending
composite, however, the matrix flow stress is lower and strength and composite ductility is obtained after the addi-
matrix yielding occurs giving raise to pronounced strain tion of 3 wt% of Cu to the Al matrix and subsequent T6
hardening, to a level equivalent to that of the SiC particles’ heat treatment. Comparable strength values are obtained
failure stress. Accordingly, at similar rupture stress and with the combined addition of 6 wt% of Zn and 1 wt% of
failure mode, the associated fracture energy is higher for Mg after T6 heat treatment. In this latter case, nearly pure
AlCu3/SiC/60p-T6 than for AlZn6Mg1/SiC/60p-T6 (cf. linear elastic behaviour is observed until ultimate compos-
Fig. 3). ite rupture, without evidence of significant matrix plastic
Following a similar composite development strategy deformation.
than that described in the present paper, Miserez et al. have For both T6 aged composites, the dominant failure
investigated the effect of matrix alloying on the tensile mechanism is SiC intra-particulate fracture, while inter-
behaviour and fracture toughness for Al-based metal particulate matrix plastic deformation and shearing, with
matrix composites with high volume fractions of polygonal unaffected SiC particles, is the dominant fracture mode in
Al2O3 particles [23]. There, the criteria for the selection of the other composite systems.
alumina particles as the reinforcement phase were twofold, Eventually, concerning the chemistry of the Al matrix
namely chemical inertness with Al under gas pressure infil- for squeeze cast AlXX/SiCp composites with desirable
tration conditions on the one hand, and high intrinsic qual- mechanical properties, the following rules can be deduced:
ity (i.e. high fracture toughness and Weibul-modulus) on
the other hand. Concerning the effect of matrix alloying 1. the alloying elements should increase the matrix flow
and heat treatment on the fracture mode, on the stress– stress, but
strain characteristics and on the associated tensile 2. the alloying elements should not give rise to interfacial
properties, our results obtained for SiC-particle reinforced reactions with the SiC particles;
Al-based composites are remarkably consistent with the 3. the alloying elements should not form primary insoluble
findings from [23]. With respect to fracture toughness, intermetallics neither at the interface nor within the
however, the concept of using high quality and inert matrix;
 O. Beffort et al. / Composites Science and Technology 67 (2007) 737–745 745

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composite. Acta Mater 1998;46(5):1771–80.
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