Processing and characterization of Al-Si alloy/SiC foam interpenetrating phase composite

Interpenetrating phase composites (IPCs) are a class of composites consisting of two or more topologically co-continuous phases and have three-dimensionally percolating interconnected structure. The co-continuous and interconnected architecture of the IPCs can provide superior properties compared to the conventional particulate reinforced composites at room and elevated temperatures. IPCs having metal/ceramic phases are finding applications in various fields like (thermal management materials, aerospace, automobile industries, light-weight armor materials, etc.). In the present work, Al-Si alloy/SiC foam IPC was fabricated by infiltrating the alloy melt into SiC foam via the squeeze-casting process. Open porous SiC foams, fabricated via the replication method, and having two different pore sizes (10 and 20 PPI) were used for IPC fabrication. The SiC foams had both macropores between the SiC foam struts and micropores within the strut walls. Results show that the Brinell hardness of the composite fabricated using a small pore size (20 PPI) SiC foam is higher than the composite fabricated with a large pore size SiC foam (10 PPI). Thorough structural characterization via scanning electron microscope and localized study of hardness distribution in different regions of the composite using nanoindentation were carried out. (C) 2021 Elsevier Ltd. All rights reserved.