Fabrication of Al/AlN in-situ nanocomposite through planetary ball milling and hot extrusion of Al/BN: Microstructural evaluation and mechanical behavior

In this study, Al/AlN in-situ nanocomposites were fabricated using Al/BN as the starting composite powders. The impact of adding hexagonal boron nitride (BN) to the Al matrix of commercial purity on the microstructure and mechanical behavior of the fabricated in-situ nanocomposites was investigated. Samples including 1, 2, and 4 wt.% boron nitride nanoparticles were produced by planetary ball milling of the composite powders and a post-process of hot extrusion. Scanning transmission electron microscopy revealed that boron nitride nanoparticles dissolved as a solid solution of B and N in the Al matrix at the as-milled state. Through the process of hot extrusion, AlN as the in-situ phase was formed by a reaction between Al and N. These led to improve the mechanical properties as well as grain refinement of Al/AlN nanocomposite. The average grain size of the fabricated composites with the use of 1, 2 and 4 wt.% BN was measured about 910, 823, and 760 nm respectively. It was found that combined strengthening mechanisms of grain refinement, a solid solution of mostly B and AlN in-situ phase formation improved the mechanical properties of Al/AlN nanocomposite. With the use of 1, 2, and 4 wt.% BN, the tensile strength of nanocomposite samples increased approximately 40, 56, and 57% in comparison with pure Al, respectively. The remarkable change in microstructure and mechanical properties of the nanocomposite was obtained when the content of BN is up to 2 wt.%. •Al/AlN nanocomposites were fabricated by planetary ball milling and hot extrusion.•BN particles were dissolved as solid solution in matrix at the as-milled state.•The in-situ AlN phase was created during hot extrusion process.•The high fraction of N and all the B were remained as solid solution in matrix.•The solid solution and AlN phase improve the mechanical property of nanocomposite.