Architecture of high-strength aluminum–matrix composites processed by a novel microcasting technique

As important lightweight structural materials, cast aluminum alloys have been largely used in the transportation and aerospace industries. In general, Al–Si-based alloys comprise more than 90% of all castings due to their excellent castability and corrosion resistance. However, even though various reinforcements have been introduced, the strength of these alloys is not that high, which severely limits their use for certain high-performance applications. Here, we report on a new strategy and technology to reinforce Al–Si alloys to increase their yield strength into the ~400–660 MPa range, a level that is 29–113% higher than that of all current cast Al–Si alloys, laboratory or commercial, and comparable to that of many high-strength steels but with ~40% lower density. By introducing continuous Ti–6Al–4V reinforcements into the Al–Si matrix through a novel microcasting process, the yield strength of the resulting alloy can be enhanced to between 4 and 6 times higher than that of the pure Al–Si alloy. The extraordinary reinforcing effect originates from the occurrence of multiscale strengthening mechanisms, including macroscale compound strengthening (the rule of mixtures amended by crack arrest mechanism), mesoscale strain-gradient strengthening, and microscale interface-affected-zone and nanoparticle strengthening. The core principle of our material design is to make all components of the composite fully participate in plastic (compatible) deformation, and thus, continuous reinforcements, instead of discrete reinforced structures (e.g., particles, whiskers, and short fibers), were introduced into the Al–Si alloy. Combined with 3-D printing technology, the present microcasting process can realize strengthening at the designed position by architecting specific reinforcements in the matrix. Metal strength: Two alloys are better than one A strategy for improving the strength of an alloy of aluminum and silicon has been developed by scientists in China and the US. Aluminum is commonly chosen as a construction material because of its light weight, but it is not as strong as steel. Adding silicon increases its strength, but researchers are continuously striving to increase it further. Zhefeng Zhang from the Institute of Metal Research, Shuo Zhao from the Shenyang Aerospace University, Shenyang, and colleagues developed a casting process that enabled them to introduce a commercial alloy of titanium, aluminum and vanadium into the aluminum–silicon alloy. They showed