Microstructural development in the directed melt-oxidized (DIMOX) Al-Mg-Si alloys

Metal-ceramic composites produced via directed melt oxidation (DIMOX) of aluminum alloys are of recent interest. The in situ composite forming method is based on the reaction of a molten alloy with a gaseous oxidant. In the present study, Al-Mg-Si alloys were subjected to directed melt oxidation, and the progressive microstructural evolution was examined by interrupted growth experiments. In the early stages, liquid alloy oxidizes to form a duplex oxide layer (MgO+MgAl2O4) on the surface. The openings in these oxide layers allow the liquid alloy to wick through to form small nodules on the surface. When further wicking occurs through these nodules, a 'cauliflower' type of colonies is formed. During the early part of the second stage, spinel growth dominates to form a multi-layered structure. In the final stage, as the magnesium reaches low levels, Al2O3 formation dominates the growth, and alumina crystals grow continuously for several tens of micrometers. The oxygen required for alumina formation is expected to come from two sources: (1) from the ingress of oxygen through microcracked oxide layers, and (2) demixing of magnesium-containing oxides in the underneath layers. (Author)