Microstructural Investigation of Al/Al-Fe alloy-Al2O3 Interpenetrating Phase Composites Produced by Reactive Metal Penetration

Abstract

Aluminum-Al₂O₃ and Al alloy-Al₂O₃ based ceramic-metallic interpenetrating phase composites (IPC's) possess unique physical and mechanical properties that are desirable for a number of potential applications. Fireline TCON, Inc. (FTi) of Youngstown, OH produces such ceramic-metallic IPC's using a reactive metal penetration (RMP) process. The RMP process allows other materials and alloying metals to be added to the composite in order to tailor its final properties. Currently, TCON® IPC's are being marketed as refractory materials for handling high temperature molten metals. However, it is desired to expand the applications of ceramic-metallic IPC's to markets such as automotive brake rotors and military vehicle and body armor. In order to tailor ceramic-metallic IPC's to different applications, a more thorough understanding of their microstructures and how they are affected by additions is necessary. In this study, the microstructural properties of two IPC's produced by the TCON RMP process were investigated. The materials include Al-Al₂O₃ and an Al-Fe alloy-Al₂O₃ ceramic-metallic IPCs. Analysis was performed using optical microscopy (OM), scanning electron microscopy (SEM), scanning/transmission electron microscopy (S/TEM), energy dispersive spectroscopy (EDS), focused ion beam (FIB), X-ray diffraction (XRD), and Vickers hardness testing. The results can be used to correlate the microstructure properties to the materials' physical performance. This information is valuable for developing IPC's modified for specific applications.