Fabrication and Characterization of Squeezed Cast Aluminum Matrix Composites Containing Boride Reinforcements

Aluminum alloys containing 2 and 4 wt.% copper reinforced with aluminum dodecaborides were successfully fabricated by squeeze casting employing pressures up to 62 MPa. The distribution of reinforcements throughout the composites was quantified, whereas the effect of pressure on the composites density and hardness was determined. In addition, the reinforcement chemical stability was examined using high-temperature x-ray diffraction which permitted to confirm the formation of AlB₂ phase a result of AlB₁₂ decomposition. The pressure effect on the squeezed composites was investigated by optical microscopy, Vickers microhardness testing, superficial Rockwell hardness testing, and differential thermal analysis. At the highest applied pressures, the castings density increased when the shrinkage porosity was practically eliminated. The composite superficial hardness improved by increasing the applied squeeze. The indirect squeeze cast technique caused Al₂Cu phase segregation to upper regions of the specimens, while conversely, the AlB₁₂ reinforcements segregated preferentially at lower regions of the casting.