Crystal morphology and growth mechanism of reinforcements synthesized by direct melt reaction in the system Al–Zr–O

In-situ Al₃Zr and Al₂O₃ particulates reinforced aluminum matrix composites were fabricated by the direct melt reaction (DMR) technique in the system Al–Zr–O. Microstructures of the composites and crystal morphology of in-situ formed Al₃Zr and Al₂O₃ particulates were analyzed by scanning-electron microscope (SEM) and transmission electron microscope (TEM). Results indicated that in-situ formed Al₃Zr and Al₂O₃ particles were finer and well distributed in aluminum matrix. Al₃Zr particulates with a tetragonal structure are mainly in the shape of polyhedron. A few of them are rectangular. The length/width ratio of the rectangular Al₃Zr is less than 2.0 and the maximum size is 4 μm. In addition, submicro Al₂O₃ particles with a hexagonal structure were also found in this system. Furthermore, it is found that twin may appear in the Al₃Zr crystal. The twin plane is (1 ). The twinning direction is 2 1].