Processing and Mechanical Properties of Cast Al (Mg,Mn)-Al2O3 (MnO2) Composites Containing Nanoparticles and Larger Particles

The composites reinforced with nanoparticles result in improved strength and ductility while those containing coarser particles of micron size have limited ductility. The present study investigates the outcome of mechanical properties in a composite reinforced simultaneously with coarse and fine particles. High energy milling of manganese dioxide particles with excess of aluminum powder ensures that nanoparticles generated, either of MnO₂ or alumina, are mostly separate and surrounded by aluminum particles. The milled powder when added to aluminum alloy melt, the excess aluminum particles will melt leaving behind separate oxide nanoparticles without significant agglomeration. Different amounts of milled powder mix have been stirred into molten aluminum alloy where nanoparticles of MnO₂ react with melt to form alumina. The resulting slurry is cast into composites, which also contains coarser (nearly micron size) alumina particles formed by internal oxidation of the melt during processing. The microstructure of the composites shows good distribution of both the size categories of particles without significant clustering. The oxide particles are primarily γ-alumina in a matrix of aluminum-magnesium-manganese alloy containing some iron picked up from the stirrer. These composites fail during tensile test by ductile fracture due to debonding of coarser particles. The presence of nanoparticles along with coarser particles in a composite improves both strength and ductility considerably, presumably due to delay in debonding of coarser particles to higher stress because of reduced mismatch in extension caused by increased strain hardening in presence of nanoparticles in the matrix. The composites containing only coarser oxide particles show limited strength and ductility attributed to early debonding of particles at a relatively lower stress due to larger mismatch in extension between matrix and larger particles. Higher addition of powder mix beyond a limit, however, results in deterioration of mechanical properties, possibly due to clustering of nanoparticles. The present work, however, did not optimize the relative amounts of the different sized particles for achieving maximum ductility.