Journal of Advanced Materials in Engineering

Journal of Advanced Materials in Engineering

Synthesis, Microstructural Characterization, and Mechanical Properties of a Layered Hybrid Aluminum-Matrix Composite Containing SiC Reinforcements and Iron-Based Amorphous Particles

Articles in Press

Document Type : Original Article

Authors
Mohammad Reza Rezaei
Reza Nazemnezhad
Alireza Saravani
School of Engineering, Damghan University, Damghan, Iran
Abstract
Introduction and Objectives: One effective approach for enhancing the mechanical properties of metal matrix composites is the design of architected layered heterogeneous structures. Hence, the present study aimed to develop aluminum matrix hybrid composites reinforced with SiC ceramic particles and iron-based amorphous particles, featuring a heterogeneous layered architecture and to investigate their mechanical properties.
Materials and Methods: The heterogeneous structure comprised alternating layers of pure aluminum and composite material with varying thicknesses, fabricated via powder metallurgy using spark plasma sintering (SPS). The microstructural and phase characteristics of the composites were investigated using scanning electron microscopy (SEM), optical microscopy (OM), and X-ray diffraction (XRD). The relationship between microstructure and mechanical properties was subsequently analyzed.
Results: Microstructural analyses, including porosity evaluation and density measurements, demonstrated enhanced densification during sintering with increasing pure aluminum layer thickness. In addition, the distribution of reinforcement particles was improved by increasing the volume fraction of the pure aluminum layers relative to the composite layers. Phase analysis of all sintered samples confirmed the preservation of the amorphous nature of the iron-based reinforcement particles and revealed no evidence of interfacial reaction products at the reinforcement–matrix interfaces. Mechanical experiments showed a favorable combination of high strength and ductility, with a compressive strength of up to 191 MPa and a fracture strain of 20% in samples with a higher volume fraction of composite layers. Furthermore, increased ductility was observed with a higher volume fraction of pure aluminum layers.
Conclusion: The introduction of a layered heterogeneous architecture in the hybrid composite, through modification of consolidation behavior and reinforcement particle distribution, resulted in superior mechanical properties compared to those of the homogeneous composite.
Keywords
Hybrid composite
Powder metallurgy
Layered structure
Microstructure
Mechanical properties
Subjects
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Journal of Advanced Materials in Engineering

Articles in Press, Accepted Manuscript
Available Online from 09 February 2026

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