Microstructure and properties of FeCoNiCrMn and Al2O3 hybrid particle-reinforced aluminum matrix composites fabricated by microwave sintering

In this paper, multiscale Al2O3 micro/nanoparticles (0–14 wt%) mixed with FeCoNiCrMn high-entropy alloy (HEA) particles (15 wt%) were used as reinforcements to prepare dual-phase-reinforced aluminum matrix composites (AMCs) through microwave sintering. The strengthening effects of doping different weight fractions of Al2O3 micro/nanoparticles on the microstructure, mechanical properties, and strengthening mechanisms of the mixed-phase particle-reinforced AMCs were investigated. The performance after 11 wt% Al2O3+HEA microparticles was similar to that obtained by adding 2 wt% and 5 wt% Al2O3+HEA nanoparticles. The hardness, yield strength, and compressive strength of the 2 wt% nano-Al2O3 composite were 109.7 HV, 286.5 MPa, and 506.7 MPa, respectively, which were 70.9%, 98.5%, and 94.7% higher than those of the single HEA-reinforced sample. In terms of the strengthening and toughening mechanisms, Orowan strengthening, dislocation strengthening, and thermal mismatch strengthening were the main strengthening mechanisms of particles species mixed in the metal matrix composites. Hall-Petch strengthening and load-transfer effects were mainly attributed to the cross-scale mixing of particles. The hybrid particles of HEA and Al2O3 synergistically delayed interfacial crack propagation. This study provides a new preparation method for high-performance metal matrix composites.