Investigation of particle size and amount of alumina on microstructure and mechanical properties of Al matrix composite made by powder metallurgy

Al matrix composite is well known, in which Al2O3 is the most widely used reinforcement. The aim of this study is to investigate the effect of alumina particle size and its amount on the relative density, hardness, microstructure, wear resistance, yield and compressive strength and elongation in Al–Al2O3 composites. To this end, the amount of 0–20 wt.% alumina with average particle sizes 48, 12 and 3 μm was used along with pure aluminum of average particle size of 30 μm. Powder metallurgy is a method used in the fabrication of this composite in which the powders were mixed using a planetary ball mill. Consolidation was conducted by axial pressing at 440 MPa. Sintering procedure was done at 550 °C for 45 min. The results indicated that as the alumina particle size is reduced, density raises at first, then, declines. Moreover, as the alumina particle size decreases, hardness, yield strength, compressive strength and elongation increase and factors such as wear resistance, microstructure grain size and distribution homogeneity in matrix decreases. For instance, as the alumina particle size gets smaller from 48 to 3 μm at 10 wt.% alumina, hardness rises from 50 to 70 BHN, compressive strength improves from 168 to 307 MPa and wear rate rises from 0.0289 to 0.0341 mm3/m. On the other hand, as the amount of alumina increases, hardness and wear resistance increase and relative density and elongation is decreased. However, compressive and yield strength rise at first, then drop. For example, if the amount of alumina with 12 μm particle size increases from 5 to 10 wt.%, hardness increases from 47 to 62 BHN and compressive strength rises from 190 to 273 MPa. Nevertheless, erosion rate after 300 m decreases from 0.0447 to 0.0311 mm3/m.