Fabrication, microstructure and mechanical properties of Al–Fe intermetallic particle reinforced Al-based composites

• A new metal matrix composite (MMC) has been developed.
• The developed MMC has a matrix/shell/core structure.
• The developed MMC has both high strength and plasticity.

In this paper, Al-based composites reinforced by Al–Fe intermetallic compounds have been successfully fabricated by powder metallurgy technique. The reinforcements were generated in the aluminum matrix by in situ solid state reaction between commercial pure Al and pure Fe powders. The effects of sintering temperature and Fe content on the microstructure and mechanical properties of the composites were systematically studied by scanning electron microscopy, energy dispersive X-ray spectroscopy, X-ray diffraction analysis and compressive tests. New core–shell structured particles were dominant reinforcements in the composites after sintered at 560 °C for 5 h. It has been shown that the yield strength of the composites remains almost the same, while the ultimate compressive strength and ductility decrease with increasing the sintering temperature and Fe content.