Processing of ultra-high strength SiCp/Al–Zn–Mg–Cu composites

The ultra-high strength SiCp/Al–10%Zn–3.6%Mg–1.8%Cu–0.36%Zr–0.15%Ni composite was prepared by spray co-deposition followed by extrusion process. The heat treatment processing, microstructures and mechanical properties of the as-processed composite were investigated. The well-bonded SiC/Al interfaces and fine grains of matrix alloy were obtained in the as-extruded composite. The precipitated phase MgZn2 dissolved during solid solution treatment at 490 °C for 1 h, but the Cu-rich phase was residual in the matrix. Comparatively, the Cu-rich phase dissolved into the matrix alloy exposed at 470 °C for 1 h and then at 490 °C for 1 h. The composite heat-treated with 470 °C/1 h + 490 °C/1 h + 120 °C/28 h exhibited high modulus above 100 GPa and ultra-high strength about 785 MPa, which was 30 MPa higher than that of the same composite treated with 490 °C/1 h + 120 °C/28 h processing. The low elongation of the composite can be attributed to the breakage of SiC particulates and interfacial debonding of SiC/Al.