Fabrication and characterization of hybrid structured Al alloy matrix composites reinforced by high volume fraction of B4C particles

In the present paper, hybrid structured B4C particles reinforced Al2024 matrix composites were prepared by the powder metallurgy method. The composites made from 100% mechanical milled composite powders have fracture strength of 670 MPa. With the addition of un-milled Al2024 powder increased from 10 vol% to 40 vol%, the room temperature compression strength decreased from 1115 MPa to 739 MPa, without any visible plastic deformation. However, when the fraction of un-milled Al2024 powder increased to 50 vol%, the compression strength was decreased to 580 MPa, while retaining a remarkable fracture strain up to 10%. The microstructures of the composites with different composition were examined by a scanning electron microscope and a transmission electron microscope. The contribution from different strengthening mechanisms was discussed. The hybrid structures are proved to account for the dramatic change of the fracture mechanism of the composites.