Strengthening of Nanocrystalline Al with Al3Zr Core-Shell Structure

High-density Al-based composites reinforced with ten-wt.% recycled nanocrystalline CuZrAgAl particles have been fabricated by mechanical milling, cold- and hot-pressing. The microstructures, phase transformations, and mechanical properties of the mixed powder and sintered samples were investigated. After milling in a ball mill for 30 h, the microhardness of the mixed powder increases to 301 ± 31 HV0.01 and 222 ± 10 HV0.01 without and with ethanol milling, respectively. On account of the interdiffusion, the melting temperature of mixed powder reduces to 574 ± 5.0 °C and 627.5 ± 6.5 °C after 30 h milling. The study showed that the reinforcing particles are homogeneously distributed in the sintered nanocrystalline Al-based composites. During the hot-pressing, a shell zone forms at the interface of reinforcing particles during hot pressing after high energy milling with a minimum of ten hours milling time. This shell zone consists of Al3Zr (D023) phase. The coarsening resistant core-shell structure and grain refinement greatly improve mechanical properties. The compression strength at room temperature varies between 650 and 800 MPa at room temperature and is 380 MPa at 400 °C for the composite containing ten-wt.% of the Cu-Zr-based amorphous-nanocrystalline phases. The Brinell hardness of the sintered composite is 329 HB.