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Integrated Fabrication of Cf/Al Composite and Joining with TC4 via Liquid-Solid Infiltration Extrusion: Microstructure Evolution and Fracture Behavior

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Abstract

Efficiently joining TC4 and carbon fiber-reinforced aluminum matrix (Cf/Al) composite greatly expands the applications of composite in the aerospace industry. In this study, a liquid-solid infiltration extrusion (LSIE) process was proposed to effectively join Cf/Al composite with TC4 while preparing them. The microstructure, interfacial properties, and phase composition of the Ti-Cf/Al interface were characterized using scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), and X-ray diffraction (XRD). The mechanical response and failure modes of the composite were investigated. The results show that a TiAl3 intermetallic transition layer with a width of about 10 μm was successfully formed at the interface of TC4 and Cf/Al composite. Compared with the Cf/Al composite, the presence of this transition layer significantly increased the shear strength of the joint by 35.8 pct. In addition, through the unique deformation mechanism of the transition layer, the joint effectively disperses the stress concentration and delays the crack extension, thus realizing the transformation of the composite material from bending brittle fracture to multi-crack progressive damage mode. Meanwhile, the deformation behavior and strengthening mechanism of the TiAl3 transition layer on the composite are also deeply explored in this study. This successful and simple toughening strategy provides a feasible way to realize the application of continuous Cf/Al composite.

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Acknowledgments

This work was supported by the National Natural Science Foundation of China (Grant Nos. 51575447, 51972271, and 52231004).

Conflict of interest

The authors declare that they have no known competing financial interests or personal relationships that could have appeared to influence the work reported in this paper.

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Authors and Affiliations

  1. School of Mechanical Engineering, Northwestern Polytechnical University, Xi’an, 710072, P.R. China

    Yunfeng Bai, Jiming Zhou, Kangdi Zhong, Chentong Zhao & Lehua Qi

  2. Shaanxi Key Laboratory of Fiber Reinforced Light Composite Materials, Northwestern Polytechnical University, Xi’an, 710072, P.R. China

    Jiming Zhou & Lehua Qi

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  1. Yunfeng Bai
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  2. Jiming Zhou
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  3. Kangdi Zhong
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Correspondence to Jiming Zhou.

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Bai, Y., Zhou, J., Zhong, K. et al. Integrated Fabrication of Cf/Al Composite and Joining with TC4 via Liquid-Solid Infiltration Extrusion: Microstructure Evolution and Fracture Behavior. Metall Mater Trans A (2024). https://doi.org/10.1007/s11661-024-07407-7

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