CHEMICAL-STABILITY OF ZIRCONIA-STABILIZED ALUMINA FIBERS DURING PRESSURE INFILTRATION BY ALUMINUM

Metal matrix composites composed of high-purity aluminum and Du Pont PRD-166 continuous zirconia-stabilized polycrystalline alumina fibers are fabricated by liquid metal infiltration using three different casting procedures. The microstructure of the composites is analyzed using optical and electron microscopy, including analytical electron microscopy. It is found that discrete faceted particles of ZrAl3 form at the interface and grow into the matrix of samples processed above the melting point of the matrix for 13 minutes or more. The formation of this compound is in agreement with thermodynamic stability calculations. It is also found that there is a reaction between solid aluminum and the fibers at 913 K, yielding a reaction product which has the same morphology as that observed with molten aluminum. When the fibers are infiltrated with an initial preform temperature below the metal melting point and a solidification time below 1 minute, no reaction products were visible in the composite using the scanning electron microscope (SEM). This leads to the conclusion that aluminum matrix composites can be cast with no apparent interfacial reaction product using these fibers provided that adequate processing parameters are chosen.