Al-2 wt-%Cu composites were produced by gas pressure infiltration of powder beds with a high volume fraction (45 to 60 vol.-%) of angular or polygonal alumina particles. The tensile behaviour and fracture toughness of the composites were characterised in as cast, solutionised and peak aged (T6) conditions. It was shown that coarse intermetallics that are formed during solidification and located preferentially at the particle/matrix interface lead to lower toughness compared with the same composites in solutionised and T6 conditions. The particle nature and shape exert a strong influence on the properties of the composites: polygonal particles are intrinsically stronger than angular particles and yield stronger, tougher, and more ductile composites. Composite toughness variations are explained in terms of fracture micromechanisms.
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