Evaluation of continuous alumina fibre reinforced composites based upon pure aluminium

Abstract

Composites of super purity aluminium unidirectionally reinforced with Altex or Nextel 610 continuous alumina basedfibre have been made by liquid metal infiltration. The composites were well consolidated, with fibre volume fractions V_f of 0.4 and 0.6 for the Altex composites and 0.7 for the Nextel composite, the higher values being obtained where preforming involved the use of sized fibre tows. Matrix porosity was very low and there was no evidence of any deleterious reaction product having formed at the fibre/matrix interface. Monotonic longitudinal tensile tests of the composites gave Youngs modulus values between 125 and 250 GPa, in line with rule of mixtures (ROM) predictions and evidence of effective load transfer between fibres. The onset of yielding in longitudinal composites was commensurate with the yield stress of unreinforced super purity aluminium for V_f = 0.4 (∼20 MPa), but increased to 225 MPafor V_f =0.7. The tensile strengths of the Altex composites were 760 and 930 MPa, values in accord with ROM predictions based upon equal load sharing of fibres up to the mean filament failure stress. Although the Nextel composite had a higher tensile strength of 1250 MPa, this was significantly lower than the ROM value of 1650 MPa and was better described by fibre ‘bundle’ theory. Predictions of the accumulation of fibre damage, by statistical analysis, indicated that filament breakage commenced at an applied stress of ∼50 MPa for the Altex composite and ∼ 500 MPa for the Nextel composite. Despite damage at the lower stress, however, the Altex composites were able to tolerate many more ‘double’ fibre breaks than the Nextel composite, the failure of which coincided with the onset of the first double break. Transverse tensile tests of the composites gave Young's modulus values between 80 and 170 GPa, in line with ROM predictions. The yield stress increased with increasing V_f, from 10 to 60 MPa, this behaviour being attributed to plane strain deformation caused by the virtually non-deformable fibres constraining matrix flow. The tensile strengths showed a similar trend, with 84 MPa for V_f =0.4 increasing to 168 MPa for V_f = 0.7.