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The goal of this study was production of an Al–15%Mg 2 Si metal matrix composite (MMC) containing 3 wt.% copper and also study microstructural and hardness properties. For this, pure Al, Mg, Si and Cu ingots were used to make composite via in situ route. The composite was characterised by X-ray diffraction, optical microscope (OM) and scanning electron microscope equipped with energy-dispersive X-ray spectroscopy (EDX) analysis. Microstructural observations explored that Mg 2 Si particles form all over the Al matrix. According to the OM characterisation, the size of primary Mg 2 Si particles was estimated to be ~20 μm. This amount could be decreased to ~7 μm (65% reduction) due to the presence of copper, mostly because of the formation of Cu-rich intermetallic phases during solidification, as detected by EDX analysis. Further results showed that these phases lead to an MMC with more hardness compared to the counterpart without Cu. In addition, because of Mg 2 Si phases in these systems which are even lighter than Al, it has high specific stiffness and strength. Therefore, it could be widely used as a lightweight material in aerospace and automobile fields, such as safety-belt pretensioner, steering wheel frame, crossbeams, wheel rims, car frame and shock absorbing cover.

Fabrication and hardness investigation of Al-15%Mg 2 Si-3%Cu in-situ cast composite