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Interfacial reactions were investigated for a novel P/M (powder metallurgy) 5056 aluminium alloy metal matrix composite reinforced with particulate intermetallic Ni 3 Al. Composites were fabricated by extrusion of a blend of matrix alloy powder and intermetallic particles produced by self-propagating high temperature synthesis. Extrusion of 5056/15 vol.% Ni 3 Al at 400 °C produced bars of excellent quality, whereas extrusion of 5056/15 vol.% Ni 3 Al at 420 °C and of 5056/25 vol.% Ni 3 Al at 380 °C resulted in severe interfacial reactions and volume expansion during extrusion. The same reactions occurred in the good quality composite during subsequent heat treatment at 500 and 520 °C. The 5056 Al alloy with its high (~5 %) Mg content exhibited a higher reactivity with Ni 3 Al than Al alloys with low Mg content. The interfacial reaction products were identified to be Al 3 Ni and Al 3 Ni 2 . The interfacial reactions consumed Al so raising the Mg content of the residual matrix. This gave the possibility for the matrix to become partially molten at lower temperatures than expected from its nominal composition. Segregation of Mg near the reinforcement particles is accelerated by the presence of a high dislocation density in the matrix generated during extrusion.

Interfacial Reactions between the Aluminium Alloy Matrix and Intermetallic Reinforcement Particles in Novel P/M 5056/Ni 3 Al p Composites