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Magnesium/ceramic composites with an interpenetrating microstructure were made by pressure infiltrating an open cellular ceramic preform. The low-density ceramic preform with a porosity of 82% was prepared by foaming a low-viscous polysiloxane/alumina suspension which formed an SiO 2 /Al 2 O 3  microcomposite ceramic foam after thermal treatment in air at 1200 °C. Foaming was achieved by an  in situ  blowing process during curing of the polysiloxane precursor at 200 – 300 °C. The open cellular structure was characterized by a mean strut thickness of 130 μm, an average cell diameter of 800 μm and a high pore connectivity. The ceramic preforms were infiltrated with AZ 31 magnesium alloy by squeeze casting at 680 °C applying a maximum pressure of 86 MPa. Interface bonding was achieved by the formation of spinel and cordierite in a reaction layer at the metal/ceramic interface. The dense metal/ceramic composite possesses significantly higher elastic modulus, yield strength and creep resistance than the monolithic alloy at room temperature and 135 °C. The experimental results suggest that filler-loaded preceramic polymers have a high potential for optimization of lightweight metal cast components.

Polysiloxane-derived ceramic foam for the reinforcement of Mg alloy