Abstract
This paper explores new routes for flake powder metallurgy, with the aim of designing an effective route for fabricating metal matrix nanocomposites, combining high strength and good ductility. A new route that uses three speeds, instead of the two speeds characterizing the shift-speed ball milling (SSBM) route, has been suggested and implemented. The mechanisms of these routes were illustrated based on the intensity of ball-powder-ball collisions and the morphology evolution. The ball milled powder were characterized using filed emission scanning electron microscope (FESEM), X-ray diffractometer (XRD) and Energy dispersive spectroscopy (EDS) to investigate the morphology evolution of the composites powder and the homogenous distribution of the SiC nanoparticles within the Al matrix. The reinforcing adequacy and interfacial bonding of 2 wt.% SiC nanoparticles in an inductively sintered composite has been investigated. Mechanical testing of the produced bulk composites resulted in achieving superior mechanical properties, characterized by 92% higher hardness, 180% higher yield strength, 101% higher ultimate strength, and 0% loss in uniform elongation, compared with those of regular SSBM. This is attributed to the homogeneous dispersion of the reinforcement into the Al matrix.