Enhanced microstructure and mechanical properties of ZrN-reinforced AlSi10Mg aluminum matrix composite

Aluminum matrix composites (AMCs), incorporating Zirconium Nitride (ZrN) as reinforcing additives, demonstrate immense promise for applications in aerospace, automotive, and power generation due to their unique combination of low density, superior mechanical properties, and excellent thermal/electrical conductivity. This study explores the influence of ZrN reinforcement on the microstructure and mechanical properties of AlSi10Mg metal-matrix composites. Utilizing high-energy ball milling (HEBM) and spark-plasma sintering (SPS), ZrN/AlSi10Mg composites were synthesized, achieving nearly full density with uniform ZrN distribution, while phase and chemical transformations were not observed in the bulk composites. The addition of ZrN resulted in a notable increase in hardness of 237% (182 ± 8 HV₂), elastic modulus of 56% (114 ± 3 GPa), compressive and tensile strength of 183% (565 ± 15 GPa), and 125% (387 ± 9 GPa), respectively, for composites containing 30% ZrN, compared to the non-reinforced alloy. Experimentally determined coefficients of thermal expansion (CTEs) for composites with 10%, 20%, and 30% ZrN content were 19.8 × 10⁻⁶ °C⁻¹, 19.1 × 10⁻⁶ °C⁻¹, and 18 × 10⁻⁶ °C⁻¹, respectively, which well relates to Schapery’s model. These findings contribute to understanding the synthesis, mechanical behavior, and thermal properties of ZrN/AlSi10Mg composites, demonstrating their potential for diverse engineering applications.