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Nucleation and growth of Al2O3/metal composites by oxidation of aluminum alloys

Published online by Cambridge University Press:  31 January 2011

O. Salas ,
H. Ni ,
V. Jayaram ,
K.C. Vlach ,
C.G. Levi  and
R. Mehrabian
O. Salas
Affiliation:
Graduate Research Assistant, University of California, Santa Barbara, California 93106
H. Ni
Affiliation:
Assistant Specialist, University of California, Santa Barbara, California 93106
V. Jayaram
Affiliation:
Assistant Professor, Indian Institute of Science, Bangalore, India
K.C. Vlach
Affiliation:
Assistant Research Engineer, University of California, Santa Barbara, California 93106
C.G. Levi
Affiliation:
Associate Professor of Materials and Mechanical Engineering, University of California, Santa Barbara, California 93106
R. Mehrabian
Affiliation:
President, Carnegie Mellon University, Pittsburgh, Pennsylvania 15213
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Abstract

The nucleation and growth mechanisms during high temperature oxidation of liquid Al−3% Mg and Al−3% Mg−3% Si alloys were studied with the aim of enhancing our understanding of a new composite fabrication process. The typical oxidation sequence consists of an initial event of rapid but brief oxidation, followed by an incubation period of limited oxide growth after which bulk Al2O3/Al composite forms. A duplex oxide layer, MgO (upper) and MgAl2O4 (lower), forms on the alloy surface during initial oxidation and incubation. The spinel layer remains next to the liquid alloy during bulk oxide growth and is the eventual repository for most of the magnesium in the original alloy. Metal microchannels developed during incubation continuously supply alloy through the composite to the reaction interface. During the growth process, a layered structure exists at the upper extremity of the composite, consisting of MgO at the top surface, MgAl2O4 (probably discontinuous), Al alloy, and finally the bulk Al2O3 composite containing microchannels of the alloy. The bulk oxide growth mechanism appears to involve continuous formation and dissolution of the Mg-rich oxides at the surface, diffusion of oxygen through the underlying liquid metal, and epitaxial growth of Al2O3 on the existing composite body. The roles of Mg and Si in the composite growth process are discussed.

Type
Articles
Information
Journal of Materials Research , Volume 6 , Issue 9 , September 1991 , pp. 1964 - 1981
Copyright
Copyright © Materials Research Society 1991

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