In this study, an attempt was made to improve the mechanical properties and in particular the strength of a precipitation-hardenable aluminum alloy while still maintaining high ductility. For this purpose, AlSi7Mg0.6 (A357) powder with an average particle diameter of d50 = 40 µm was consolidated using field assisted sintering technique (FAST), and two material conditions were compared: an as-sintered and an underaging heat treated condition (T61). Mechanical properties were determined using tensile tests and hardness measurements. In addition, the microstructure was investigated by optical microscopy. Further, porosity and density were analyzed after the different heat treatments. By the underaging heat treatment, the surface hardness was increased by 100% and the yield strength was increased by 80% compared to the as-sintered material. However, the elongation to failure dropped to one third of that of the as-sintered material. Presumably, this effect was a result of an increased porosity due to the heat treatment. It is assumed that the observed pores were generated by artefacts from the FAST process used to manufacture the samples. The internal gas pressure and equilibrium diffusion supported by heat treatment temperature, and the reduction in surface energy caused by coalescent micropores, led to the enlargement of previously undetectable inhomogeneities in the as-sintered material that resulted in pores in the heat-treated sintered alloy.

AlSi7Mg/SiCp aluminium matrix composites (AMCs) with a high ceramic content (35 vol.%) that were produced by using the field-assisted sintering technique (FAST) were subjected to tribological preconditioning and evaluated as a potential lightweight material to substitute grey cast iron brake discs. However, since an uncontrolled running-in process of the AMC surface can lead to severe wear and thus to failure of the friction system, AMC surfaces cannot be used directly after finishing and have to be preconditioned. A defined generation of a tribologically conditioned surface (tribosurface) is necessary, as was the aim in this study. To simulate tribological conditions in automotive brake systems, the prepared AMC samples were tested in a pin-on-disc configuration against conventional brake lining material under dry sliding conditions. The influence of the surface topography generated by face turning using different indexable inserts and feeds or an additional plasma electrolytic treatment was investigated at varied test pressures and sliding distances. The results showed that the coefficient of friction remained nearly constant when the set pressure was reached, whereas the initial topography of the samples studied by SEM varied substantially. A novel approach based on analysing the material ratio determined by 3D surface measurement was developed in order to obtain quantitative findings for industrial application.

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In the present study, 35vol% SiCp/AlSi7Mg0,6 composites were prepared using field assisted sintering technique in order to investigate the effect of different particle fractions and size distributions of the AlSi7Mg matrix powder on the tensile properties of the produced composite material. In most usecases the size of the reinforcement phase is given by the application and is only variable within narrow limits (< 20pm particle size in this work). On the other hand, there is potential for optimization of the matrix powder. In this investigation, fine (d50 = 25 µm), coarse (d50 = 52 µm), bimodal (50wt% of fine + 50wt% of coarse, d50 = 36 µm) and as received (d50 = 40 µm) aluminum powder was used as the matrix powder. Using fine matrix powder has improved yield strength by 5 % and ultimate tensile strength by 7 % compared to the as received condition. This is largely due to the lower porosity of the composite produced under the use of the fine matrix powder ((0.07 ± 0.04) %) in contrast to the composite using the as received aluminum powder ((0.62 ± 0.35) %). At the same time, the consumed heating energy of the composite was decreased by almost a third when using the fine matrix powder in comparison to the use of the as-received matrix powder. This paper presents results of an optimization approach for mechanical properties of aluminum matrix composites without any changes of the sintering parameters.

Particle-reinforced aluminium matrix composites (AMC) with a high-volume fraction of ceramic reinforcement (>30 vol.%) combine high specific strength and stiffness with good wear resistance and thermal stability, resulting in their increasing popularity in high-load applications, such as brake discs and bearings. It is hence assumed that AMC will accumulate as scrap in the near future. Appropriate recycling strategies must therefore be developed to maintain AMC’s inherent properties. Melt-metallurgical recycling routes bear the danger of dissolving the ceramic reinforcement in the liquid metallic matrix and contaminating primary melts or forming intermetallic phases in secondary melts. Here, a solid-state AMC recycling route with crushing and sintering is investigated, wherein all steps are carried out below the solidification temperature of the aluminium matrix. A sintered primary AMC is mechanically converted into a particulate/powdery secondary raw AMC in coarse, medium, and milled quality (i.e., with d ≈ 7–12 mm, d ≈ 3–7 mm, and d < 300 µm) and subsequently resistance heating sintered to a secondary AMC under a variation of the sintering pressure. The two AMC generations are analysed and discussed regarding their microstructure and mechanical properties. Since the secondary AMC show reduced the mechanical strength, the fracture surfaces are analysed, revealing iron contaminations from the mechanical processing.