6061Al/Al–SiCp bi-layer composites produced by plasma-spraying process

Abstract Al/Al–SiC p bi-layer composites were produced by plasma spraying the premixed Al (or Al alloy) and SiC powders onto a 6061Al substrate. The obtained composites can be used for electronic packaging and are easy to join with other packaging components by the unreinforced substrate. A transition zone of lowered SiC particle volume fraction in the sprayed layers near the substrate surface was often formed. It can be affected by several factors, such as the initial temperature of substrate. No interfacial reactions between Al and SiC, as well as oxidation reaction, were found in the sprayed layers of the composites. SiC particles remained intact after spraying impact.