Microstructure and electrical conductivity of Al-SiCp composites produced by spray forming process

Al- SiCp composites have been synthesized by spray forming process with variation in particle flow rate, size of reinforcement particles and their volume fraction. The microstructure of composites and their electrical conductivity have been investigated. The results showed a uniform dispersion of large size particulate phase in the matrix of the primary α- phase with its equiaxed grain morphology. However, clustering of small size particles was observed at the grain boundary and grain junctions. The grain size of the composite materials was observed to be lower than that of the base Al- alloy. The composite materials invariably indicated their lower electrical conductivity compared to that of the monolithic Al- alloy. The electrical conductivity of composites decreased with increase in the volume fraction and decrease in size of the reinforcement particles. A high flow rate of particles during spray deposition resulted in a decrease in its conductivity. These results are explained in the light of thermal mismatch between the matrix and the reinforcement phases resulting in generation of high dislocation density. The droplet- particle interaction and resulting microstructure evolution during the spray deposition of the composites are discussed.