Ultrasound‐Assisted Liquid‐Phase Synthesis and Mechanical Properties of Aluminum Matrix Nanocomposites Incorporating Boride Nanocrystals

Abstract Incorporating boride nanocrystals could significantly impact the mechanical properties of aluminum alloys. Molten salts synthesis offers opportunities to fabricate superhard boride nanoparticles, which can sustain the harsh conditions during the liquid‐phase design of metallic nanocomposites. Here hafnium diboride‐aluminum nanocomposites are unveiled from molten salt‐derived HfB₂ nanoparticles sequentially dispersed in aluminum by ultrasound treatment. The structure and size of the nanocrystals are retained in the final nanocomposites, supporting their high chemical stability. Semicoherent interfaces between the nanoparticles and the matrix are then evidenced by TEM, suggesting that the nanocrystals could promote heterogeneous nucleation of Al and then limit the Al grain size to ≈20 µm. Nanoindentation measurements reveal significant grain boundary strengthening and grain refinement effects. It is finally shown that HfB₂ nanoparticles also enable a decrease in matrix grain size and an increase in the hardness of the AlSi₇Cu_0.5Mg_0.3 alloy. These proof‐of‐concept materials are paving the way to light‐weight Al matrix nanocomposites doped by molten‐salt synthesized nanoparticles.