By superposition, the individual strengthening mechanisms via hardness analyses and the particle dispersion contribution to strengthening were estimated for Al–C and Al–C–Cu composites and pure Al. An evident contribution to hardening due to the density of dislocations was observed for all samples; the presence of relatively high-density values was the result of the difference in the coefficients of thermal expansion (CTE) between the matrix and the reinforced particles when the composites were subjected to the sintering process. However, for the Al–C–Cu composites, the dispersion of the particles had an important effect on the strengthening. For the Al–C–Cu composites, the maximum increase in microhardness was ~210% compared to the pure Al sample processed under the same conditions. The crystallite size and dislocation density contribution to strengthening were calculated using the Langford–Cohen and Taylor equations from the microstructural analysis, respectively. The estimated microhardness values had a good correlation with the experimental. According to the results, the Cu content is responsible for integrating and dispersing the Al₄C₃ phase. The proposed mathematical equation includes the combined effect of the content of C and Cu (in weight percent). The composites were fabricated following a powder metallurgical route complemented with the mechanical alloying (MA) process. Microstructural analyses were carried out through X-ray analyses coupled with a convolutional multiple whole profile (CMWP) fitting program to determine the crystallite size and dislocation density.

Different Al–4Cu–1.5Mg/WC composites were synthesized through powder metallurgy to establish the effect of WC particle addition on the abrasive wear behavior of an Al–4Cu–1.5Mg (wt. %) alloy. The wear tests were performed using a pin-on-disc tribometer at room temperature in dry conditions using SiC abrasive sandpaper as a counterbody and tribometer of linear configuration. The results showed that WC additions increase the hardness of the Al–4Cu–1.5Mg alloy due to the strengthening effect of particle dispersion in the aluminum matrix, which generates an improvement in the wear resistance of the composites by preventing direct contact of the sample with the counterbody, in turn delaying the plastic deformation phenomena responsible for the degradation sequence. In addition, the dominant wear mechanism was abrasive wear, and the increased friction coefficient did not bring a rapid wear rate, which was related to the enhanced deformation resistance due to the high hardness.

In this study, Al-Al₄C₃ compounds were manufactured by mechanical milling followed by heat treatment. To analyze the microstructural evolution, the composites were sintered at 550 °C at different sintering times of 2, 4 and 6 h. The mechanical results suggest that dislocation density and crystallite size primarily contribute to hardening before the sintering process, with a minimal contribution from particle dispersion in this condition. The compound exhibited a significant 75% increase in hardness after 2 h of sintering, primarily attributed to the nucleation and growth of Al₄C₃ nanorods. The HRTEM analysis, combined with geometric phase analysis (GPA) at and near the Al-Al₄C₃ interface of the nanorods, revealed strain field distributions primarily associated with partial screw dislocations and the presence of closely spaced dislocation dipoles. These findings are consistent with the microstructural parameters determined from X-ray diffraction pattern analysis using the convolutional multiple whole profile (CMWP) method. This analysis showed that the predominant dislocation character is primarily of the screw type, with the dislocation dipoles being closely correlated. Based on these results, it is suggested that samples with a lower weight percentage of reinforcement and longer sintering times may experience reduced brittleness in Al/Al₄C₃ composites. Strengthening contributions were calculated using the Langford–Cohen and Taylor equations.

Al–Cu–Mg composites reinforced with sub-micron tungsten carbide (WC) particles were synthesized by powder metallurgy and subjected to T6 heat treatment to clarify the interplay between dispersion strengthening and precipitation hardening. Composites with 1–3 wt.% WC (average size 0.8 μm) were solution-treated at 540 °C for 3 h, water-quenched, and aged at 195 °C for up to 100 h. Microstructural analyses confirmed a uniform distribution of WC and demonstrated that its presence did not modify the dissolution–precipitation sequence of the Al-Cu-Mg matrix. Transmission Electron Microscopy observations provided direct evidence of θ′ (Al₂Cu) precipitates. The 3 wt.% WC composite reached peak hardness after 5 h (78 HRF), a 15% increase over the T6-treated unreinforced alloy, and exhibited a 40% higher yield strength (330 MPa). These improvements were attributed to the combined effects of Orowan strengthening and age-hardening precipitates (θ′). The results demonstrate that integrating powder metallurgy, sub-micron WC reinforcement, and T6 treatment is an effective route to enhance strength in Al–Cu–Mg alloys without delaying aging kinetics.

High-energy ball milling is a process suitable for producing composite powders whose achieved microstructure can be controlled by the processing parameters. Through this technique, it is possible to obtain a homogeneous distribution of reinforced material into a ductile metal matrix. In this work, some Al/CGNs nanocomposites were fabricated through a high-energy ball mill to disperse nanostructured graphite reinforcements produced in situ in the Al matrix. To retain the dispersed CGNs in the Al matrix, avoiding the precipitation of the Al₄C₃ phase during sintering, the high-frequency induction sintering (HFIS) method was used, which allows rapid heating rates. For comparative purposes, samples in the green and sintered state processed in a conventional electric furnace (CFS) were used. Microhardness testing was used to evaluate the effectiveness of the reinforcement in samples under different processing conditions. Structural analyses were carried out through an X-ray diffractometer coupled with a convolutional multiple whole profile (CMWP) fitting program to determine the crystallite size and dislocation density; both strengthening contributions were calculated using the Langford–Cohen and Taylor equations. According to the results, the CGNs dispersed in the Al matrix played an important role in the reinforcement of the Al matrix, promoting the increase in the dislocation density during the milling process. The strengthening contribution of the dislocation density was ~50% of the total hardening value, while the contribution by dispersion of CGNs was ~22% in samples with 3 wt. % C and sintered by the HFIS method. Atomic force microscopy (AFM) and scanning electron microscopy (SEM) were used to analyze the morphology, size, and distribution of phases present in the Al matrix. From the analyses carried out in AFM (topography and phase images), the CGNs are located mainly around crystallites and present height profiles of 1.6 to 2 nm.

In this study, Al-Al4C3 compounds were manufactured by mechanical milling followed by heat treatment. To analyze the microstructural evolution, the composites were sintered at 550°C during different sintering times of 2, 4 and 6 hours. The mechanical results suggest that dislocation density and crystallite size primary contribute to hardening before the sintering process, with a minimal contribution from particle dispersion in this condition. The compound exhibited a significant 75% increase in hardness after 2 hours of sintering, primarily attributed to the nucleation and growth of Al4C3 nanorods. The HRTEM analysis, combined with ge-ometric phase analysis (GPA) at and near the Al-Al4C3 interface of the nanorods, revealed strain field distributions primarily associated with partial screw dislocations and the presence of closely spaced dislocation dipoles. These findings are consistent with the microstructural parameters determined from X-ray diffraction pattern analysis using the convolutional multi-ple whole profile (CMWP) method. This analysis showed that the predominant dislocation character is primarily of the screw type, with the dislocation dipoles being closely correlated. Based on these results, it is suggested that samples with a lower weight percentage of rein-forcement and longer sintering times may experience reduced brittleness in Al/Al4C3 compo-sites. Strengthening contributions were calculated using the Langford–Cohen and Taylor equations.