Conventional manufacturing processes for aluminum matrix composites (AMCs) involve complex procedures that require unique equipment and skills at each stage. This increases the process costs and limits the scope of potential applications. In this study, a simple and facile route for AMC manufacturing is developed, a mixture of Al powder and the ceramic reinforcement is simply heated under nitrogen atmosphere to produce the composite. During heating under nitrogen atmosphere, the surface modification of both Al and the reinforcement is induced by nitridation. When the oxide layer covering Al powder surface is transformed to nitrides, temperature in the local region increases rapidly, resulting in a partial melt of Al powder. The molten Al infiltrates into the empty space among Al powder and reinforcement, thereby enabling consolidation of powders without external forces. It is possible to fabricate AMCs with various types, sizes, volume fractions, and morphologies of the reinforcement. Furthermore, the manufacturing temperature can be lowered below the melting point of Al (or the solidus temperature for alloys) because of the exothermic nature of the nitridation, which prevents formation of un-wanted reactants. The relative simplicity of this process will not only provide sufficient price competitiveness for the final products but also contribute to the expansion of the application scope of AMCs.

While nanocrystalline (NC) metals exhibit superior strength to conventional microcrystalline metals, their thermal instability has hampered their application at high temperatures. Herein, two-dimensional (2D) boron nitride nanosheets (BNNS) are proposed as reinforcement to enhance the strength as well as the thermal stability of NC Al. The strength of pure Al was increased from 80 to 468 MPa by refining its grains from ~600 to ~40 nm, and it was further enhanced to 685 MPa by incorporating 2 vol% of BNNS. Moreover, the small amount of BNNS was found to effectively suppress grain growth of NC Al at 580 °C (~0.9 T_m, where T_m is the melting point of Al), which prevented a strength drop at high temperature. Finally, the Zener pinning model in conjunction with phase-field simulations was utilized to qualitatively analyze the effect of the BNNS on the grain boundary pinning as a function of volume, shape, and orientation of the reinforcement. The model demonstrated that the pinning force of 2D reinforcements is much higher than that of spherical particles. Hence, 2D BNNS offer the possibility of developing Al-matrix nanocomposites for high-temperature structural applications.

Although many studies have focused on the unique plastic deformation behavior of nanocrystalline aluminum (e.g., the positive deviation from Hall-Petch relation, the unusual yield-drop phenomenon in tensile mode, etc.), the data reported by different research groups are inconsistent with each other, possibly because of different fabrication processes. In this study, aluminum samples with a wide grain-size spectrum – from a few micrometers down to 100 nanometers – are manufactured by powder metallurgy. The grain size was measured by X-ray diffraction analysis and transmission electron microscope observation. Furthermore, the tensile behavior, which varied according to a grain size, is discussed with a comparison of the theoretical models.