Aluminum-based ceramic/metal composites with tailored thermal expansion fabricated by spark plasma sintering

We have devised a moderate temperature spark plasma sintering route for preparing aluminum matrix composites which possess tailored coefficients of thermal expansion (CTEs) in combination with tunable electrical and thermal conductivities. Due to its isotropic negative thermal expansion over a wide temperature range, cubic-phase ZrW2-xMoxO8 (x = 0.0, 1.0) is an ideal secondary phase for metal matrix composites with suitable CTEs. In this study, high-density ZrW2O8/Al and ZrWMoO8/Al composites containing 30-70 vol% Al were fabricated using spark plasma sintering. X-ray diffraction analysis indicated that the composites were composed of a thermally-stable cubic phase at temperatures as high as 873 K for ZrW2O8 and 773 K for ZrWMoO8, without any orthorhombic high-pressure phase derived from the large thermal mismatch between the ceramic and metal during sintering. The thermal expansion curves of the ZrW2-xMoxO8/Al composites were consistent with the predictions made using the Rule-of-Mixtures. The CTEs could be controlled from negative to positive and even close to zero by simply varying the volume fraction of aluminum. Similarly, the thermal and electrical conductivity of the ZrW2-xMoxO8/Al composites increases with increasing Al content, which is thought to be mainly related to the contribution of the free electron conduction path of Al in the composites. High-density ZrW2-xMoxO8/Al composites containing 30 to 70 vol% Al were fabricated by SPS at 773-873 K. The CTEs of the ZrW2-xMoxO8/Al composites could be controlled from near-zero to positive simply by changing the volume fraction of Al.