Mechanical Property and Failure Mechanism of Metal Rubber/ZA8 Composite Made by Squeeze Casting Process

High-performance lightweight composites are developed by integrating metal rubber (MR) into a zinc alloy (ZA8) matrix via squeeze casting. MR, comprising 304 stainless steel wires (SSWs) with diameters of 0.15 mm, forms 3D network skeletons with volume fractions of 8.8 vol% (S1), 11.1 vol% (S2), and 13.4 vol% (S3), respectively. The preparation parameters of the composites are optimized, and their microhardness is investigated. Special attention is paid to the ultimate compression and shear performance at 25, 150, and 250 degrees C. The microstructure and failure analysis are performed via scanning electron microscopy. The results reveal a 48.0% increase in microhardness at composite interfaces relative to ZA8. At 25 degrees C, S2 possesses an ultimate compressive strength (UCS) of 401.4 MPa, which is 33.7% higher than that of ZA8. At 150 and 250 degrees C, S3 exhibits UCS values of 180.3 and 74.3 MPa, exceeding those of ZA8 by 61.7% and 110.5%, respectively. Meanwhile, the ultimate shear strength of composites slightly drops below that of the matrix: the corresponding value of S1 specimen (158.4 MPa) at 250 degrees C is 11.5% below that of ZA8. Therefore, compression and shear failure mechanisms of MR/ZA8 composites are quite intricate, involving SSW separation, necking, and ZA8 fractures. High-performance lightweight composites are developed by integrating 3D network stainless steel wire (SSW) into a ZA8 zinc alloy via squeeze casting. The composites achieve a porosity of 0.8% after process optimization. At 150 and 250 degrees C, the composites ultimate compressive strength is enhanced by 61.7% and 110.5% than ZA8. The composites failure mechanisms involve SSW separation, necking, and ZA8 fractures.image (c) 2023 WILEY-VCH GmbH