Thermal expansion behaviour of plasma sprayed Al-SiCp composites

Al with 55 and 75 vol.-%SiC powders were free mechanically mixed or ball milled as feedstock. The powder feedstock was deposited onto a graphite substrate to form near net shape of Al/SiC composites by air plasma spraying. The pores and the gaps at the Al/SiC interface as well as at the boundary of Al grains exist extensively in the as sprayed composites. Coefficient of thermal expansion (CTE) of the sprayed composites was measured in the temperature range of 25-300 degrees C. The composites plasma sprayed with Al-75SiC powder feedstock can reach a low CTE value of 8x10(-6)degrees C-1. The effect of pore on the CTE of the composites has been discussed. The gap at Al/SiC interface has an influence on thermal expansion behaviour only at lower test temperatures. Reduction and elimination of the gap with temperature can offset the thermal expansion of the as sprayed composites, resulting in lower CTE at the beginning of the CTE test. Roughly quantitative consideration of the effect of the interfacial gaps between Al and SiC on CET was given. Linear rule of mixture ( ROM), Turner and Kerner's models were used to estimate the CTE of the sprayed composites. It was found that ROM and Kerner's model give closer CTE prediction for the present composites.