Al Clad CF/Al Composite Fabricated by a One-Step Liquid–Solid Infiltration–Extrusion Process: Electrochemical Corrosion and Mechanical Behavior

Carbon fiber-reinforced aluminum matrix (CF/Al) composite should be covered with a corrosion-resistant alloy to enable broad usage without being affected by corrosion. In this study, a strategy was proposed to prepare Al cladding with CF/Al composite in a single process using liquid–solid infiltration. The microstructures, elemental distributions, and phase compositions of the composite were analyzed using a scanning electron microscope equipped with energy dispersive spectroscopy and x-ray diffraction. Furthermore, the corrosion behavior, mechanical response, and failure mode of both composite were investigated. The results revealed uniform fiber distribution, sufficient matrix alloy infiltration, and robust interfacial bonding between the Al cladding and the CF/Al composite. In terms of mechanical properties, Al clad CF/Al composite changed the fracture behavior from brittle to progressive fracture without losing tensile strength. The shear strength between the cladding Al and CF/Al composite was higher than that between the interlaminar layers of the CF/Al composite. Additionally, the corrosion current density (i_corr) of Al clad CF/Al was one order of magnitude lower than that of CF/Al composite. This research provides a reliable way to expand the application of fiber-reinforced metal matrix composite.