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<p>Traditional ex situ methods for aluminum matrix composites (AMCs) suffer from poor wettability and bifilm defects. In situ synthesis via direct oxidation of aluminum offers a promising alternative. This review analyzes direct oxidation technologies from the perspective of oxide film behavior, aiming to establish a unified design strategy. The DIMOX process disrupts the surface oxide film continuity via alloying, enabling directional growth of a 3D Al<sub>2</sub>O<sub>3</sub> network and avoiding bifilm defects; however, its product is a ceramic matrix composite with very low elongation (~0.2%), limiting applicability. The ALUHAB process shows that adjusting oxygen content controls oxide film thickness and stability on bubble surfaces. The key insight is that oxide film stability and rupture behavior determine whether oxidation leads to effective particle dispersion or bifilm defects. This review identifies the Pilling–Bedworth ratio as a critical parameter linking alloy composition to film fragmentation in the ALUHAB process. A unified design strategy is proposed that synergistically tailors alloy composition and gas–liquid reaction conditions. As an example, a “pre‑hydrogenation–internal oxygen blowing” process is analyzed: Hydrogen‑assisted surface combustion generates local high temperatures (&gt; 980&#xa0;°C), triggering controlled oxide film rupture and suppressing bifilm defects. Quantitative results show that this strategy achieves synergistic optimization of strength and workability. The as‑cast AlSi7Fe1/Al<sub>2</sub>O<sub>3</sub> composite reaches 175&#xa0;MPa (38% increase over matrix). The cold‑rolled AlFe1.8Ti0.4/Al<sub>2</sub>O<sub>3</sub> composite achieves 269&#xa0;MPa (55% improvement) with 3.2% elongation and can be rolled into 20-μm-thick foils. Compared to DIMOX and conventional in situ composites, this approach offers a superior balance of strength, ductility, and processability. This review establishes the relationship between oxide film behavior, gas–liquid reaction conditions, and composite architecture, providing a theoretical basis for low‑cost, scalable production of high‑performance AMCs.</p>

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In Situ Synthesis of Al-Al2O3 Composites by Direct Oxidation: An Analytical Review

  • 期刊论文

  • 发表日期：

    2026年6月18日

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  • Jingtao Miao,
  • A. B. Finkelstein,
  • A. A. Shaefer,
  • V. A. Khotinov

摘要

Traditional ex situ methods for aluminum matrix composites (AMCs) suffer from poor wettability and bifilm defects. In situ synthesis via direct oxidation of aluminum offers a promising alternative. This review analyzes direct oxidation technologies from the perspective of oxide film behavior, aiming to establish a unified design strategy. The DIMOX process disrupts the surface oxide film continuity via alloying, enabling directional growth of a 3D Al2O3 network and avoiding bifilm defects; however, its product is a ceramic matrix composite with very low elongation (~0.2%), limiting applicability. The ALUHAB process shows that adjusting oxygen content controls oxide film thickness and stability on bubble surfaces. The key insight is that oxide film stability and rupture behavior determine whether oxidation leads to effective particle dispersion or bifilm defects. This review identifies the Pilling–Bedworth ratio as a critical parameter linking alloy composition to film fragmentation in the ALUHAB process. A unified design strategy is proposed that synergistically tailors alloy composition and gas–liquid reaction conditions. As an example, a “pre‑hydrogenation–internal oxygen blowing” process is analyzed: Hydrogen‑assisted surface combustion generates local high temperatures (> 980 °C), triggering controlled oxide film rupture and suppressing bifilm defects. Quantitative results show that this strategy achieves synergistic optimization of strength and workability. The as‑cast AlSi7Fe1/Al2O3 composite reaches 175 MPa (38% increase over matrix). The cold‑rolled AlFe1.8Ti0.4/Al2O3 composite achieves 269 MPa (55% improvement) with 3.2% elongation and can be rolled into 20-μm-thick foils. Compared to DIMOX and conventional in situ composites, this approach offers a superior balance of strength, ductility, and processability. This review establishes the relationship between oxide film behavior, gas–liquid reaction conditions, and composite architecture, providing a theoretical basis for low‑cost, scalable production of high‑performance AMCs.