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<p>This study investigates the development and mechanical characterization of AA7075-based metal–matrix composites reinforced with silicon nitride (SiN) and zirconium carbide (ZrC), fabricated using powder metallurgy followed by either conventional or microwave sintering. The microwave-sintered AA7075/7 wt.% SiN composite demonstrated the highest tensile strength of 238 MPa, surpassing the conventionally sintered counterpart (7 wt.% SiN, 192 MPa). Hybrid composites containing 7 wt.% SiN and varying ZrC contents (1-5 wt.%) were developed, with the 3 wt.% ZrC hybrid composite exhibiting superior mechanical performance, including tensile strength of 302 MPa, compression strength of 379 MPa, hardness of 122 HV, and impact energy of 9.54 J. Microstructural analysis revealed uniform reinforcement distribution and strong interfacial bonding, while porosity was minimized at optimized reinforcement levels. XRD analysis identified the formation of stable Al<sub>3</sub>Zr intermetallics that enhanced the strength and thermal stability, whereas the presence of brittle Al<sub>4</sub>C<sub>3</sub> phases at higher ZrC levels contributed to interface degradation and reduced performance. Additionally, fractography confirmed ductile fracture features at optimal compositions and brittle characteristics at higher ZrC due to agglomeration and pore formation. The enhanced mechanical behavior is attributed to multiple strengthening mechanisms, including Orowan looping, thermal-mismatch-induced dislocations, and grain boundary strengthening. These results establish that microwave sintering with optimal hybrid reinforcement (7% SiN + 3% ZrC) produces high-performance AA7075 composites suitable for aerospace, defense, and advanced automotive applications.</p> Graphical Abstract <p></p>

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Exploring the Microstructural and Mechanical Response of Aluminum Hybrid Composite Reinforced with SiN and ZrC Fabricated through Hybrid Microwave Sintering Techniques

  • 期刊论文

  • 发表日期：

    2026年7月26日

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  • Chintha Sunil,
  • K. Venkateswara Reddy,
  • Guttikonda Manohar

摘要

This study investigates the development and mechanical characterization of AA7075-based metal–matrix composites reinforced with silicon nitride (SiN) and zirconium carbide (ZrC), fabricated using powder metallurgy followed by either conventional or microwave sintering. The microwave-sintered AA7075/7 wt.% SiN composite demonstrated the highest tensile strength of 238 MPa, surpassing the conventionally sintered counterpart (7 wt.% SiN, 192 MPa). Hybrid composites containing 7 wt.% SiN and varying ZrC contents (1-5 wt.%) were developed, with the 3 wt.% ZrC hybrid composite exhibiting superior mechanical performance, including tensile strength of 302 MPa, compression strength of 379 MPa, hardness of 122 HV, and impact energy of 9.54 J. Microstructural analysis revealed uniform reinforcement distribution and strong interfacial bonding, while porosity was minimized at optimized reinforcement levels. XRD analysis identified the formation of stable Al3Zr intermetallics that enhanced the strength and thermal stability, whereas the presence of brittle Al4C3 phases at higher ZrC levels contributed to interface degradation and reduced performance. Additionally, fractography confirmed ductile fracture features at optimal compositions and brittle characteristics at higher ZrC due to agglomeration and pore formation. The enhanced mechanical behavior is attributed to multiple strengthening mechanisms, including Orowan looping, thermal-mismatch-induced dislocations, and grain boundary strengthening. These results establish that microwave sintering with optimal hybrid reinforcement (7% SiN + 3% ZrC) produces high-performance AA7075 composites suitable for aerospace, defense, and advanced automotive applications.

Graphical Abstract