Application of anodizing and CAR processes for manufacturing Al/Al2O3 composite

In this study, an anodizing process with different conditions was used to grow four different thicknesses of alumina on the surface of aluminum strips. Then, a continual annealing and roll-bonding (CAR) process was done to produce an aluminum matrix composite dispersed with four different volume fractions of alumina particles. The results demonstrate that when the number of cycles was increased, the distribution of alumina particles in the aluminum matrix improved, the particles became finer, and the tensile strength of the composites increased. The microstructure of the fabricated composites after 8 CAR cycles also showed an excellent distribution of alumina particles in the matrix. Moreover, it was observed that increasing alumina quantities through longer anodizing times enhanced the tensile strength of the composite to become 1.65 times higher than that of the monolithic aluminum produced by the same method, while negligible reductions were observed in the elongation value. Fracture surfaces after tensile tests were observed by scanning electron microscopy (SEM) to investigate the failure mode. Observations reveal that the failure mode in both CAR-processed composites and monolithic aluminum was the typical ductile fracture showing deep equiaxed dimples.