Thermodynamics and kinetics of the formation of Al2 O3/ MgAl2O4/MgO in Al-Silica metal matrix composite

The formation of Al₂O₃, MgAl₂O₄, and MgO has been widely studied in different Al base metal matrix composites, but the studies on thermodynamic aspects of the Al₂O₃/ MgAl₂O₄/MgO phase equilibria have been limited to few systems such as Al/Al₂O₃ and Al/SiC. The present study analyzes the Al₂O₃/MgAl₂O₄ and MgAl₂O₄/MgO equilibria with respect to the temperature and the Mg content in Al/SiO2 system using an extended Miedema model. There is a linear and parabolic variation in Mg with respect to the temperature for MgAl₂O₄/MgO and Al₂O₃/MgAl₂O₄ equilibria, respectively, and the influence of Si and Cu in the two equilibria is not appreciable. The experimental verification has been limited to MgAl₂O₄/MgO equilibria due to the high Mg content (≥0.5 wt pct) required for composite processing. The study has been carried out on two varieties of Al/SiO₂ composites, i.e., Al/Silica gel and Al/Micro silica processed by liquid metallurgy route (stir casting route). MgO is found to be more stable compared to MgAl₂O₄ at Mg levels ≥5 and 1 wt pct in Al/Silica gel and Al/Micro silica composites, respectively, at 1073 K. MgO is also found to be more stable at lower Mg content (3 wt pct) in Al/Silica gel composite with decreasing particle size of silica gel from 180 micron to submicron and nanolevels. The MgO to MgAl₂O₄ transformation has taken place through a series of transition phases influenced by the different thermodynamic and kinetic parameters such as holding temperature, Mg concentration in the alloy, holding time, and silica particle size.