J. Uddin, A. Malakar, M. Lastovich, F. Ishrak, F-Y Tsai, B. Gwalani
North Carolina State University,
United States
Keywords: solid state reactive processing, composites, nano thermites, nanoparticles, magnetic Al alloys
Summary:
Solid-State Reactive Processing (SSRP) was employed to synthesize multifunctional aluminum matrix composites through in-situ nano-thermitic reactions during friction-assisted plastic deformation. An Al-Mg alloy was reinforced with Fe3O4 particles, initiating a controlled reduction reaction that produced Fe nanoparticles encapsulated in a Mg-rich oxide shell finely dispersed in the matrix. This technique integrates mechanical deformation, chemical potential gradients, and thermal activation to achieve uniform particle distribution while suppressing brittle intermetallic formation (e.g., Al13Fe4, FeAl3). The resulting nanocomposite exhibited enhanced microhardness, increased electrical resistivity, and ferromagnetic behavior. Embedding magnetic Fe in Al has traditionally been hindered by the formation of brittle intermetallics, but SSRP enables kinetic control to mitigate this issue. These composites offer potential for magnetic actuators in extremeenvironment robotics, replacing polymer-bonded magnets, and serve as lightweight, wear-resistant structural materials for automotive, aerospace, and energy applications due to their multifunctional performance.