Fabrication of carbon fiber reinforced aluminum matrix composites by inorganic binders

Infiltration is an important issue for unidirectional carbon fiber-reinforced aluminum matrix (CF/Al) composites. In the present study, aluminum dihydrogen phosphate (ADP) and silica sol were used to prepare CF preforms, then CF/Al composites were prepared by simulated horizontal continuous casting. The results showed that silica sol significantly affects the curing process of ADP. When the content of silica sol is 50 % and heated at 500 °C, the product transformed from Al(PO3)3 (cubic system) to an amorphous phase with good thermostability. The mixture binder can fully fill the gaps between CFs, leading to a dense CF preform. The obtained CF/Al composite has a good bonding interface between Al and CFs, without pores or crack defects, and thus shows an obvious enhancement in tensile strength of 64.9 MPa, which is 34.6 % improved compared with that of CPAl. The CF/Al composites also maintained a good electrical conductivity of 56.9 % IACS, similar to that of CPAl.