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Acta Metall Sin  2026, Vol. 62 Issue (5): 923-940    DOI: 10.11900/0412.1961.2025.00291
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Advances in Interface of Powder Metallurgy Aluminum Matrix Composites Fabricated via In Situ Reaction: A Review
ZHAO Naiqin(), WANG Zhenbo, RONG Xudong, ZHAO Dongdong, HE Chunnian
School of Materials Science and Engineering, Tianjin University, Tianjin 300350, China
Cite this article: 

ZHAO Naiqin, WANG Zhenbo, RONG Xudong, ZHAO Dongdong, HE Chunnian. Advances in Interface of Powder Metallurgy Aluminum Matrix Composites Fabricated via In Situ Reaction: A Review. Acta Metall Sin, 2026, 62(5): 923-940.

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Abstract  

Aluminum matrix composites (AMCs) can be widely employed across fields such as aerospace and transportation owing to their high-specific strength and modulus as well as excellent thermal and electrical conductivity. In situ reaction technology enables the formation of thermodynamically stable reinforcements within the Al matrix, resulting in clean interfaces and strong interfacial bonding that considerably enhance the overall mechanical properties of AMCs. Consequently, this technology has emerged as a pivotal approach for fabricating high-performance AMCs. This review aims to comprehensively elucidate the design principles, interface optimization, and performance regulation of powder metallurgy AMCs fabricated via in situ reactions, thereby promoting the development of a new generation of high-performance AMCs. Specifically, the reaction mechanisms as well as reinforcement types and characteristics in various in situ reaction systems developed via powder metallurgy are systematically investigated. In addition, the interfacial microstructure characteristics between in situ reinforcements and the Al matrix are examined, with particular emphasis on the influence of crystallographic orientation relationships on interfacial properties. Moreover, research progress in optimizing interfacial bonding via modification strategies is discussed, and the influence of interfacial structure on the mechanical properties of AMCs is summarized along with an outlook on future development directions.

Key words:  aluminum matrix composites      powder metallurgy      in situ reaction      interface structure      strengthening and toughening mechanism     
Received:  28 September 2025     
ZTFLH:  TG146.2  
Fund: National Natural Science Foundation of China(U23A20546);National Natural Science Foundation of China(52025015);National Natural Science Foundation of China(52130105);National Natural Science Foundation of China(52422103);National Natural Science Foundation of China(52201162);Natural Science Foundation of Tianjin(22JCZDJC00020);Natural Science Foundation of Tianjin(24JCQNJC00150)
Corresponding Authors:  ZHAO Naiqin, professor, Tel: (022)85356661, E-mail: nqzhao@tju.edu.cn

URL: 

https://www.ams.org.cn/EN/10.11900/0412.1961.2025.00291     OR     https://www.ams.org.cn/EN/Y2026/V62/I5/923

Fig.1  Microstructures of CNT/Al composites and RGO/Al composites based on interfacial in situ reactions (CNT—carbon nanotube, RGO—reduced graphene oxide)
(a, b) TEM (a) and HRTEM (b) images of the interface of CNT/Al composite[34]
(c-f) TEM images of the inner walls of deformed MWCNTs and HRTEM image of the interface of MWCNT/Al composite[35] (MWCNT—multi-walled carbon nanotube. White arrows in Fig.1c show the individually dispersed MWCNTs in the Al matrix; yellow arrows in Fig.1d indicate the inner-wall regularities in deformed MWCNTs during processing. Inset in Fig.1e is the SAED pattern of formed Al4C3)
(g-i) TEM (g) and HRTEM (h, i) images of the interface of RGO/Al composite[37]
Fig.2  Preparation process schematics and microstructures of the in situ synthesized CNT/Al composites and graphene nanosheets (GNPs)/Al composites by chemical vapor deposition (CVD) technology
(a) preparation process schematic of CNT/Al composites[40]
(b, c) TEM images of in situ synthesized CNTs (b) and CNT/Al composite (c)[40] (Inset in Fig.2b shows the magnified image of CNT)
(d) preparation process schematic of GNPs/Al composites[43]
(e, f) TEM images of in situ synthesized GNPs/Al composite powders (e) and CNT/Al composite (f)[43] (Inset in Fig.2e is the SAED pattern of the red solid box; and inset in Fig.2f is the SAED pattern of the blue solid box)
Fig.3  Microstructures of CuO/Al composite, B2O3/Al composite, and TiO2/Al composite (a, b) distributions of Al2O3 (a) and Al-Cu intermetallic compounds formed in CuO/Al composite (b)[55] (c-h) TEM (c, e, g) and HRTEM (d, f, h) images of secondary phases in the CuO/Al composite[56] (Insets in Figs.3d-f are corresponding fast Fourier transform (FFT)) (i, j) SEM images showing the distributions of Al2O3 and AlB2 in the B2O3/Al composites with different magnificaitons[57] (k-n) TEM images of Al3Ti (k, l), Al-Al3Ti interface (m), and Al2O3 (n) in the TiO2/Al composite[58] (Insets in Figs.3k and n are corresponding SAED patterns)
Fig.4  Microstructures of La2O3/Al composite, CeO2/Al composite, B4C/Al composite, and (B4C + Al2O3)/Al composite
(a-c) TEM image (a), EDS mapping (area B in Fig.4a) (b), and HRTEM image (position C in Fig.4b) (c) of the La2O3/Al composite[59]
(d) a ring of amorphous Al2O3 (am-Al2O3) wrapped around unreacted CeO2 particles with corresponding FFT (inset)[60]
(e) a ring of am-Al2O3 wrapped around a nano-Al11Ce3 particle and isolated dispersed am-Al2O3[60]
(f) am-Al2O3 network at the grain boundary in B4C/Al composite[61]
(g, h) am-Al2O3 at grain boundaries (g) and intragranular distribution (h) in the (B4C + Al2O3)/Al composite[62]
SystemPreparation methodAdvantageDisadvantageApplication field
Ex situ carbon materials/Al[34,35]Ball milling + sintering

Simple process

Difficulty in dispersion control, interface reactions not easily regulatedHigh-strength conductive components, electronic packaging, precision instruments
In situ synthesized carbon materials/Al[40,43]

In situ growth by CVD

Uniform reinforcement distribution, good interface bonding

Complex process, high cost, limited production

Oxide/Al[54,55]

Sintering reactionHigh reaction driving force, good thermal stability of reinforcementsDifficult to control precursor ratio and reaction kinetics

Lightweight structural components, wear-resistant parts, heat-resistant alloy substitutes

am-Al2O3/Al[59,60]

Ball milling pre-treatment + sintering reactionGood thermal stability and high-temperature performancePossible crystallization of amorphous phase at high temperatures
Al-Ti-X (X = C, B, Si)[64-66]Sintering reactionHigh hardness and good thermal stability of reinforcementsComplex reaction pathways in multi-component systems
Table 1  Main in situ reaction system, preparation methods, characteristics, and application fields involved in powder metallurgy Al matrix composites (AMCs) fabricated via in situ reaction[34,35,40,43,54,55,59,60,64-66]
Fig.5  TEM images of the interfaces of in situ reaction AMCs fabricated by solid-phase diffusion strategy
(a-f) HRTEM images of MgAl2O4 interface (a-d) and MgAlB4/Al interface (e, f)[77]
(g) HRTEM image of the Al2O3/Al interface with corresponding FFT (inset)[54]
(h) stereographic projection on (22¯0) plane, [112] zone axis of Al (marked by red) and (311) plane, [01¯1] zone axis of Al2O3 (marked by yellow)[54]
(i) “Al2O3-intermixing region-Al” interface structure with corresponding FFT and inverse FFT (IFFT)[54]
Fig.6  Microstructures of AMCs fabricated by interface decoration strategy
(a-f) STEM image of GNPs-Cu nanoplatelets (NPLs) (a), HRTEM image of GNPs-Cu hybrid structure (b), STEM image of GNPs-Cu/Al composite powders (c), and HRTEM image and corresponding FFT and IFFT of the marked box region at the interface between GNPs-Cu NPL and Al matrix (d-f)[90] (BF—bright field)
(g, h) TEM images of as-synthesized Cu2O@CNTs powders (Inset in Fig.6g is the related image of Cu2O@CNTs powders dispersed in ethanol; insets in Fig.6h are corresponding EDS mapping and FFT image)[91]
(i) typical HAADF-STEM image of the Cu2O@CNTs/Al composite (Inset shows the O element distribution)[91]
(j-l) TEM image of CNTs-Al interface (j) and magnified images of the frames I (k) and II (l) recorded in Fig.6j (Inset in Fig.6l shows the statistical result of the diameter of CuAl2 precipitates (indicated by white arrows in Fig.6j))[91]
Fig.7  Crack propagation of CuO/Al composites and BNNS/Al composite
(a-c) fracture behaviors of the in situ CuO/Al composite (a, b) and the ex-Al2O3/Al-5.6Cu composite (c)[54] (GB—grain boundary)
(d-k) fracture behaviors of the 750 oC-BNNS/Al composite (d-g) and 600 oC-BNNS/Al composite (h-k)[74] (BNNS—boron nitride nanosheet, t—time)
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