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Effect of polycarbosilane precursor state on in-situ SiC formation and property enhancement in A356 aluminum alloy
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DOI：10.1080/09276440.2026.2618299.png)
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Abstract
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This study examines the influence of precursor physical state on the in-situ formation of SiC ceramic reinforcement in A356 aluminum alloy using a polymer-derived ceramic route. Polycarbosilane was introduced through two methods: (i) Pyrolysis - powder route processed at 800 degrees C (PP-800) and (ii) Pyrolysis - liquid route (spray injection) processed at 800 degrees C (PL-800). Both processes were carried out at 800 degrees C to isolate precursor-state effects under identical pyrolysis conditions. Fourier transform infrared spectroscopy (FTIR) and Thermogravimetric analysis - Differential thermal analysis (TGA - DTA) confirmed near-complete ceramization and SiC formation at similar to 800 degrees C. Microstructural analysis revealed that PL-800 produced finer dendrites (Secondary dendrite arm spacing approximate to 25 +/- 2 mu m) and uniformly dispersed sub-micron SiC particles, whereas PP-800 showed coarser dendrites with grain-boundary-segregated SiC clusters due to delayed decomposition. XRD verified SiC formation in both routes, with significantly reduced Al4C3 formation in PL-800. Porosity was lowest for PL-800 (similar to 0.8%), compared to 2.1% for PP-800. The PL-800 composite exhibited superior mechanical properties (Ultimate tensile strength approximate to 225 MPa, Yield strength approximate to 110 MPa, elongation approximate to 4.5%) owing to refined microstructure and cleaner interfaces. Overall, the ultrasonic spray-assisted liquid Polymer route is demonstrated as a more effective method for producing high-performance A356-SiC composites. [GRAPHICS] .
Keywords:
Polycarbosilane
polymer-derived ceramics
A356 alloy
in-situ SiC formation
ultrasonic spray injection
microstructural refinement
improved mechanical properties
porosity control
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