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Effects of radio-frequency plasma spheroidization on the microstructure and properties of nano-TiB2-reinforced Al-Si matrix composites fabricated by spark plasma sintering
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DOI：10.1016/j.msea.2026.150874.png)
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Abstract
En 中文
With increasing thermal loads in high-power and highly integrated electronic systems, lightweight materials combining high mechanical strength with efficient heat transport are receiving growing attention for thermal-management applications. In this study, we engineered a high-conductivity nano-ceramic/aluminum-silicon matrix composite (HC-NC/ASMC) to overcome this limitation. The composite was synthesized through in situ reactive gas atomization and radio-frequency plasma spheroidization to eliminate defects, followed by spark plasma sintering and T6 aging for rapid densification. Moderate plasma treatment at 1500 W improved powder morphology and densification while retaining a refined hierarchical microstructure containing dispersed nanoscale TiB2 particles, refined primary Si, and abundant θ′-Al2Cu nanoprecipitates. The relatively low-mismatch, semi-coherent TiB2/Al interfaces and nanoscale precipitates contributed to strengthening while limiting additional electron and phonon scattering. The optimized PS 1500W T6 composite exhibited a Young's modulus of 79.76 GPa, an ultimate tensile strength of 303.6 MPa, an ultimate compressive strength of 893.7 MPa, a thermal conductivity of 160.07 W/(m·K), an electrical conductivity of 31.27% IACS, and a CTE of 17.96 × 10−6 K−1. This work presents a robust, lightweight material paradigm for advanced thermal-management applications.
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