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The SiC/Al–Mg–Si composite was obtained by in-situ synthesis, and the effects of Mg addition were investigated in this process. Mechanism of in situ SiC growth in the Resin–Al–Mg–Si system was investigated by fabricating and characterizing a SiC/Al–Mg–Si composite under moderate conditions. X-ray Diffraction (XRD), Scanning Electron Microscopy (SEM) and Transmission Electron Microscopy (TEM) were used to analyze the phase and its microstructure, with the aim of investigating the evolvement of grains in the alloy matrix. Mg2Si formed under higher Mg added conditions, which decreased the molten liquid and Si solute concentrations. Tiny amounts of MgO and MgAl2O4 proved that the pyrolysis gas of resin reacts slightly with the matrix. The key conditions of in-situ synthesis SiC were found that the Mg addition and the Si concentration in the molten alloy were 3%–5% and over 17. 27 % respectively. Ostwald ripening was used to explain the decrease in tiny SiC grains at elevated temperatures. In situ SiC growth is controlled by the interfacial reaction-diffusion mixed model through two different routes in the molten alloy. Two modes of in-situ synthesis were suggested. The intermediate product and template for in situ SiC growth are Al4C3, and Si was shown to diffuse into its particles gradually. Flowing Si in molten alloy reacted with pyrolysis C directly. Specimens validated the peak bending strength with a rise in temperature. The maximal bending strength was 251.89 MPa.

Al matrix composite, reinforced with the in situ synthesized 3C–SiC, MgAl2O4, and MgO grains, was produced via the casting process using phenolic resin pyrolysis products in flash mode. The contents and microstructure of the composites’ fracture characteristics were analyzed by X-ray diffraction (XRD) and scanning electron microscopy (SEM). Mechanical properties were tested by universal testing machine. Owing to the strong propulsion formed in turbulent flow in the pyrolysis process, nano-ceramic grains were formed in the resin pyrolysis process and simultaneously were homogeneously scattered in the alloy matrix. Thermodynamic calculation supported that the gas products, as carbon and oxygen sources, had a different chemical activity on in situ growth. In addition, ceramic (3C–SiC, MgAl2O4, and MgO) grains have discrepant contents. Resin pyrolysis in the molten alloy decreased oxide slag but increased pores in the alloy matrix. Tensile strength (142.6 ± 3.5 MPa) had no change due to the cooperative action of increased pores and fine grains; the bending and compression strength was increasing under increased contents of ceramic grains; the maximum bending strength was 378.2 MPa in 1.5% resin-added samples; and the maximum compression strength was 299.4 MPa. Lath-shaped Si was the primary effect factor of mechanical properties. The failure mechanism was controlled by transcrystalline rupture mechanism. We explain that the effects of the ceramic grains formed in the hot process at the condition of the resin exist in mold or other accessory materials. Meanwhile, a novel ceramic-reinforced Al matrix was provided. The organic gas was an excellent source of carbon, nitrogen, and oxygen to in situ ceramic grains in Al alloy.