Characterization of AlSi10Mg-CP-Ti Metal/Metal Composite Materials Produced by Electro-Sinter-Forging

Metal–metal composites represent a particular class of materials showing innovative mechanical and electrical properties. Conventionally, such materials are produced by severely plastically deforming two ductile phases via rolling or extruding, swaging, and wire drawing. This study presents the feasibility of producing metal–metal composites via a capacitive discharge-assisted sintering process named electro-sinter-forging. Two different metal–metal composites with CP-Ti/AlSi10Mg ratios (20/80 and 80/20 vol.%) are evaluated, and the effects of the starting compositions on the microstructural and compositional properties of the materials are presented. Bi-phasic metal–metal composites constituted by isolated α-Ti and AlSi10Mg domains with a microhardness of 113 ± 13 HV0.025 for the Ti20-AlSi and 244 ± 35 HV0.025 for the Ti80-AlSi are produced. The effect of the applied current is crucial to obtain high theoretical density, but too high currents may result in Ti dissolution in the Ti80-AlSi composite. Massive phase transformations due to the formation of AlTiSi-based intermetallic compounds are observed through thermal analysis and confirmed by morphological and compositional observation. Finally, a possible explanation for the mechanisms regulating densification is proposed accounting for current and pressure synergistic effects.