Effect of reinforcement particle size on the corrosion and mechanical properties of spark plasma sintered aluminium matrix composites

Abstract In this study, the effects of different sizes of reinforcing particles on the corrosion behaviour and mechanical properties of aluminium (Al)‐based composites produced by spark plasma sintering (SPS) are analysed. In the study, the effects of SPS parameters, including electrical power, applied pressure and sintering temperature, on the consolidation process and microstructure evolution of the composite are closely investigated. The results reveal a nuanced relationship between the sintering conditions and the properties of the particles, which in turn determine the sintering dynamics and the formation of the microstructural features. The evaluation of mechanical properties indicates a remarkable influence of particle size distribution on the hardness of the composites, showing an initial improvement with the introduction of nanoparticles, followed by a slight decrease as the balance between nano‐ and micron‐sized Al 2 O 3 particles shifts. A scanning electron microscopy (SEM) study demonstrates the influence of particle dimensions on the change of grain boundaries and the spatial arrangement of the composite matrix. Electrochemical experiments in a 0.1 M NaCl solution show a consistent corrosion potential ( E corr ) across all samples, while the current densities associated with corrosion ( i corr ) show considerable variation. The presence of nano‐sized Al 2 O 3 particles was found to increase corrosion resistance, in contrast to the detrimental effects observed with larger microparticles. In particular, composites with a bimodal distribution of particle sizes showed a 3.5‐fold increase in corrosion resistance compared to pure Al. The specific Al‐2n8mAl 2 O 3 composite that exhibited active electrochemical properties at elevated potentials without a defined passivation range emphasises the significant role of particle size. This study draws attention to bimodal microstructures as a promising route to achieving uniformity and improved corrosion resistance in Al matrix composites, while pointing to the need for further research to fully elucidate the operative mechanisms.