ABSTRACT
Great efforts are aimed towards the synthesis and the development of structural
composite materials. Direct metal oxidation, DIMOX introduced for hybrid composite
processing. However, oxidation temperatures around 1100oC lead to the formation
of porous ceramic materials. To utilize this porosity intentionally for foam production,
a new approach based on synergetic effect of alloying elements, DIMOX and
semisolid (rheocsting) processing is developed. A semisolid reaction, rheocasting is
introduced to control porosity shape and size. Aluminum alloy 6xxx (automobile
scrap pistons) is recycled for this objective and DIMOX at 1100oC for 30 min, then
rheocasting, at 750oC for 30 minutes. The effect of a-Fe powder, Mg powder, and
Boric acid powder established for the objective of a hybrid structural metal matrix
composite in bulk foam matrix. The kinetic of formation of hybrid metal matrix foam
composite is introduced. Microstructural and mechanical characterization established
for high performance Aluminum foam hybrid composite materials.