Semi-solid powder processing is a promising technology, combining the advantages of semi-solid forming and powder metallurgy. In this study, spray deposition process combined with semi-solid powder processing was used to synthesize an aluminum alloy composite and to control its microstructure. Silicon carbide (SiC) reinforced aluminum alloy composites were fabricated with and without microstructure pattern. The influence of different composite microstructure on mechanical properties was analyzed by microstructure analysis, bend test and fracture analysis. Bend test results showed that patterned microstructure has the potential to significantly improve composite strength with minimal sacrifice of ductility.

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