Effects of Simulated Service Environments on the Microstructure and Interfacial Properties of Ceramic Fiber-Reinforced Al-Matrix Composites

SiC fiber-reinforced aluminum matrix (SiCf/Al) composites have the potential to replace titanium alloys for fan/compressor blades due to their low density and favorable high-temperature performance. In this study, thermal exposure and thermal cycling tests were conducted to simulate service environments and to clarify their effects on the microstructure and interfacial properties of a SiCf/AlFe5Si2 composite. Thermal exposure was performed at 260–450 °C for 20–100 h, and thermal cycling was carried out between 300 or 350 °C (1 h dwell) and room temperature for 20–100 cycles. Interfacial shear strength was evaluated by push-out tests, while microstructural evolution was examined using SEM, TEM/EDS, and XRD. Three-dimensional finite element simulations were used to assess mismatch-driven residual-stress distributions during the cooling stage after thermal excursion. The results showed that interfacial shear strength decreased with increasing exposure temperature/time and degraded more severely under thermal cycling than under isothermal exposure at the same temperature. A rapid loss of interfacial strength occurred above ~400 °C, associated with significant interfacial-layer thickening and the formation of brittle AlxSiOy phases. The interfacial reaction layer followed parabolic growth kinetics, yielding a preliminary apparent activation energy of Q ≈ 150 kJ/mol estimated from two isothermal temperatures. The simulations indicated large opposing stresses between the matrix and the carbon-rich layer, supporting a mechanical driving force for interfacial debonding; however, heating/dwell time-dependent effects were not explicitly modeled and are discussed as limitations. These findings provide quantitative guidance for defining service-temperature limits and improving interfacial thermal stability in SiCf/AlFe5Si2 composites.