Actual microstructure-based modeling and failure evolution of SiC and SiC+B₄C reinforced Al matrix composites

The integration of actual microstructure-based modeling is essential for advancing the properties of particle-reinforced metal matrix composites. Two reinforced composites, Al/SiC and Al/SiC+B₄C, were utilized in the current study to simulate the actual microstructure and analyze their damage evolution and failure behavior. The model integrates key aspects, specifically particle distribution and morphology, along with traction-separation interface debonding, metal matrix fracture, and brittle damage of ceramic particles. The simulation findings demonstrate that the model accurately predicts the composite's performance and effectively reveals its damage mechanisms. The analysis indicates that the effective diameter of irregular particles significantly impacts the shape factors, with increase in diameter leading to higher aspect ratio and circularity. The geometrical variation and particle clustering cause localized stress concentrations at sharp corners and interfaces, leading to crack initiation and damage evolution. The hybrid Al/SiC+B₄C composite exhibited a notable enhancement in tensile strength of 299.3 MPa as compared to 279.6 MPa for Al/SiC, however this improvement in strength was accompanied by a 37 % reduction in ductility. The simulated results closely align with the experimental data, with an error of ∼2 %, confirming the accuracy of the developed model. This study establishes a foundation for understanding the failure mechanisms of composites using microstructure-based modeling and provides insights for optimizing design and mechanical performance.