Aluminum-fiber composites containing intermetallic phase at the matrix-fiber interface

A method for producing a solid aluminum-fiber composite, the method comprising:

• (i) mixing coated fibers with a molten aluminum-containing matrix comprising elemental aluminum to produce a mixture of said molten aluminum-containing matrix and coated fibers, wherein each of said coated fibers comprises a fiber and a coating on surfaces of said fibers, wherein said coated fibers have a different composition than said aluminum-containing matrix and impart additional strength to said aluminum-containing matrix as compared to said aluminum-containing matrix in the absence of said coated fibers embedded therein, wherein said coating has a composition different from said aluminum-containing matrix and the uncoated portion of said coated fibers and contains at least one element other than aluminum and which alloys with at least aluminum;
• and
• (ii) cooling said mixture of molten aluminum-containing matrix and coated fibers to produce said solid aluminum-fiber composite, wherein said solid aluminum-fiber composite comprises said coated fibers embedded within said aluminum-containing matrix, wherein an intermetallic layer is present as an interface between each of said fibers and the aluminum-containing matrix, and said intermetallic layer has a composition that comprises the composition of said coating and at least one element from the aluminum-containing matrix.

A method for producing a solid aluminum-fiber composite, the method comprising:

• (i) mixing uncoated fibers with a molten aluminum-containing matrix comprising elemental aluminum to produce a mixture of molten aluminum-containing matrix and uncoated fibers, wherein said aluminum-containing matrix is an alloy comprising aluminum and at least one alloying element other than aluminum, wherein said uncoated fibers have a different composition than said aluminum-containing matrix and impart additional strength to said aluminum-containing matrix as compared to said aluminum-containing matrix in the absence of said uncoated fibers embedded therein;
• (ii) cooling said mixture to produce said solid aluminum-fiber composite, wherein said solid aluminum-fiber composite comprises said uncoated fibers embedded within said aluminum-containing matrix, wherein said intermetallic layer is present as an interface between each of said uncoated fibers and the aluminum-containing matrix, and said intermetallic layer has a composition different from said aluminum-containing matrix and said uncoated fibers and that comprises at least said alloying element from the matrix and at least one element from said uncoated fibers.