Sustainability in the Manufacturing of Eco-Friendly Aluminum Matrix Composite Materials

The purpose of this work was to consolidate the eco-friendly Al–SiC composites prepared with various weight fractions of ceramic particles (0; 2.5; 5; 10; 15 wt.% SiC) in the energy-saving sintering process under vacuum and in a nitrogen atmosphere at 600 °C. The density of the manufactured composites was determined using Archimedes’ method. The mechanical properties and strength characteristics of the metal–ceramic interface were measured using three-point flexural and uniaxial compression tests, as well as the Brinell hardness measurement. The tribological properties were evaluated by determining the coefficients of friction and weight losses of the tested materials and identifying the tribological wear mechanisms. Advanced microstructural observation methods, such as scanning electron microscopy (SEM) and transmission electron microscopy (TEM), were used to analyze the microstructure of the composites in detail, including the identification of the phase composition using X-ray analysis methods. Low-cost composites with a porosity not exceeding 7% were successfully produced via energy-saving production routes. Simultaneously, owing to the formation of aluminum nitrides during sintering in a nitrogen atmosphere, these composites exhibited mechanical and tribological properties superior to those of materials sintered under vacuum.