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Solid state sintering of cast aluminum powders by resistance heating sintering (RHS), also known as spark plasma sintering or field-assisted sintering technique, creates a very fine microstructure in the bulk material. This leads to high performance material properties with an improved strength and ductility compared to conventional production routes of the same alloys. In this study, the mechanical behavior of an RHS-sintered age-hardenable A357 (AlSi7Mg0.6) cast alloy and a SiCp/A357 aluminum matrix composite (AMC) was investigated. Aiming for high strength and good wear behavior in tribological applications, the AMC was reinforced with a high particle content (35 vol.%) of a coarse particle fraction (d50 = 21 µm). Afterwards, separated and combined effects of particle reinforcement and heat treatment were studied under compressive load both at room temperature and at 350 °C. At room temperature compression, the strengthening effect of precipitation hardening was about twice as high as that for the particle reinforcement, despite the high particle content. At elevated temperatures, the compressive deformation behavior was characterized by simultaneously occurring temperature-activated recovery, recrystallisation and precipitation processes. The occurrence and interaction of these processes was significantly affected by the initial material condition. Moreover, a rearrangement of the SiC reinforcement particles was detected after hot deformation. This rearrangement lead to a homogenized dispersion of the reinforcement phase without considerable particle fragmentation, which offers the potential for secondary thermo-mechanical processing of highly reinforced AMCs.

Particle-reinforced aluminium matrix composites (AMC) with a high-volume fraction of ceramic reinforcement (>30 vol.%) combine high specific strength and stiffness with good wear resistance and thermal stability, resulting in their increasing popularity in high-load applications, such as brake discs and bearings. It is hence assumed that AMC will accumulate as scrap in the near future. Appropriate recycling strategies must therefore be developed to maintain AMC’s inherent properties. Melt-metallurgical recycling routes bear the danger of dissolving the ceramic reinforcement in the liquid metallic matrix and contaminating primary melts or forming intermetallic phases in secondary melts. Here, a solid-state AMC recycling route with crushing and sintering is investigated, wherein all steps are carried out below the solidification temperature of the aluminium matrix. A sintered primary AMC is mechanically converted into a particulate/powdery secondary raw AMC in coarse, medium, and milled quality (i.e., with d ≈ 7–12 mm, d ≈ 3–7 mm, and d < 300 µm) and subsequently resistance heating sintered to a secondary AMC under a variation of the sintering pressure. The two AMC generations are analysed and discussed regarding their microstructure and mechanical properties. Since the secondary AMC show reduced the mechanical strength, the fracture surfaces are analysed, revealing iron contaminations from the mechanical processing.