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A microstructure-based numerical simulation is performed to understand the mechanical properties and fracture of a Ti-Al3Ti core-shell structured particulate reinforced A356 composite ((Ti-Al3Ti)cs/A356). A series of two-dimensional (2D) representative volume element (RVE) models are generated automatically by embedding Ti-Al3Ti core-shell structured particulates in an A356 matrix. Microstructure-based 2D RVE of monolithic Al3Ti particulate reinforced A356 composite (Al3Tip/A356) is also simulated for comparison. The ductile fracture of both Ti core and A356 matrix as well as the brittle fracture of the Al3Ti shell are considered. The simulation confirms that the high elongation of the (Ti-Al3Ti)cs/A356 composite is attributed to the uniform distribution of the overall ductile globular reinforcing particulates, which prevent a premature failure effectively by reducing local stress concentration both on and inside the core-shell structured particulates. The surrounding ductile phases of the Al3Ti shell blunt the crack tips effectively and, therefore, restricting the propagation of the cracks in a nominal strain range of 2.2%–6.1%. For both (Ti-Al3Ti)cs/A356 and Al3Tip/A356 composites, the simulation results are in good agreement with microstructural observations during an in-situ tensile test in a scanning electron microscope.

A bimodal microstructure composed of large primary α-Al phases (PPs) and small secondarily solidified grains (SSGs) is fabricated in 6061 aluminum alloy by powder thixoforming (PTF) method after solution treatment. Artificial aging treatment introduces nanosized precipitates into the bimodal microstructure, in which the number and growth rate of precipitates are different: the number in PPs is larger than that in SSGs due to the higher density of dislocations and lattice distortions in PPs, while the growth rate in SSGs is higher than that in PPs owing to the higher solute concentration in SSGs. As the number and size of precipitates are optimized in the bimodal microstructure, i.e., in peak-aged state, remarkable increments of 56.1% and 130.3% in ultimate tensile strength and yield strength while a moderate increase of 6.3% in ductility are achieved compared with the as-fabricated state, which overcomes the trade-off in strength and ductility of conventional aging-treated 6061 alloys with unimodal microstructure. The strengthening comes from the geometrically necessary dislocations induced by the deformation incompatibility of bimodal microstructure and from precipitate strengthening by nanosized precipitates, while the toughening is from the enhanced dislocation accumulation in this alloy.