Effects of Red Mud Particles and Oxides on the Microstructure and High-Temperature Tensile Properties of ZL109 Aluminum Alloy

Nickel coatings were deposited onto the surfaces of red mud, Al2O3, and Fe2O3 particles via an electroless plating technique. The nickel-coated particles (1.5 wt.%) were subsequently incorporated into a ZL109 aluminum alloy matrix to fabricate three types of composites using a stir-casting process, followed by a T6 heat treatment consisting of solution treatment at 515 °C for 8 h, water-bath quenching at 90–100 °C, and artificial aging at 175 °C for 12 h. The microstructural morphology and phase identification were examined by scanning electron microscopy (SEM) and X-ray diffraction (XRD). Furthermore, the high-temperature tensile properties of the fabricated alloys were evaluated at 350 °C and 400 °C. The results showed that the addition of 1.5 wt.% nickel-coated red mud led to a more uniform distribution of eutectic silicon and an increase in the content of the Al5Cu2Mg8Si6, Al7Cu4Ni, and Al2Cu strengthening phases. These microstructural changes significantly enhanced the high-temperature tensile performance of the alloy. At 350 °C and 400 °C, the alloy reinforced with 1.5 wt.% nickel-coated red mud achieved tensile strengths of 97.8 MPa and 86.2 MPa, respectively. The combination of an appropriate amount of nickel-coated red mud and a suitable heat treatment process effectively improves the high-temperature stability and tensile properties of the ZL109 aluminum alloy, which could be attributed to the synergistic strengthening effect arising from the precipitation of high-temperature stable phases and the Orowan mechanism.