Study on 3D Characteristics of Pores in Bimodal SiCp Preforms Using X-Ray Micro-Computed Tomography

Particle-reinforced metal matrix composites, wherein preform pore structure dominates liquid infiltration behavior and final composite quality, are essential for high-performance industries. Conventional empirical models predict pore characteristics for bimodal preforms based on ideal particle stacking assumptions yet ignore real compression-induced microstructural changes including particle contact compaction and particle fracture, yielding systematic deviations from actual pore characteristics. This study adopted high-resolution 3D X-ray micro-computed tomography (μ-CT) to quantify such discrepancies for bimodal SiCp preforms across six coarse-to-fine particle ratios (0–100%). Three-dimensional pore network models were extracted to quantify key characteristics including areal porosity, surface area, and pore/throat dimensions. The results demonstrated that the average areal porosity fell to a minimum at a 67% coarse fraction then rose, while the pore distribution homogeneity steadily declined. Additionally, μ-CT measurements revealed that particle contact compactness reduced the particle surface area per unit volume at coarse fractions below 25% whereas particle fracture increased it at fractions above 25%, deviating significantly from empirical predictions. Larger coarse particle fractions reduced pore/throat quantities but increased their average size and volume. Beyond using established pore network extraction, this work distinguishes these two competing micro mechanisms and provides reasonable datasets to support bimodal preform optimization for composite manufacturing.