Research progress on the preparation, interfacial control and properties of Si₃N₄-particle-reinforced aluminum matrix

Aluminum matrix composites offer distinct advantages, including low density, high specific strength and modulus, superior thermal conductivity, and high corrosion and wear resistance. These materials are widely implemented in aerospace, transportation, electronic devices, and thermal management systems. Silicon nitride (Si₃N₄) ceramics, when utilized as a reinforcement, exhibit high hardness and elastic modulus, significant thermal conductivity, and a relatively low coefficient of thermal expansion (CTE). Si₃N₄/Al composites effectively meet the requirements for matched CTE and tailored mechanical properties in structural components. This paper systematically reviews the research progress on Si₃N₄/Al composites, encompassing primary fabrication techniques, interfacial control, mechanical properties, and joining methods. Key quantitative findings demonstrate that stir casting and hot-extruded composites achieve a 31% increase in hardness, 11% higher yield strength, and 66% greater elongation, as compared with unreinforced alloys. Pressure-infiltrated composites with high Si₃N₄ volume fractions achieve a thermal conductivity of 252 W/(m·K) and a low CTE of 7 × 10^–6–10 × 10^–6 /K. Furthermore, spark plasma-sintered composites reach near-full density (>99%) with refined microstructures. The critical influence of interfacial reactions is emphasized, particularly the role of Mg in promoting the formation of beneficial phases such as MgAl₂O₄. Advanced joining techniques, including ultrasonic brazing, are discussed for their potential to enable flux-free, reliable component integration. Future challenges and directions include achieving scalable, cost-effective manufacturing with uniform microstructure; developing atomic-scale understanding and precise control of interfacial reactions; overcoming the strength–toughness trade-off through multi-scale architectural design; standardizing reliable joining processes; and expanding applications within the aerospace and advanced electronics fields. This review establishes a comprehensive foundation for the design and application of high-performance Si₃N₄/Al composites.