A composite consisting of nickel aluminate ceramic - aluminum metal was fabricated by melting the metal in the ceramic skeleton. The porous nickel aluminate skeleton was fabricated by a polyurethane foam process with synthesized nickel aluminate powder. In the fabrication of the composite, powder-type aluminum alloys were melted in the porous nickel aluminate. The aluminum alloy containing Mg and Mn was used and melted in nitrogen atmosphere at 1000oC. The mechanical properties of the composites, which have a unique microstructure consisting of continuous phases of ceramic and metal, were examined according to the pore size of the nickel aluminate skeleton. A flexural strength of 370 MPa was obtained in the composite prepared from the nickel aluminate skeleton having a pore size of 300 μm, showing a non-brittle fracture behavior. A numerical study for the prediction of the mechanical failure behavior of the composite was also performed under the modification of finite - element code in DIANA.

Keywords: Nickel aluminate, Aluminum, Composite, Strength, Computer simulation.