Study of the Microstructure Characterization and In Situ Observation of Crack Propagation in TC4/Al₃Ti Metal–Intermetallic Laminated Composites

TC4/Al₃Ti metal–intermetallic laminated (MIL) composites were fabricated by the vacuum hot-pressing process at 650 °C. The microstructure characteristics, i.e., grain boundary distribution, crystallographic orientation and Kernel Average Misorientation (KAM) map, were analyzed using EBSD. Meanwhile, the distribution of local strain and the fracture behavior of TC4/Al₃Ti MIL composites during tensile process were determined by Digital Image Correlation (DIC) and in situ tensile experiments, respectively. Results show that the TC4/Al₃Ti interfaces are well bonded and exhibit a distinct wavy morphology. The obvious Kirkendall pores and centerline are observed within the central region of the Al₃Ti layer. The texture components of (10-10) <0001> and (11-20) <10-10> are predominant in the TC4 layers; (100) <001> and (110) <001> are observed in the Al₃Ti layer. Additionally, the average geometrically necessary dislocation (GNDs) density is 2.53 × 10¹⁴ m⁻² in the TC4 layer, whereas it is 1.74 × 10¹⁴ m⁻² in the Al₃Ti layer. In the tensile test, the fracture resistance of TC4/Al₃Ti MIL composites is significantly improved by the plastic deformation of the TC4 layers and the suppression of crack-tip instability. It is found that the extrinsic toughening mechanisms contain crack deflection, crack blunting, crack bridging, multiple cracking modes, and the plastic deformation of ductile TC4 layers in TC4/Al₃Ti MIL composites. The real-time observation technique may provide more complete insights into the relationship between fracture behavior and enhanced toughness.