Utilizing recycled beryllium swarf and aluminum, Be/Al composites containing varying volume fractions of beryllium were fabricated via the pressure infiltration method, which realized the direct and green recycling of beryllium swarf without dust. This study systematically investigates the microstructure and mechanical properties of Be/Al composites. Under pressure infiltration conditions, the molten aluminum successfully repaired the defects in the beryllium swarf. Additionally, the serrated morphology of the swarf increased the contact area between the beryllium swarf and aluminum matrix, enhancing interfacial bonding strength. As the volume fraction of beryllium swarf increased, the tensile strength, yield strength, and elastic modulus of the composite material increased, while elongation exhibited a different trend. Considering the service conditions of the material, 60% volume fraction is the optimal parameter. The fracture of Be/Al composites comprised both ductile fracture of the Al phase and brittle fracture of the Be phase. The debonded surface of beryllium swarf reinforcement was generally smooth rather than densely cracked or large serrated.
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