Enhancement of Physical Properties and Corrosion Resistance of Al-Cu-Al2O3/Graphene Nanocomposites by Powder Metallurgy Technique

In this study, we enhanced the adhesion of graphene nanosheets to achieve homogeneous dispersion, consequently improving the electrical and thermal conductivity, coefficient of thermal expansion, and corrosion resistance with an aluminum matrix containing up to 1.5 wt. % graphene. First, 2.5 wt. % Al2O3 and varying ratios of graphene up to 1.5 wt. % were coated with 5 wt. % silver nanoparticles to metalize their surfaces. Predetermined portions of coated alumina and graphene were mixed with Al/10 wt. % Cu powder for 45 h. Mixed samples were compacted under 600 MPa and sintered at 565 degrees C in a vacuum furnace for 60 min with a low heating rate of 2 degrees C/min. The strengthening effect of the added materials on the density, microstructure, electrical and thermal conductivities, thermal expansion, and corrosion behavior of aluminum were investigated. Excellent adhesion and homogeneous dispersion of the investigated reinforcements were achieved. Three phenomena were observed: (1) an improvement in the densification, electrical and thermal conductivity, thermal expansion, and corrosion rate by adding 10 wt. % Cu to the aluminum matrix; (2) deterioration of the properties of Al/10 wt. % Cu with the addition of 2.5 wt. % alumina nanoparticles; and (3) improved properties with the addition of graphene nanosheets up to 1 wt. % and a decrease in property values beyond 1.5 wt. % graphene content due to the formation of agglomerations and pores in the metal matrix.