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Frontiers of Materials Science

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Front. Mater. Sci.    2021, Vol. 15 Issue (1) : 79-97    https://doi.org/10.1007/s11706-021-0541-0
REVIEW ARTICLE
Recent progress in graphene-reinforced aluminum matrix composites
Jinlong SU, Jie TENG()
College of Materials Science and Engineering, Hunan University, Changsha 410082, China
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Abstract

Recent years witnessed a growing research interest in graphene-reinforced aluminum matrix composites (GRAMCs). Compared with conventional reinforcements of aluminum matrix composites (AMCs), graphene possesses many attractive characteristics such as extremely high strength and modulus, unique self-lubricating property, high thermal conductivity (TC) and electrical conductivity (EC), and low coefficient of thermal expansion (CTE). A lot of studies have demonstrated that the incorporation of graphene into Al or Al alloy can effectively enhance mechanical and physical properties of the Al matrix. The purpose of this work is aimed to trace recent development of GRAMCs. Initially, this paper covers a brief overview of fabrication methods of GRAMCs. Then, mechanical, tribological, thermal and electrical properties of recently developed GRAMCs are presented and discussed. Finally, challenges and corresponding solutions related to GRAMCs are reviewed.
Keywords graphene      aluminum      metal matrix composite      mechanical properties      tribological properties     
Corresponding Author(s): Jie TENG   
Online First Date: 22 January 2021    Issue Date: 11 March 2021
 Cite this article:   
Jinlong SU,Jie TENG. Recent progress in graphene-reinforced aluminum matrix composites[J]. Front. Mater. Sci., 2021, 15(1): 79-97.
 URL:  
https://academic.hep.com.cn/foms/EN/10.1007/s11706-021-0541-0
https://academic.hep.com.cn/foms/EN/Y2021/V15/I1/79
Material Properties
UTS/MPa η/GPa ρ/(g·cm−3) Tm/°C EC/(S·m−1) As/(m2·g−1) TC/(W·m−1·K−1) CTE/K−1
Al 80 70 2.7 660 3.2×107 – 237 (21–24)×10−6
Single-layer graphene 1.3×105 1.0×103 1.06 5727 9.6×107 2630 1000–5000 a) −8.0×10−6b)
Tab.1  Properties of pure Al and single-layer graphene [4–10]
Fig.1  Chemical formulae of (a) GO and (b) RGO. Reproduced with permission from Ref. [14].
Method Advantages Disadvantages
Shaker ball milling high energy input and time-saving low production rate; risk of contamination and formation of Al4C3
Planetary ball milling high productivity and cost-effectiveness risk of contamination and formation of Al4C3
Cryomilling achievement of grain refinement; suppression of recovery and recrystallization; reduced usage of PCA, resulting in less contamination and a clean interface high cost
Tab.2  Advantages and disadvantages of several ball milling methods
Fig.2  SEM images of mixed Al/GNSs powders with different milling time: (a)(b) 1 h; (c)(d) 2 h; (e)(f) 3 h; (g)(h) 4 h. Reproduced with permission from Ref. [18].
Fig.3  SEM images of (a) Al powders and (b) mixed Al/GO powders. Reproduced with permission from Ref. [20].
Method Advantages Disadvantages
Conventional sintering low cost and high production rates; formation of complex shapes poor densification and long dwell time
Hot pressing better densification than conventional sintering long dwell time
HIP uniform densification and isotropic properties long dwell time
MWS higher heating rates, shorter sintering time relative to conventional sintering poor densification relative to SPS
SPS high heating rates, short dwell times, low porosity and excellent mechanical properties high cost
Tab.3  Advantages and disadvantages of several consolidation methods
Fig.4  Schematic representation of the FSP setup. Reproduced with permission from Ref. [26].
Fig.5  Schematic diagram of the processing route of the AlSi10Mg/graphene composite. Reproduced with permission from Ref. [33].
Consolidation method Composite a) μ/HV YTS/MPa UTS/MPa δ/% η/GPa Ref.
Vacuum hot pressing Al – 30 104 12.5 21.2 [61]
Al/0.5 vol.% GNSs – 70 223 9.6 17.5
Al/1.5 vol.% GNSs – 205 315 7.3 15.6
Al/2.5 vol.% GNSs – 225 318 4.5 8.3
Vacuum hot pressing+ hot rolling Al – 131 161 23.5 – [62]
Al/0.5 vol.% Ni-GNSs – 203 230 17.5 –
Al/1.0 vol.% Ni-GNSs – 237 266 19.1 –
Al/1.5 vol.% Ni-GNSs – 255 279 13.2 –
AlCu 70.0 226 244 8.5 – [63]
AlCu/1.0 vol.% GNSs 73.8 242 254 7.2 –
AlCu/2.0 vol.% GNSs 79.8 260 280 6.3 –
Vacuum hot pressing+ hot forging+ FSP Al2009/1.0GNPs (1-pass FSP) – 314 398 4 – [42]
Al2009/1.0GNPs (2-pass FSP) – 398 514 10 –
Al2009/1.0GNPs (3-pass FSP) – 378 468 7 –
Al2009/1.0GNPs (4-pass FSP) – 363 462 8 –
Cold compaction+ sintering+ hot extrusion Al – 67 103 48.2 68.2 [43]
Al/0.4GNPs – 64 106 31 63.7
Al/2.0GNPs – 64 117 30 65.6
Al – 193 233 17.4 71.0 [44]
Al/0.25 vol.% GNSs – 207 257 17.6 72.5
Al/0.5 vol.% GNSs – 215 287 17.3 74.9
Al 59.1 – 203 30.5 – [20]
Al/0.3RGO 74.3 – 255 19.2 –
Al/0.6RGO 71.3 – 241 13.2 –
Al 54.3 88.1 – 20.3 70.41 [45]
Al/0.5Ni-GNSs 59.9 162.5 – 13.3 77.34
Al/1.0Ni-GNSs 63.7 182.1 – 11.1 89.80
Al/1.5Ni-GNSs 65.3 204.5 – 10.0 96.82
Al/2.0Ni-GNSs 63.6 185.4 – 8.7 93.13
Al 85.1 80.5 133.4 25.2 – [46]
Al/0.5Cu-graphene 102.1 121.3 189.9 20.3 –
Al/0.75Cu-graphene 123.4 140.2 223.5 17.5 –
Al/1.0Cu-graphene 109.3 125.5 201.3 12.8 –
Al 54.0 138 175 23.5 – [17]
Al/1.0Cu-GNPs 87.8 225 278 17.5 –
Al/2.5Cu-GNPs 116.5 360 402 10.6 –
Al/3.0Cu-GNPs 117.0 316 363 12.8 –
Al6061 60 – – – – [47]
Al6061/0.25GNSs 68 – – – –
Al6061/0.5GNSs 63 – – – –
Al 39.3 83.6 130 25.6 – [48]
Al/0.7GNPs 61.4 141 197 14.0 –
Al – – 135 26.0 – [49]
Al/0.24Ni-GNPs – – 163 31.3 –
Al/0.34Cu-GNPs – – 180 22.5 –
Cold compaction+ sintering+ hot extrusion+ cold drawing Al – 139 144 0.89 71.8 [43]
Al/0.4GNPs – 208 219 0.84 76.7
Al/2.0GNPs – – 137 0.30 85.5
Al – 141.8 190.4 4.6 – [50]
Al/2.0GNPs – 150.0 187.6 4.3 –
SPS Al – 51 105 41.9 – [51]
Al/0.25GNPs – 81 148 33.1 –
Al/0.5GNPs – 101 171 29.9 –
Al/1.0GNPs – 48 71 4.4 –
Almicro – 51 105 41.9 85 [52]
Almicro/0.5GNPs – 101 171 29.9 89
Alnano – 80 148 6.6 83
Alnano/0.5GNPs – 148 233 5.1 88
Al-4Cu 87 78 215 28 – [53]
Al–4Cu/0.3RGO 99 115 275 15 –
Al–4Cu/0.5RGO 101 129 290 12 –
Al–4Cu/0.7RGO 113 133 310 11 –
Al–4Cu/1.0RGO 125 139 320 10 –
Flake PTF Al2024 – 203 301 15.2 – [54]
Al2024/0.4RGO – 294 439 8.5 –
Stir casting Al7075/0.5GNPs – – 147.7 14.7 – [22]
Al7075/1.0GNPs – – 150 14.9 –
Al7075/1.5GNPs – – 155.1 15.6 –
Al7075/2.0GNPs – – 139.1 16.0 –
Continuous casting+ hot rolling Al 37.42 – 114 11 – [55]
Al/0.2GNPs 43.6 – 156 4 –
Pressure infiltration Al5083 – 156.9 289.9 21.3 72 [56]
Al5083/GO – 184.5 282.7 9.0 72.6
Al5083/GNPs – 186.9 331.0 6.3 72.6
Pressure infiltration+ hot extrusion Al6063 – – 225.9 14 – [18]
Al6063/GNSs – – 276.7 14.7 –
Al6061 – 334 357 12.1 – [57]
Al6061/0.6GNPs – 389 500 2.1 –
FSP Al 31.6 50 84 33 – [13]
Al/graphene 48.7 94 147 26 –
Al6061/GNPs – 88.27 111.38 3.73 25.64 [58]
FSP+ hot extrusion Al – – 127.2 21.7 – [59]
Al/graphene – – 149.2 29.3 –
Deformation-driven processing Al – – 119 20.8 69.1 [60]
Al/GNPs – – 497 15.2 76.9
SLM Al 38 – – – – [31]
Al/0.5graphene 47.1 – – – –
Al/1.0graphene 49.6 – – – –
Al/2.5graphene 66.6 – – – –
AlSi10Mg 120 – 357 5.5 – [35]
AlSi10Mg/1.0graphene 169 – 396 6.2 –
Tab.4  Mechanical properties of GRAMCs prepared by various processing methods [13,17–18,20,22,31,35,42–63]
Fig.6  Schematic diagrams of the effects of GNSs on the wear behavior: (a)(b) general view of the wear test; (c) wrapping effect of GNSs around wear debris; (d) bridging effect of GNSs between subsurface cracks; (e)(f) the self-lubricating mechanism of GNSs. Reproduced with permission from Ref. [68].
Fig.7  Illustration of the wear mechanism: (a) Al–Si/SiC under all loads; (b) Al–Si/SiC/0.5 wt.% RGO under lower loads; (c) Al–Si/SiC/0.7 wt.% RGO under higher loads. Reproduced with permission from Ref. [71].
Matrix Reinforcement Process Tribological properties a) Dominant wear mechanism e) Ref.
AlSi10Mg ~1 wt.% GNPs SLM ~42% increase in wear rate b) abrasive wear for the composite [32]
Al 0.5 wt.% GNPs PM 70% decrease in COF, 67% decrease in wear rate c) adhesive wear for both samples [41]
A355 1 vol.% GNSs PM 39% decrease in COF, 85% decrease in wear rate abrasive and adhesive wear for both samples for the composite, with relatively weak abrasive wear due to a lower COF [68]
Al6061 SiC+ GNPs FSP >20% decrease in COF, 56% decrease in wear rate adhesive wear (matrix) and abrasive wear (composite) [69]
Al–7Si/10SiC 0.5 wt.% RGO PM 65% decrease in wear rate d) delamination wear for Al–Si/SiC and abrasive wear for Al–Si/(SiC+ RGO) [71]
AA2124 3 wt.% graphene PM 25% decrease in COF, 34% decrease in wear rate·· abrasive wear for both samples [73]
Al 0.1 wt.% GNPs PM no obvious change in COF, ~8% decrease in wear rate c) abrasive wear for the composite [74]
1 wt.% GNPs PM ~3% decrease in COF, ~24% increase in wear rate c) abrasive wear for the composite
Tab.5  Tribological properties of recently developed GRAMCs [32,41,68–69,71,73–74]
Fig.8  TEM images of (a) Al/graphene/Al and (b) passivated Al/graphene/passivated Al. Reproduced with permission from Ref. [10].
Fig.9  HRTEM images of the interfacial area of Al6063/GNSs composites with (a) 1 h and (b) 3 h ball milling. Reproduced with permission from Ref. [18].
Fig.10  Illustrations of the tensile behavior of Al/GNP composites with weak mechanical bonding and strong chemical bonding. Reproduced with permission from Ref. [50].
Fig.11  Schematic diagrams of the nucleation and the growth mechanisms of Al4C3. Reproduced with permission from Ref. [90].
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