Manufacturing of Aluminum Nano-Composites Reinforced with Nano-Copper and High Graphene Ratios Using Hot Pressing Technique
Abstract
:1. Introduction
2. Experimental Work
Materials and Method
- The Al with ~100 nm and 99.99% purity;
- The nano-Cu deposited by the electroless plating process;
- The graphene nano-platelets (GNPs) with thickness of less than 10 nm and purity of 99.99%.
3. Composite Characterization
4. Results and Discussion
4.1. XRD Observation
4.2. Density Measurements
4.3. Microstructure Investigation
4.4. Hardness
4.5. Compressive Strength
5. Conclusions
- Due to the continued stirring of graphene during the cleaning and the coating with Ag and Cu and then mixing them with the nano-aluminum particles for 6 h, a homogenous dispersion of it at high ratios was achieved.
- New intermetallic (Cu9Al4) between Al and Cu was formed. The formed intermetallic enhances the grain boundaries’ strength and, consequently, the fabricated aluminum matrix’s hardness.
- Due to encapsulating the GNs/Ag layers with Cu, the interaction between them and aluminum was restricted, and no peaks for Al4C3 were detected.
- The high magnification of the microstructure showed that the GNP layers were transparent and in a horizontal position. In addition, the adhesion at the edges of the GNP layers with the Al matrix was improved due to coating of GNPs with Ag, where the wettability was improved.
- The GNPs content significantly improved the hardness of the nanocomposite to reach 328.24 HV for samples containing 1.8% GNPs compared with 216.2 HV and 230 HV for the pure Al and Al/Cu samples, respectively.
- Increasing the GNPs up to 1.8 wt% GNs ratio led to increasing the compressive strength to 266.9 MPa compared with 194.43 MPa and 204.1 for pure Al and Al/15Cu nanocomposites, respectively.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Acknowledgments
Conflicts of Interest
References
- Hamid, R.G. A Review of Methods for Synthesis of Al Nanoparticles. Orient. J. Chem. 2014, 30, 1941–1949. [Google Scholar]
- Arash, B.; Rasoul, S.M. Investigation of different liquid media and ablation times on pulsed laser ablation synthesis of aluminum nanoparticles. Appl. Surf. Sci. 2010, 256, 7559–7564. [Google Scholar]
- Li, H.; Mohammed, J.M.; Lu, F.; Christopher, E.B.; Elena, A.; Guliants, E.A.; Sun, Y.-P. Templated synthesis of aluminum nanoparticles-A new route to stable energetic materials. J. Phys. Chem. C 2009, 113, 20539–20542. [Google Scholar] [CrossRef]
- Nida, T.K.; Namra, J. Copper Nanoparticles-Synthesis and Applications. Acta Sci. Pharm. Sci. 2018, 2, 41–43. [Google Scholar]
- Yehia, H.M.; Ali, A.I.; Abd-Elhameed, E. Effect of Exfoliated MoS2 on the Microstructure, Hardness, and Tribological Properties of Copper Matrix Nanocomposite Fabricated via the Hot Pressing Method. Trans. Indian Inst. Met. 2023, 76, 195–204. [Google Scholar] [CrossRef]
- Yehia, H.M.; Nouh, F.; El-Kady, O.A.; Abd-Elaziem, W.; Elsayed, E.M. Studying the microstructure, electrical, and electrochemical behavior of the Cu-10WC/x GNs for electrochemical machining electrode and energy application. Int. J. Mach. Mach. Mater. 2022, 4, 6430–6452. [Google Scholar]
- Matthew, J.A.; Vincent, C.T.; Richard, B.K. Honeycomb carbon: A review of graphene. Chem. Rev. 2010, 110, 132–145. [Google Scholar]
- Ba, K.; Jiang, W.; Cheng, J.X.; Bao, J.X.; Xuan, N.N.; Sun, Y.Y.; Liu, B.; Xie, A.Z.; Wu, S.W.; Sun, Z.Z. Chemical and bandgap engineering in monolayer hexagonal boron nitride. Sci. Rep. 2017, 7, 45584. [Google Scholar] [CrossRef]
- Liang-Xu, D.; Qiang, C. Properties, synthesis, and characterization of graphene. Front. Mater. Sci. China 2010, 4, 45–51. [Google Scholar]
- Ervina, E.M.N.; Siti, S.N.; Mohd, M.A. Fabrication Method of Aluminum Matrix Composite (Amcs): A Review. Key Eng. Mater. Submitt. 2016, 700, 102–110. [Google Scholar] [CrossRef]
- Mustafa, M.A.; Bilge, D.; Muhammet, E.T. Hybrid Reinforced Magnesium Matrix Composites (Mg/Sic/GNPs): Drilling Investigation. Metals 2018, 8, 215–229. [Google Scholar]
- Karl, U.K. Metal Matrix Composites: Custom-made Materials for Automotive and Aerospace Engineering; Wiley-VCH Verlag GmbH & Co., KGaA: Hoboken, NJ, USA, 2006. [Google Scholar] [CrossRef]
- Peng, H.X. Manufacturing titanium metal—Matrix composites by consolidating matrix coated fibers. J. Mater. Sci. Technol. 2005, 21, 647–651. [Google Scholar]
- Fathy, A.; Abu-Oqail, A.; Wagih, A. Improved mechanical and wear properties of hybrid Al-Al2O3/GNPs electro-less coated Ni nanocomposite. Ceram. Int. 2018, 44, 22135–22145. [Google Scholar] [CrossRef]
- Saboori, A.; Novara, C.; Pavese, M.; Badini, C.; Giorgis, F.; Fino, P. An Investigation on the Sinterability and the Compaction Behavior of Aluminum/Graphene Nanoplatelets (GNPs) Prepared by Powder Metallurgy. J. Mater. Eng. Perform. 2017, 26, 993–999. [Google Scholar] [CrossRef]
- Li, D.; Ye, Y.; Liao, X.; Qin, Q.H. A novel method for preparing and characterizing graphene nanoplatelets/aluminum nanocomposites. Nano Res. 2018, 11, 1642–1650. [Google Scholar] [CrossRef]
- Li, G.; Xiong, B. Effects of graphene content on microstructures and tensile property of graphene-nanosheets/aluminum composites. J. Alloys Compd. 2017, 697, 31–36. [Google Scholar] [CrossRef]
- Hunt, W.H. Metal matrix composites. Compr. Compos. Mater. 2000, 3, 57–66. [Google Scholar]
- Mallick, P.K. Advanced materials for automotive applications: An overview. Adv. Mater. Automot. Eng. 2012, 5–27. [Google Scholar] [CrossRef]
- Zhang, C. Understanding the wear and tribological properties of ceramic matrix composites. In Advances in Ceramic Matrix Composites; Woodhead Publishing: Cambridge, UK, 2014; pp. 312–339. [Google Scholar] [CrossRef]
- Thoppul, S.D.; Finegan, J.; Gibson, R.F. Mechanics of mechanically fastened joints in polymer-matrix composite structures—A review. Compos. Sci. Technol. 2009, 69, 301–329. [Google Scholar] [CrossRef]
- Hossam, M.Y.; Abu-Oqail, A.; Maher, A.E.; Omayma, A.E. Microstructure, hardness, and tribology properties of the (Cu/MoS2)/graphene nanocomposite via the electroless deposition and powder metallurgy technique. J. Compos. Mater. 2020, 54, 3435–3446. [Google Scholar]
- Yehia, H.M. Microstructure, physical and mechanical properties of the Cu/(WC-TiC-Co) nano-composites by the electro-less coating and powder metallurgy technique. J. Compos. Mater. 2019, 53, 1963–1971. [Google Scholar] [CrossRef]
- El-Kady, O.; Yehia, H.M.; Fathy., N. Preparation and characterization of Cu/(WC-TiC-Co)/graphene nano-composites as a suitable material for heat sink by powder metallurgy method. Refract. Met. Hard Mater. 2019, 79, 108–114. [Google Scholar] [CrossRef]
- Yehia, H.M. Daoush, W.M.; Mouez, F.A.; El-Sayed, M.H.; El-Nikhaily, A.E. Microstructure, Hardness, Wear, and Magnetic Properties of (Tantalum, Niobium) Carbide-Nickel–Sintered Composites Fabricated from Blended and Coated Particles. Mater. Perform. Character. 2020, 9, 543–555. [Google Scholar]
- Güler, O.; Varol, T.; Alver, Ü.; Canakci, A. Effect of Al2O3 content and milling time on the properties of silver coated Cu matrix composites fabricated by electroless plating and hot pressing. Mater. Today Commun. 2020, 24, 101153. [Google Scholar] [CrossRef]
- Güler, O.; Varol, T.; Alver, Ü.; Kaya, G.; Yıldız, F. Microstructure and wear characterization of Al2O3 reinforced silver coated copper matrix composites by electroless plating and hot pressing methods. Mater. Today Commun. 2021, 27, 102205. [Google Scholar] [CrossRef]
- Yehia, H.M.; Abdelalim, N.; El-Mahallawi, I.; Abd-elmotaleb, T.; Hoziefa, W. Characterization of swarf Al/(Al2O3/GNs) Ag composite fabricated using stir casting and rolling process. J. Mech. Sci. Technol. 2023, 37, 1803–1809. [Google Scholar] [CrossRef]
- Nour-Eldin, M.; Elkady, O.; Yehia, H.M. Timeless Powder Hot Compaction of Nickel-Reinforced Al/(Al2O3-Graphene Nanosheet) Composite for Light Applications Using Hydrazine Reduction Method. J. Mater. Eng. Perform. 2022, 31, 6545–6560. [Google Scholar] [CrossRef]
- Zidan, H.M.; Hegazy, M.; Abd-Elwahed, A.; Yehia, H.M.; El Kady, O.A. Investigation of the Effectuation of Graphene Nanosheets (GNS) Addition on the Mechanical Properties and Microstructure of S390 HSS Using Powder Metallurgy Method. Int. J. Mater. Technol. Innov. 2021, 1, 52–57. [Google Scholar] [CrossRef]
- Elkady, O.A.; Yehia, H.M.; Ibrahim, A.A.; Elhabak, A.M.; Elsayed, E.M.; Mahdy, A.A. Direct Observation of Induced Graphene and SiC Strengthening in Al-Ni Alloy via Hot Pressing Technique. Crystals 2021, 11, 1142. [Google Scholar] [CrossRef]
- Yehia, H.M.; Nyanor, P.; Daoush, W.M. Characterization of Al-5Ni-0.5Mg/x (Al2O3-GNs) nanocomposites manufactured via Hot Pressing Technique. Mater. Charact. 2022, 191, 112139. [Google Scholar] [CrossRef]
- Yehia, H.M.; Allam, S. Hot Pressing of Al-10 wt% Cu-10 wt% Ni/x (Al2O3–Ag) Nanocomposites at Different Heating Temperatures. Met. Mater. Int. 2021, 27, 500–513. [Google Scholar] [CrossRef]
- Abolkassem, S.A.; Elkady, O.A.; Elsayed, A.H.; Hussein, W.A.; Yehya, H.M. Effect of consolidation techniques on the properties of Al matrix composite reinforced with nano Ni-coated SiC. Result Phys. 2018, 9, 1102–1111. [Google Scholar] [CrossRef]
- Yehia, H.M.; Menisy, M.; Allam, S.; Kaytbay, S. Fabrication of aluminum matrix nanocomposites by hot compaction. J. Petrol. Min. Eng. 2020, 22, 16–20. [Google Scholar] [CrossRef]
- Barakat, W.; Elkady, O.; Abuoqail, A.; Yehya, H.; EL-Nikhaily, A. Effect of Al2O3 coated Cu nanoparticles on properties of Al/Al2O3 composites. J. Pet. Min. Eng. 2020, 22, 1–9. [Google Scholar] [CrossRef]
- Yehia, H.M.; Hakim, M.; El-Assal, A. Effect of the Al2O3 powder addition on the metal removal rate and the surface roughness of the electrochemical grinding machining. Proc. Inst. Mech. Eng. Part B J. Eng. Manuf. 2020, 234, 1538–1548. [Google Scholar] [CrossRef]
- El-Kady, O.A.; Yehia, H.M.; Nouh, F.; Ghayad, I.M.; El-Bitar, T.; Daoush, W.M. Enhancement of Physical Properties and Corrosion Resistance of Al-Cu-Al2O3/Graphene Nanocomposites by Powder Metallurgy Technique. Materials 2022, 15, 7116. [Google Scholar] [CrossRef]
- Yehia, H.M.; Nouh, F.; El-Kady, O.A.; Abdelwahed, K.; El-Bitar, T. Homogeneous dispersion and mechanical performance of aluminum reinforced with high graphene content. J. Compos. Mater. 2022, 56, 4515–4528. [Google Scholar] [CrossRef]
Sample No. | Composition |
---|---|
1 | Pure Al |
2 | 85 wt% Al–15 wt% Cu |
3 | 99.6 wt% (85% Al + 15% Cu)/0.4 wt% GNPs/Ag |
4 | 99.4 wt% (85% Al + 15% Cu)/0.6% GNPs/Ag |
5 | 98.8 wt% (85% Al + 15% Cu)/1.2% GNPs/Ag |
6 | 98.2 wt% (85% Al + 15% Cu)/1.8% GNPs/Ag |
C | Si | Mn | Cr | Mo | V |
---|---|---|---|---|---|
0.31 | 0.30 | 0.35 | 2.90 | 2.70 | 0.50 |
Material | Relative Density (%) |
---|---|
Pure Al | 99.6% |
Al/15% Cu | 99.9% |
Al-15% Cu/0.4 wt% GNPs | 99.5% |
Al-15% Cu/0.6 wt% GNPs | 99.2% |
Al-15% Cu/1.2 wt% GNPs | 98.8% |
Al-15% Cu/1.8 wt% GNPs | 98.7% |
Material | Micro-Hardness (HV) |
---|---|
Pure Al | 216.2 |
Al/15% Cu | 230 |
Al-15% Cu/0.4 wt% GNPs | 279.16 |
Al-15% Cu/0.6 wt% GNPs | 286 |
Al-15% Cu/1.2 wt% GNPs | 289.4 |
Al-15% Cu/1.8 wt% GNPs | 328.42 |
Sample No. | CYS (MPa) | UCS (MPa) |
---|---|---|
Pure Al | 35.113 | 194.43 |
Al + 15 wt% Cu | 39.1 | 204.145 |
Al + 15 wt% Cu/0.4 wt% GNPs | 41.685 | 248.6 |
Al + 15 wt% Cu/0.6 wt% GNPs | 44.741 | 260.843 |
Al + 15 wt% Cu/1.2 wt% GNPs | 45.734 | 263.21 |
Al + 15 wt% Cu/1.8 wt% GNPs | 54.9932 | 266.9956 |
Disclaimer/Publisher’s Note: The statements, opinions and data contained in all publications are solely those of the individual author(s) and contributor(s) and not of MDPI and/or the editor(s). MDPI and/or the editor(s) disclaim responsibility for any injury to people or property resulting from any ideas, methods, instructions or products referred to in the content. |
© 2023 by the authors. Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (https://creativecommons.org/licenses/by/4.0/).
Share and Cite
Yehia, H.M.; Elmetwally, R.A.H.; Elhabak, A.M.; El-Kady, O.A.; Shash, A.Y. Manufacturing of Aluminum Nano-Composites Reinforced with Nano-Copper and High Graphene Ratios Using Hot Pressing Technique. Materials 2023, 16, 7174. https://doi.org/10.3390/ma16227174
Yehia HM, Elmetwally RAH, Elhabak AM, El-Kady OA, Shash AY. Manufacturing of Aluminum Nano-Composites Reinforced with Nano-Copper and High Graphene Ratios Using Hot Pressing Technique. Materials. 2023; 16(22):7174. https://doi.org/10.3390/ma16227174
Chicago/Turabian StyleYehia, Hossam M., Reham A. H. Elmetwally, Abdelhalim M. Elhabak, Omayma A. El-Kady, and Ahmed Yehia Shash. 2023. "Manufacturing of Aluminum Nano-Composites Reinforced with Nano-Copper and High Graphene Ratios Using Hot Pressing Technique" Materials 16, no. 22: 7174. https://doi.org/10.3390/ma16227174