Advances in graphene reinforced metal matrix nanocomposites: Mechanisms, processing, modelling, properties and applications

Study of the Effect of Graphene Content on the Electrical and Mechanical Properties of Aluminium-Graphene Composites

The present paper is dedicated to the search for an alternative material based on an aluminum (Al)-few-layer graphene (FLG) composite for use in electrical applications. Due to its excellent properties, graphene has the potential for use in many applications, especially in electronics, electrical engineering, aerospace, and the automotive industry. One area where the properties of graphene can be exploited is in overhead power transmission, where the main challenge at the moment is to reduce transmission losses. The utilization of conductors that exhibit superior electrical conductivity is instrumental in ensuring the mitigation of transmission losses. The utilization of graphene or other carbon allotropes is appealing due to their elevated electrical conductivity, substantial mechanical strength, and considerable heat resistance, which can enhance the properties of the composite, thereby increasing its resistance to operational conditions, particularly long-term exposure to temperature, a parameter closely related to the current carrying capacity of the OHL. This article presents the findings of research on the production of a composite based on aluminum powder and graphene, as well as the identification of its electrical and mechanical properties. The primary challenge in this research lies in the development of a method to synthesize carbon materials with aluminum using powder metallurgy, with particular attention paid to the mixing and compacting process, which is of significant importance in ensuring the appropriate distribution of carbon material in the composite. The research carried out has determined the influence of the graphene content (0.1-1 wt.%) on the electrical conductivity (max. 35.4 MS/m) and mechanical properties of Al-FLG composites (UTS = 156 MPa).

Recent Advances in Electrodeposition of Nickel-Based Nanocomposites Enhanced with Lubricating Nanoparticles

Recently, nanomaterials such as graphene, polytetrafluoroethylene, WS2, and MoS2 have emerged as pioneering additives and fillers in metal nanocomposite electrodeposition, offering innovative solutions for lubrication and tribological enhancement. Electrodeposition, known for its high efficiency, reliability, operational simplicity, and cost-effectiveness, has become a preferred method for the protection of industrial components from excessive wear or abrasion. In particular, nickel (Ni) matrix composites fabricated via electrodeposition function as an environmentally friendly substitute for coatings such as hard chromium. These Ni-based composites exhibit multifunctional properties, including enhanced hardness, modified surface wettability, improved anti-friction/wear performance, and lubrication properties. This review begins by explaining the principles and mechanisms of electrodeposition, along with the chemical structures and properties of lubricating nanoparticles. It discusses dispersion methodologies of these nanoparticles in the electrolyte solution to address aggregation problems. In addition, it introduces codeposition models for Ni/nanomaterials and examines the key parameters that influence this codeposition process. This review systematically explores the mechanical properties, tribological performance, and surface wettability of resulting Ni-based nanocomposites, along with their potential applications and practical advantages. Finally, it discusses the opportunities and challenges associated with nanomaterial-enhanced metal composites, aiming to introduce new avenues for their utilization in electrodeposition.

Microstructural and Mechanical Characterization of Al Nanocomposites Using GCNs as a Reinforcement Fabricated by Induction Sintering

High-energy ball milling is a process suitable for producing composite powders whose achieved microstructure can be controlled by the processing parameters. Through this technique, it is possible to obtain a homogeneous distribution of reinforced material into a ductile metal matrix. In this work, some Al/CGNs nanocomposites were fabricated through a high-energy ball mill to disperse nanostructured graphite reinforcements produced in situ in the Al matrix. To retain the dispersed CGNs in the Al matrix, avoiding the precipitation of the Al4C3 phase during sintering, the high-frequency induction sintering (HFIS) method was used, which allows rapid heating rates. For comparative purposes, samples in the green and sintered state processed in a conventional electric furnace (CFS) were used. Microhardness testing was used to evaluate the effectiveness of the reinforcement in samples under different processing conditions. Structural analyses were carried out through an X-ray diffractometer coupled with a convolutional multiple whole profile (CMWP) fitting program to determine the crystallite size and dislocation density; both strengthening contributions were calculated using the Langford–Cohen and Taylor equations. According to the results, the CGNs dispersed in the Al matrix played an important role in the reinforcement of the Al matrix, promoting the increase in the dislocation density during the milling process. The strengthening contribution of the dislocation density was ~50% of the total hardening value, while the contribution by dispersion of CGNs was ~22% in samples with 3 wt. % C and sintered by the HFIS method. Atomic force microscopy (AFM) and scanning electron microscopy (SEM) were used to analyze the morphology, size, and distribution of phases present in the Al matrix. From the analyses carried out in AFM (topography and phase images), the CGNs are located mainly around crystallites and present height profiles of 1.6 to 2 nm.

Tribological and Hardness Analyses of Friction-Stir-Processed Composites Using the Taguchi Approach

The friction stir process (FSP) is becoming a highly utilized method to manufacture composites since it refines the microstructure and improves the physical characteristics like hardness, strength, and wear resistance of their surfaces. In this study, the hardness and wear behaviours of Al6061-based surface composites prepared by the FSP were investigated and compared for the influences of various parameters-FSP tool geometry, reinforcement composition, number of FSP passes, pin load, etc. The Taguchi design with an L27 orthogonal array was developed to analyze the influence of five input parameters on the output parameter, i.e., wear rate during wear tests. The hardness of the composite samples for different reinforcement compositions was investigated, and the results were statistically compared with the obtained wear rates. It was concluded from the results that various parameters influenced the surface wear and hardness of the composites. Tool geometries cylindrical pin and square pin had the maximum and minimum wear rates, respectively. Additionally, the optimal composition of the reinforcements copper and graphene as 1:3 possessed the maximum wear rate and minimum hardness. However, the reinforcement composition 3:3 (Cu:Gr) by weight had the minimum wear rate and maximum hardness. The higher the FSP pass numbers, the lesser the wear rate and the higher the hardness, and vice-versa. This work helps identify the influence of numerous factors on the wear and hardness aspects of surface composites prepared by the FSP. In the future, this study can be modified by combining it with thermal analysis, sensor data analysis of the composites, and optimization of the parameters for desirable microstructure and physical properties.

Effect of Grain Size on the Properties of Aluminum Matrix Composites with Graphene

The structure and mechanical properties of composites consisting of a metal matrix based on aluminum and its alloys of different compositions (AA-3003 and AA-5154) and graphene synthes sized in situ under a layer of molten salts were investigated depending on the chemical composition and grain size of the matrix. Aluminum matrix composites of three compositions were studied in as-cast coarse-grained, deformed fine-grained (grain size < 1 mm), and deformed sub microcrystalline (grain size < 1 μm) states in order to compare the structural characteristics of composites with different grain sizes. The composites were subjected to deformation with a split Hopkinson (Kolsky) bar and to dynamic-channel angular pressing. The hardness and dynamic mechanical properties of the composites were measured at strain rates ε˙ from 1.8 − 4.7 × 103 to 1.6 − 2.4 × 105 s−1. It was found that grain refinement induced a sharp increase in the hardness of composites with various compositions (by a factor of 1.6–2.6). A correlation of the elastic-plastic properties of the aluminum matrix composites with the grain sizes and chemical compositions of the matrices was established. A transition from coarse-grained to sub microcrystalline structure was shown to improve the elastic-plastic properties on average by a factor of 1.5. It was proved that the reinforcing effect of graphene increased with the decreasing grain size of the matrix. Mechanisms of reinforcement of the aluminum matrix composites using graphene were proposed.

Role of defects in the mechanical properties of graphene-copper heterostructures

Through molecular dynamics simulations of tensile tests, the role that vacancies and Stone-Wales defects play in the mechanical properties of sandwich-like heterostructures, composed by graphene and two symmetric copper layers at nanoscale, is studied. The dependence on the armchair and zigzag chiralities of the graphene layer is also investigated. During elastic deformation, defects negatively affect the mechanical response. However, defective systems can show an improvement of the plastic properties. Vacancies have a stronger impact compared to Stone-Wales defects. Elasticity, toughness, and ductility are enhanced along the zigzag chirality, while stiffness is improved along the armchair direction. The Poisson's ratio was calculated for all graphene-copper heterostructures. At a critical strain it becomes negative along the thickness direction, preserving the auxetic property at higher strains. In general, the behavior is governed by the graphene response. Our findings can be useful to understand the strengthening mechanism induced by this two-dimensional material in metals like copper and for the design of similar systems.

Reconfigurable meta-radiator based on flexible mechanically controlled current distribution in three-dimensional space

In this paper, we provide an experimental proof-of-concept of this dynamic three-dimensional (3D) current manipulation through a 3D-printed reconfigurable meta-radiator with periodically slotted current elements. By utilizing the working frequency and the mechanical configuration comprehensively, the radiation pattern can be switched among 12 states. Inspired by maximum likelihood method in digital communications, a robustness-analysis method is proposed to evaluate the potential error ratio between ideal cases and practice. Our work provides a previously unidentified model for next-generation information distribution and terahertz-infrared wireless communications.