The extraordinary effect of very low content of hybrid carbonaceous reinforcement on the microstructural and mechanical properties of 7075 aluminum alloy

Until recently, the strengthening efficiency of carbonaceous reinforcements in aluminum-based matrix nanocomposites (AlMNCs) was lower than expected. The intrinsic characteristics of matrix and carbonaceous reinforcements and fabrication technique, which affected the microstructural characterization, played main roles in determining the performance of Cs/AlMNCs. In this study a novel strategy was developed via flake powder metallurgy followed by slurry blending combined with rheocasting and hot-extrusion processing to prepare hybrid AA7075-matrix composite reinforced with CNTs + GNPs. No Al4C3 phase was detected in Raman spectrums, while uniform dispersion of carbonaceous hybrid reinforcements with minimal structural damage was observed. There were ~ 9% and 39% decrease in the average grain size of the as-casted and extruded CNTs + GNPs/AA7075 composites, respectively, compared to AA7075 alloy. In the extruded CNTs + GNPs/AA7075 composite, plate precipitates were predominant and some lath-like dynamic precipitates were observed at the GNPs/AA7075 interfaces. The micro-hardness, tensile yield strength (TYS), ultimate tensile strength (UTS) and uniform elongation (UE) of the CNTs + GNPs/AA7075 composite were improved by ~ 17%, 51%, 7% and 20% compared to AA7075 alloy. An ultra-high yield strengthening efficiency of carbonaceous hybrid reinforcements in AA7075 alloy up to 3950 was obtained, where load bearing was the main strengthening mechanism and carbonaceous reinforcements illustrated bridging and pulling-out in the fracture surfaces of composite.