Synthesis of new metal-matrix Al–Al2O3–graphene composite materials

The mechanism of formation of ceramic microparticles (alumina) and graphene in a molten aluminum matrix is studied as a function of the morphology and type of precursor particles, the temperature, and the gas atmosphere. The influence of the composition of an aluminum composite material (as a function of the concentration and size of reinforcing particles) on its mechanical and corrosion properties, melting temperature, and thermal conductivity is investigated. Hybrid metallic Al–Al2O3–graphene composite materials with up to 10 wt % alumina microparticles and 0.2 wt % graphene films, which are uniformly distributed over the metal volume and are fully wetted with aluminum, are synthesized during the chemical interaction of a salt solution containing yttria and boron carbide with molten aluminum in air. Simultaneous introduction of alumina and graphene into an aluminum matrix makes it possible to produce hybrid metallic composite materials having a unique combination of the following properties: their thermal conductivity is higher than that of aluminum, their hardness and strength are increased by two times, their relative elongation during tension is increased threefold, and their corrosion resistance is higher than that of initial aluminum by a factor of 2.5–4. We are the first to synthesize an in situ hybrid Al–Al2O3–graphene composite material having a unique combination of some characteristics. This material can be recommended as a promising material for a wide circle of electrical applications, including ultrathin wires, and as a structural material for the aerospace industry, the car industry, and the shipbuilding industry.