In situ synthesis of high-performance Al4C3/Al matrix composites for electric conductor

Abstract Increased strength of Al matrix composites (AMCs) with a high electrical conductivity are in demand to replace copper conductors. In this study, a high-performance Al4C3/Al composite was synthesized in situ via the high-energy densification of uniform graphene oxide (GO)/Al powder combination; GO was completely transformed to monocrystalline Al4C3 nanorod structures, robustly bridging across the Al grain boundary. The formation mechanism of interfacial Al4C3 was illustrated by high-resolution transmission electron microscope observations. The Al4C3 nanorods were homogeneously dispersed and possessed an intimate and faceted interface with the matrix, resulting in the enhanced tensile strength of Al. Moreover, the Al4C3/Al composite retained the required electrical conductivity similar to that of pure Al, in addition to the stable interface at elevated temperatures and long-term service reliability in moist environment. The findings of this study will be significant in providing the basis of designing novel heat-resistant AMCs in electrical applications.