Carbon Materials Reinforced Aluminum Composites: A Review

doi:10.1007/s40195-014-0160-1

Abstract

Abstract:

Carbon materials, including carbon fibers, graphite, diamond, carbon foams, carbon nanotubes, and graphene, are attractive reinforcements for aluminum matrix composites due to their excellent mechanical and/or physical properties as well as light weight. Carbon materials reinforced aluminum (C/Al) composites are promising materials in many areas such as aerospace, thermal management, and automobile. However, there are still some challenging problems that need to be resolved, such as interfacial reactions, low wettability, and anisotropic properties. These problems have limited the use of these composites. This review mainly focuses on the categories, fabrication processes, existing problems and solutions, coatings and interfaces, challenges and opportunities of C/Al composites so as to provide a useful reference for future research.

Key words: Carbon materials, Aluminum composites, Fabrication, Interface, Coatings

Huang Yu, Ouyang Qiubao, Zhang Di, Zhu Jing, Li Ruixiang, Yu Hong. Carbon Materials Reinforced Aluminum Composites: A Review[J]. Acta Metallurgica Sinica (English Letters), 2014, 27(5): 775-786.

Figures/Tables 16

Table 1 Properties of carbon materials

Materials	Density (g/cm³)	Strength (GPa)	Modulus (GPa)	TC (W m⁻¹ K⁻¹)	CTE (10⁻⁶K⁻¹)	Ref.
PAN-based carbon fibers	1.75-1.93	2.5-7.0	250-400	8-70	(−0.6)-(−1.1)	[1, 61-63]
Pitch-based carbon fibers	2.10-2.19	1.5-3.5	200-800	530-1,100	(−1.3)-(−1.45)	[1, 61-63]
VGCFs	2.0	2.35-2.9	180-245	1,950	1-4	[8, 64, 65]
Crystalline graphite	2.3	-	-	x-y: 3,000	x-y: −1.0	[66]
				z: 6	z: 29
Graphite flakes	2.1-2.3	-	-	a	a	[66]
Graphite particles	2.1-2.3	-	-	b	b	[66]
Carbon foams	0.9	-	-	x-y: 70	x-y: 1.02	[66]
				z: 245	z: −1.07
Diamond	3.51	-	-	2,000-2,200	1.3	[66]
CNTs	2.1	11-150	270-950	500-3,500	(−10)-(−12)	[7, 8, 67]
Graphene	-	130	1,002	4,840-5,300	−1.3	[8, 67]

Fig. 1 Common orientations of graphite planes in fibers [58]: a radial; b random; c onion skin

Fig. 2 Schematic illustration of a 2/1 carbon fibers/Al laminate [69]

Fig. 3 Formation of Al4C3 in some typical C/Al composites [15, 90]: a Carbon fibers/Al composites; b Diamond/Al composites

Fig. 4 Contact angle between carbon materials and aluminum [8, 58]: a schematic diagram; b carbon substrate; c graphite substrate

Fig. 5 Schematic diagram of stir casting [8]

Fig. 6 Schematic diagram of gas pressure infiltration [60]

Fig. 7 Schematic diagram of squeeze casting [37]

Fig. 8 Fabrication apparatus and microstructure of continuous carbon fibers/Al composites wires [104, 105]

Fig. 9 Schematic diagram of spark plasma sintering [8]

Fig. 10 Schematic diagram of vacuum hot pressing [72]

Fig. 11 a, b Wetting improvement of Ni-coated carbon materials by aluminum [31]; c Interfacial microstructure of Ni-coated carbon fibers/Al composites [31]

Fig. 12 a, b Wetting improvement of carbon materials by aluminum with Cu coating [125]; c Interfacial microstructure of Cu-coated carbon fibers/Al composites [29]

Fig. 13 Interfacial microstructure of SiC-coated carbon fibers/Al composites [127]: a Al-2 wt% Si matrix; b Al-12 wt% Si matrix

Fig. 14 Schematic diagram of liquid metal transfer agent method [51]

Fig. 15 Interfacial microstructure of Al2O3-coated short carbon fibers/Al composites [54]: a Al2O3 coating-carbon fiber interface; b Al2O3 coating-aluminum matrix interface

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