Fabrication of Fullerene-Reinforced Aluminum Matrix Nanocomposites

doi:10.1007/s40195-017-0629-9

Abstract

Abstract:

Fullerene-reinforced Al matrix nanocomposites were fabricated by high-energy mechanical milling followed by consolidation through hot extrusion or high-pressure torsion (HPT). The results indicate that a relatively homogeneous microstructure consisting of elongated, micrometer-sized Al grains is formed in the hot-extruded specimens. However, the microstructure is not uniform along the radius of the HPT disks, which includes coarse grains near the center of the disk and ultrafine grains in the middle and along the edge of the specimen. Microstructural evaluations of the HPT disks indicate that Al grain refinement occurs due to the addition of fullerene, as grain size is reduced to 60 nm from 118 nm. The formation of the harmful aluminum carbide phase is not detected during the fabrication of Al/C₆₀ nanocomposites. The hardness, yield stress, and ultimate tensile strength of the Al-2 vol.% C₆₀ nanocomposites are about 27-160% higher than those of the monolithic Al samples, revealing the effective strengthening of fullerene particles in Al matrix. Moreover, mechanical properties of the Al/fullerene nanocomposites are significantly enhanced (59-272%) by utilizing HPT in comparison to hot-extruded specimens due to their much finer Al grain structure. The reduction in the number and the size of the dimples, as well as the formation of smooth regions on the tensile fracture surface of Al/C₆₀, results in their overall lower ductility compared to monolithic Al.

Key words: Aluminum, Fullerene, High-pressure torsion, Hot extrusion, Microstructure, Mechanical properties

Hamed Asgharzadeh, Hamid Faraghi, Hyoung Seop Kim. Fabrication of Fullerene-Reinforced Aluminum Matrix Nanocomposites[J]. Acta Metallurgica Sinica (English Letters), 2017, 30(10): 973-982.

Figures/Tables 10

Fig. 1 Schematic illustration of HPT disk and locations for tensile samples, microhardness measurements, and OM and TEM observations

Fig. 2 SEM images of powders: a gas-atomized Al; b mechanically milled Al, c mechanically milled Al/C60

Fig. 3 Optical micrographs of mechanically milled powders: a Al, b Al/C60

Fig. 4 XRD pattern of: a Al powder; b Al/C60 powder; c Al/C60 extrudate

Table 1 Density, hardness, and tensile properties of Al and Al-2 vol.% fullerene fabricated by high-pressure torsion and hot extrusion

Material type	Consolidation method	Density (g cm^-3)	Relative density	Hardness (HV)	Offset yield stress (MPa)	Ultimate tensile strength (MPa)	Strain to fracture (%)
Al	HPT	2.659 ± 0.004	0.985	92 ± 1	305	321	25.9
Al	Hot extrusion	2.661 ± 0.002	0.986	30 ± 3	63	124	36
Al-2 vol.% fullerene	HPT	2.647 ± 0.002	0.984	139 ± 2	409	409	0.6
Al-2 vol.% fullerene	Hot extrusion	2.655 ± 0.003	0.983	78 ± 9	110	258	14.1

Fig. 5 OM micrographs of hot-extruded and HPT-processed specimens: a Al, hot extrusion; b Al/C60, hot extrusion; c Al, HPT-center; d Al/C60, HPT-center; e Al, HPT-middle; f Al/C60, HPT-middle; g Al, HPT-edge; h Al/C60, HPT-edge

Fig. 6 TEM images and SAD patterns from the microstructure of the samples subjected to HPT for ten turns: a, c Al, b, d Al/C60

Fig. 7 a HAADF TEM, b HRTEM images of HPT-processed Al/C60 nanocomposite. The arrows in a show fullerene within the Al matrix

Fig. 8 Variation of Vickers microhardness with distance from the center of the HPT disks

Fig. 9 Tensile fracture surfaces of Al and Al/C60 samples at two different magnifications: a, b Al, hot extrusion; c, d Al, HPT; e, f Al/C60, hot extrusion; g, h Al/C60, HPT

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