The preparation and properties of reduced graphene oxide (rGO) and graphene nanosheets (GNSs) reinforcement of aluminium matrix nanocomposites (AMCs) are reported. For the rGO-AMCs, commercial colloidal GO was coated onto aluminium powder particles and then reduced via thermal annealing. For the GNS-AMCs, graphene exfoliated from graphite through ultrasonication and centrifugation was coated onto aluminium particle surfaces via dispersion mixing, filtering and drying. Pure aluminium and aluminium composites with various reinforcement concentrations of rGO and GNS were cold compacted into disc-shaped specimens and sintered in inert atmosphere. The mechanical properties and microstructure were studied and characterised via Vickers hardness, X-ray diffraction, density measurement, and scanning electron microscopy. The reinforcements were uniformly distributed onto the aluminium particle surfaces before and after consolidation within the composites. The relevant factors for the powder metallurgy process (compaction pressure, density, and sintering conditions) were optimised. Increased levels of increased hardness were recorded, over baseline compacted and sintered pure aluminium samples, prepared under identical experimental conditions, of 32% and 43% respectively for the 0.3wt.% rGO-Al and 0.15wt.% GNSs-Al composites. The process developed and presented herein provides encouraging results for realising rGO-AMC and GNS-AMC nanocomposites via low cost cold powder compaction and sintering metallurgy techniques.
In this work, pure aluminium powders of different average particle size were compacted, sintered into discs and tested for mechanical strength at different strain rates. The effects of average particle size (15, 19, and 35 µm), sintering rate (5 and 20 °C/min) and sample indentation test speed (0.5, 0.7, and 1.0 mm/min) were examined. A compaction pressure of 332 MPa with a holding time of six minutes was used to produce the green compacted discs. The consolidated green specimens were sintered with a holding time of 4 hours, a temperature of 600 °C in an argon atmosphere. The resulting sintered samples contained higher than 85% density. The mechanical properties and microstructure were characterized using indentation strength measurement tests and SEM analysis respectively. After sintering, the aluminium grain structure was observed to be of uniform size within the fractured samples. The indentation test measurements showed that for the same sintering rate, the 35 µm powder particle size provided the highest radial and tangential strength while the 15 µm powder provided the lowest strengths. Another important finding from this work was the increase in sintered sample strength which was achieved using the lower sinter heating rate, 5°C/min. This resulted in a tangential stress value of 365 MPa which was significantly higher than achieved, 244 MPa, using the faster sintering heating rate, 20 °C/min.
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