STUDY ON METAL-NANOCARBON COMPOSITES: PROCESSING, CHARACTERIZATION, AND PROPERTIES

Abstract

Introduction of nanocarbons, such as graphene and carbon nanotubes, to metal matrices, may enhance the electrical and thermal transport, mechanical properties and some other properties of the composite materials. However, uniform distribution of the nanocarbon phase in the matrix material and manufacturing the composites in large scale can be challenging using traditional mixing methods. In this study, a facile method to fabricate metal-nanocarbon composites was developed. Firstly, copper (Cu)-polydopamine (PDA) composite was fabricated by coating Cu powders with the bioinspired PDA polymer, which was then converted to a graphite-like structure during the subsequent sintering. In terms of the properties, compared to the pure Cu sample, the Cu-PDA composite showed increased electrical and thermal conductivity, higher microindentation hardness, and enhanced wear resistance. These findings suggest the inclusion of nanocarbon phase converted from PDA can simultaneously improve the electrical, thermal, and mechanical properties of sintered Cu materials. Effect of sintering temperature and coating time (carbon content) on the microstructure and properties of the composites were discussed. Secondly, aluminum (Al)-copper nanoparticles (CuNP)-PDA composite was fabricated with a new method, to improve the sintering behavior of Al for serving as feedstock materials of additive manufacturing (AM). CuNPs were synthesized by directly reducing Cu ions in the aqueous solution. With the assistance of the PDA coating, the CuNPs can be better attached to the Al powder surfaces. The composite samples showed better sintering behavior by exhibiting higher electrical conductivities and mechanical properties, which may be due to local nanosized alloying phases generation after sintering. These findings illustrated that the composite powders could be a good candidate feedstock material for AM. The structural characterizations of the metal nanocarbon powders and the composites were performed with SEM, TEM, XRD and Raman spectroscopy. With the help of these techniques, the formation of the targeted structures in the composite was studied, including graphite-like structures of cPDA and nano alloying phases in Al-CuNP-PDA composites. Apart from the composite materials fabrication, a novel and facile manufacturing method based on metal powders was also developed. In this study, a new type of Cu- binder paste was formed, which not only can be utilized with direct ink/paste printing but also can be casted into a soft silicone rubber mold. Three-dimensional (3D) metal parts can then be subsequently obtained after sintering. Comparing to other additive manufacturing methods that involve high energy laser or electron beams, this new approach does not require expensive facilities, and it is less time-consuming. Moreover, the silicone rubber molds can be easily removed and reused. In summary, the composite powders fabricated in this study can be utilized as feedstock materials for additive manufacturing of metals and alloys. The new soft-mold casting could be used as an alternative method to manufacture 3D metal components. Therefore, the materials and the processing methods developed in the current study could have broad applications in various metal industries.