Search Results (17)

Improving the energy release and safety of composite solid propellants is a key focus in energetic materials research. Graphene, with its excellent thermal conductivity and lubrication properties, is a promising additive. In this study, Al@AP core–shell particles doped with graphene were prepared via an in-situ deposition method. The structure, thermal decomposition, combustion, and safety performance of the graphene-doped Al@AP samples were investigated. Results showed that AP effectively coated aluminium to form a typical core-shell structure, with graphene uniformly loaded into the framework. Graphene contents of 1.0 and 4.0 wt.% reduced AP’s thermal decomposition temperature by 0.97 and 16.68 °C, respectively. Closed-bomb and laser ignition tests revealed that pressure rise rates and combustion intensity increased with graphene content up to 1.0 wt.% but declined beyond that. Peak pressure reached 114.65 kPa at 1.0 wt.% graphene, and the maximum pressure increase rate was 13.29 kPa ms⁻¹ at 2.0 wt.%. Additionally, graphene significantly improved safety by reducing sensitivity to impact and friction. The enhanced performance is attributed to graphene’s large surface area and excellent thermal and electrical conductivity that promote AP decomposition and combustion, combined with its lubricating effect that enhances safety, though excessive graphene may hinder these benefits. This study provides balanced design criteria for graphene-doped Al@AP as solid propellants. Full article

The present paper is dedicated to the search for an alternative material based on an aluminum (Al)—few-layer graphene (FLG) composite for use in electrical applications. Due to its excellent properties, graphene has the potential for use in many applications, especially in electronics, electrical engineering, aerospace, and the automotive industry. One area where the properties of graphene can be exploited is in overhead power transmission, where the main challenge at the moment is to reduce transmission losses. The utilization of conductors that exhibit superior electrical conductivity is instrumental in ensuring the mitigation of transmission losses. The utilization of graphene or other carbon allotropes is appealing due to their elevated electrical conductivity, substantial mechanical strength, and considerable heat resistance, which can enhance the properties of the composite, thereby increasing its resistance to operational conditions, particularly long-term exposure to temperature, a parameter closely related to the current carrying capacity of the OHL. This article presents the findings of research on the production of a composite based on aluminum powder and graphene, as well as the identification of its electrical and mechanical properties. The primary challenge in this research lies in the development of a method to synthesize carbon materials with aluminum using powder metallurgy, with particular attention paid to the mixing and compacting process, which is of significant importance in ensuring the appropriate distribution of carbon material in the composite. The research carried out has determined the influence of the graphene content (0.1–1 wt.%) on the electrical conductivity (max. 35.4 MS/m) and mechanical properties of Al-FLG composites (UTS = 156 MPa). Full article

This research presents a comprehensive dynamic finite element analysis (FEA) of a cryogenic fuel tank made from an innovative aluminium/lithium–graphene nano-composite material, assessing its suitability for aerospace launch vehicles carrying cryogenic hydrogen and oxygen. The study focuses on the effects of lightweighting, utilizing 0.5 wt.% reinforced graphene in the Al 2195 matrix, a material poised to revolutionize the aerospace industry. Objectives include developing a digital twin of the fuel tank, CAD modeling to aerospace standards, and conducting ANSYS simulations under launch conditions to evaluate stress, strain, and deformation. Numerical results reveal a significant weight reduction of approximately 19,420 kg and a notable maximum stress reduction of 1.3% compared to traditional Al 2195 alloy tanks. The novelty of this research lies in its pioneering analysis of aluminium/lithium–graphene composites for lightweighting in cryogenic fuel tanks under space launch conditions. Conclusions affirm the composite’s viability, advocating for the development of lighter yet robust aerospace structures and fostering innovation in spacecraft design and materials science. Full article

Addressing the exceptional properties of aluminium alloy composites reinforced with graphene, this study presents an interpretable machine learning approach to aid in the rapid and efficient design of such materials. Initially, data on these composites were gathered and optimised in order to create a dataset of composition/process-property. Several machine learning algorithms were used to train various models. The SHAP method was used to interpret and select the best performing model, which happened to be the CatBoost model. The model achieved accurate predictions of hardness and tensile strength, with coefficients of determination of 0.9597 and 0.9882, respectively, and average relative errors of 6.02% and 5.01%, respectively. The results obtained from the SHAP method unveiled the correlation between the composition, process and properties of aluminium alloy composites reinforced with graphene. By comparing the predicted and experimental data in this study, all machine learning models exhibited prediction errors within 10%, confirming their ability to generalise. This study offers valuable insights and support for designing high-performance aluminium matrix composites reinforced with graphene and showcases the implementation of machine learning in materials science. Full article

Graphene has become an ideal reinforcement for reinforced metal matrix composites due to its excellent mechanical properties. However, the theory of graphene reinforcement in graphene/aluminum matrix composites is not yet well developed. In this paper, the effect of different temperatures on the mechanical properties of the metal matrix is investigated using a classical molecular dynamics approach, and the effects of the configuration and distribution of graphene in the metal matrix on the mechanical properties of the composites are also described in detail. It is shown that in the case of a monolayer graphene-reinforced aluminum matrix, the simulated stretching process does not break the graphene as the strain increases, but rather, the graphene and the aluminum matrix have a shearing behavior, and thus, the graphene “pulls out" from the aluminum matrix. In the parallel stretching direction, the tensile stress tends to increase with the increase of the graphene area ratio. In the vertical stretching direction, the tensile stress tends to decrease as the percentage of graphene area increases. In the parallel stretching direction, the tensile stress of the system tends to decrease as the angle between graphene and the stretching direction increases. It is important to investigate the effect of a different graphene distribution in the aluminum matrix on the mechanical properties of the composites for the design of high-strength graphene/metal matrix composites. Full article

Graphene-reinforced aluminium composites have been widely studied due to their excellent mechanical properties. However, only a few studies have reported their dynamic compression properties. The purpose of this study is to investigate the quasi-static and dynamic compression properties of graphene-reinforced aluminium composites. The addition of graphene improved the compressive stress resistance and energy absorption capacity of the aluminium matrix. An aluminium-0.5 wt.% graphene composite exhibited good compressive properties due to the different interfacial wave impedance generated by the additional grain boundaries or Aluminium-Graphene interfaces. Full article

In this work, the microstructure and wear characteristics of a surface-reinforced composite based on an aluminium alloy with a mixture of graphene nanoplatelets (GNP) and silicon carbide (SiC), referred to as g-SiC, fabricated by Friction Stir Processing (FSP), are investigated. To further improve the tribological performance, different volume fractions (0 vol%, 5 vol%, 10 vol% and 15 vol%) of g-SiC-reinforced aluminium alloy are prepared by FSP. It is concluded that the Friction Stir Processed (FSPed) AA5083/g-SiC (15 vol%) specimen has optimum reduction in average friction coefficient (61.13%) and optimum reduction in specimen weight (72.97%). In summary, such hybrid reinforcements effectively improve the mechanical and tribological properties of metals with minimal negative impact on the environment and humans, while reducing material loss and overall manufacturing costs. Full article

This work investigates the feasibility of increasing the electric conductivity of an AA1370 aluminium wire by using pulse-reverse electrodeposition to realize Cu-Graphene composite coating. The graphene adopted was in the form of nanoplates (GnP). To study the effects of plating parameters, a 2³ factorial plan was developed and tested. During the tests, the following process parameters were varied: the current density, the frequency and the duty cycle. The ANalysis Of VAriance (ANOVA)) was adopted to evaluate their influence on the coated wires’ morphology and electrical conductivity resistance. The results show that all the tested conditions allow good compactness to the coating, and the amount of graphene is well incorporated within the microstructure of the copper deposit. In addition, in the best conditions, the electrical resistivity decreases up to 3.4% than the uncoated aluminum. Full article

Efficient and effective lubricants have great application prospects in the manufacturing industries. Minimum quantity lubrication (MQL) machining with low flow rate of nanolubricants is investigated for cooling and lubrication during the process. This paper investigates the characterization of graphene-mixed aluminium oxide (G-Al₂O₃) hybrid nanomixture spent lubricants for MQL machining purposes. The main advantage of this method is to reduce the disposal lubricants to develop high-performance cooling-lubrication by using nanolubricants of G-Al₂O₃ nanoparticles in different volume composition ratios at a constant 1.0% volume concentration in a base liquid mixture of 40% spent lubricants. Before conducting the measurements of the nanolubricants’ thermal conductivity and dynamic viscosity, the nanolubricants were homogenous and stable. The tribological performance of all ratios was evaluated by using a four-ball wear tribotester machine. The thermal conductivity peak value for the G-Al₂O₃ hybrid nanolubricant was obtained and the highest enhancement, up to 29% higher than the base liquid solution, was obtained. The dynamic viscosity variation for all ratios was lower than the 40:60 ratio. The properties enhancement ratio suggests that G-Al₂O₃ hybrid nanolubricants with 1.0% volume concentration aid in the heat transfer, especially for ratios of 60:40 and 20:80. The lowest coefficient of friction (COF) for a ratio of 60:40 was obtained to be 0.064, with 45% enhancement as compared to the base liquid solution. In conclusion, optimum ratios for G-Al₂O₃ hybrid nanolubricants were determined to be 20:80 and 60:40. Regarding the properties enhancement ratio, the combination of enhanced thermophysical and tribological properties had more advantages for cooling lubrication application. Full article

Research in metal matrix composites (MMCs) indicates that superior mechanical properties may be achieved by embedding reinforcement materials. However, the development of new composite powder for additive manufacturing requires an in-depth understanding of its key characteristics prior to its use in the fabrication process. This paper focuses on the low-energy ball milling (LEBM) of aluminium 2024 alloy (AA2024) reinforced with graphene nanoplatelets (GNPs). The main aim is to investigate the effect of the milling time (from 0.5 to 16 h) on the morphology and flowability of the powder. The study shows that, while short milling times (under 2 h) could not break the Van der WaRals forces between nanoparticles, GNPs were well separated and sufficiently covered the powder surface after 4 h of milling, thanks to the continuously applied impact energy. Longer milling time provides increasingly similar flowability results, confirmed by both the experimental work and discrete element model (DEM) simulations. Moreover, the ball milling process decreases the crystallite size of the milled powder by 24%, leading to a 3% higher microhardness. Lastly, the surface energy of the powder was determined as 1.4 mJ/m² by DEM, using the angle of repose of the as-received powder from experimental work. Full article

Thixoforming is a promising method that offers several advantages over both liquid and solid processing. This process utilizes semi-solid behaviour and reduces macrosegregation, porosity and forming forces during the shaping process. Microstructural and mechanical characterization of 0.3, 0.5 and 1.0 wt% graphene nanoplatelet (GNP) reinforced A356 aluminium alloy composite fabricated by thixoforming was investigated. Stir casting was employed to fabricate feedstocks before they were thixoformed at 50% liquid. The microstructure was characterized and evaluated by field emission scanning electron microscopy with an energy dispersive X-ray detector and X-ray diffraction. Mechanical testing, such as microhardness and tensile testing, was also performed to estimate the mechanical properties of the composites. The incorporation of 0.3 wt.% GNPs in Al alloy increased by about 27% in ultimate tensile strength and 29% in hardness. The enhancement in tensile strength is primarily attributed to load transfer strengthening due to the uniform dispersion of these GNPs within the Al matrix, which promotes effective load transfer during tensile deformation, and GNPs’ wrinkled surface structure. Simultaneously, the addition of GNPs enhances the grain refinement effect of the Al alloy matrix, resulting in a grain size strengthening mechanism of the GNPs/Al composites. The results reveal that thixoformed composite microstructure consists of uniformly distributed GNPs, α-Al globules and fine fibrous Si particles. The composites’ grains were refined and equiaxed, and the mechanical properties were improved significantly. This study creates a new method for incorporating GNPs into Al alloy for high-performance composites. Full article

The development of aluminium composite with the inclusion of advanced materials is a continuous research process due to the increasing industrial demand for advanced hybrid materials. To cater for this need, this research work focuses on the development of Al 7075 alloy reinforced with TiB₂ and graphene and on the evaluation of its strengthening mechanism. Two different modes of improving the strength of the hybrid composite have been followed; one is by the inclusion of graphene at three levels of 0.1, 0.2 and 0.3%, and another by the processing route, squeeze casting technique by compression of the molten hybrid composite slurry before casting. The microstructure and characterisation of the composite material are examined and analysed with the help of XRD, SEM, EDAX and chemical spectroscopy. A microstructure evaluation is employed to justify the homogenous dispersal and the existence of reinforced particles. A tensile test is conducted at room temperature and high temperature environments to assess the tensile strength. The research outcome affirms that a significant improvement in tensile and hardness has been noted in comparison with base alloy. The fracture-morphology results affirm the change in fracture mode from brittle to ductile when the tensile testing environment changes from room temperature to high temperature. Finally, the dispersion strengthening mechanism is validated with an empirical approach. Full article

From the aspect of exploring the alternative lightweight composite material for the aerospace launch vehicle external fuel tank structural components, the current research work studies three different grades of Aluminium alloy reinforced with varying graphene weight percentages that are processed through powder metallurgy (P/M) route. The prepared green compacts composite ingots are subjected to microwave processing (Sintering), hot extruded, and solution treated (T6). The developed Nano-graphene reinforced composite is studied further for the strength–microstructural integrity. The nature of the graphene reinforcement and its chemical existence within the composite is further studied, and it is found that hot extruded solution treated (HEST) composite exhibited low levels of carbide (Al₄C₃) formations, as composites processed by microwaves. Further, the samples of different grades reinforced with varying graphene percentages are subjected to mechanical characterisation tests such as the tensile test and hardness. It is found that 2 wt% graphene reinforced composites exhibited enhanced yield strength and ultimate tensile strength. Microstructural studies and fracture morphology are studied, and it is proven that composite processed via the microwave method has exhibited good ductile behaviour and promising failure mechanisms at higher load levels. Full article

Pure aluminium poses inferior properties that limit its use in load-bearing applications. Reinforcing multiwall carbon nano-tube (solid lubricant) and graphene to aluminium matrix offers better (antifriction, hardness, and wear resistance) properties in composites for such applications. A stir casting processing route is employed to prepare the hybrid composite (aluminium-multiwall carbon nanotube-graphene Al-MWCNT-GR). The Taguchi L16 experimental matrix representing four variables (percent reinforcement of graphene, die temperature, melt temperature, and stir speed) operating at four levels were studied to analyze and obtain higher hardness and low wear rate in hybrid composites. Percent reinforcement of graphene showed maximum impact, and die temperature resulted with the least contribution towards both the responses. Criteria importance through intercriteria correlation (CRITIC) method is applied to determine the weight fractions (importance) for hardness and wear rate equal to 0.4752 and 0.5482, respectively. Grey relational analysis (GRA) and multi-objective optimization by the ratio analysis (MOORA) method converts multiple objective functions into a single objective function with weight fractions assigned to each output. Taguchi-CRITIC-MOORA outperformed the Taguchi-CRITIC-GRA method, which could result in 31.77% increase in hardness and a 36.33% decrease in wear rate compared to initial conditions. The optimal conditions ensure a dense microstructure with minimal pores, result in enhanced properties compared to that obtained for initial and average stir casting conditions. The worn-out surface results in a few thin and slender grooves between tracks with less crack propagation, ensuring self-lubrication in composites fabricated with the optimized condition. The better properties resulted in the hybrid composites correspond to optimized stir casting conditions and can be implemented in industries for large-scale applications. Full article

Previously, we reported that amorphous poly(ethylene terephthalate) (PET) filled with irregular nodular aluminium (Al) particles gave simultaneous increases in tensile modulus, tensile strength, and impact resistance, which is unusual for materials. Here, we investigated the effect of the particle shape and size by using nano-platelet Al. The Al nano-platelets had a thickness higher than graphenes and clays, but lower than mica and talc, and due to their large widths, they had high aspect ratios. Due to the ductility of Al, the platelets maintained the high aspect ratio and did not snap during injection moulding. In addition to avoiding the usual drop in tensile strength and impact, the composites with nano Al platelets gave an unusually high flexural modulus (8 GPa), which was almost double that attained practically with talc, mica, and graphene. This was because of the high tendency of the Al nano platelets to become oriented during moulding. The Al–PET composite would be a more cost-and-performance effective combination for making conductive composites. The Al is a cheaper material than graphene, surface treatment for adhesion (to PET) is unnecessary, and dispersion issues, such as exfoliation and de-aggregation, are not a problem. Full article