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Microstructural characterization of Al4C3 in aluminum–graphite composite prepared by electron-beam melting

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Abstract

We prepared graphite-infused aluminum composites by electron-beam vacuum melting and electromagnetic stirring with 0% and 4 wt% graphite addition. Bulk density of 2.69 g/cm3 was measured for samples with 0% graphite addition (AlCv0) and 2.66 g/cm3 for samples with 4 wt% graphite addition (AlCv4). Both are > 99% of their theoretical values. X-ray diffraction indicated that AlCv0 is phase pure, while the AlCv4 sample is a composite consisting of aluminum, Al4C3, and graphite. Electron microscopy and energy-dispersive X-ray spectroscopy revealed pockets of carbon-rich phase of 10–50 μm in sizes dispersed in the Al matrix in AlCv4. Scanning transmission electron microscopy showed that Al4C3 crystallites of 1–2 μm sizes are mostly located near the outer shell of the pockets of carbon-rich phase and with undissolved graphite at the center. Thermal conductivity of 107.8 W/m K was measured for the AlCv4 and 226.7 W/m K for the AlCv0. Our work demonstrated the feasibility of producing pore-free high-density graphite-infused aluminum composite materials by electron-beam melting and electromagnetic stirring in vacuum.

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Acknowledgements

This work was funded by the US Department of Energy (DOE), Advanced Manufacturing Office, under Contract No. DE-AC02-06CH11357. This work was performed, in part, at the Center for Nanoscale Materials, a US Department of Energy Office of Science User Facility, and supported by the US Department of Energy, Office of Science, under Contract No. DE-AC02-06CH11357. The authors are grateful to Dr. R. A. Erck in the Energy Systems Division and Dr. R. E. Koritala in the Nanoscience and Technology Division at Argonne National Laboratory for their technical assistance.

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Authors and Affiliations

  1. Energy Systems Division, Argonne National Laboratory, Argonne, IL, 60439, USA

    Beihai Ma, Tae H. Lee, Stephen E. Dorris & Uthamalingam Balachandran

  2. Center for Nanoscale Materials, Nanoscience and Technology Division, Argonne National Laboratory, Argonne, IL, 60439, USA

    Jie Wang & Jianguo Wen

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  1. Beihai Ma
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  3. Tae H. Lee
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Correspondence to Beihai Ma.

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Disclaimer The submitted manuscript has been created by UChicago Argonne, LLC, Operator of Argonne National Laboratory (“Argonne”). Argonne, a U.S. Department of Energy Office of Science laboratory, is operated under Contract No. DE-AC02-06CH11357. The U.S. Government retains for itself, and others acting on its behalf, a paid-up nonexclusive, irrevocable worldwide license in said article to reproduce, prepare derivative works, distribute copies to the public, and perform publicly and display publicly, by or on behalf of the Government.

This work was supported by the U.S. Department of Energy, Energy Efficiency and Renewable Energy, Advanced Manufacturing Office, under Contract No. DE-AC02-06CH11357.

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Ma, B., Wang, J., Lee, T.H. et al. Microstructural characterization of Al4C3 in aluminum–graphite composite prepared by electron-beam melting. J Mater Sci 53, 10173–10180 (2018). https://doi.org/10.1007/s10853-018-2336-y

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