Electrical and structural characterization of nano-carbon–aluminum composites fabricated by electro-charging-assisted process

Incorporating nano-carbon phases into metal-matrix composites is a promising strategy for simultaneously enhancing electrical conductivity and mechanical properties of metals. Here, we describe the manufacture of novel nano-carbon-aluminum composites by an electro-charging-assisted process (EAP) that show 5.6% ± 1.7% increase in electrical conductivity compared to the base metal alloy. The source of nano-carbon that was used in this study is activated carbon with particle size less than 100 nm. The enhancement is attributed to nano-graphitic structures that extend through the lattice of the metal. Through electron transfer from the metal to the nano-structures the electron density at the interface of nano-crystalline graphite and the metal lattice increases thereby enhancing the bulk electrical conductivity. We identify the important fabrication parameters of the EAP for a reaction system employing a tapered graphite cathode. A high current density of 100 A/cm2 causes ionization and crystallization of the carbon in the liquid metal. The increase in electrical conductivity of the composite is directly related to the incorporation of the nanocrystalline carbon in the metal lattice. The superior performance of these nano-carbon aluminum composites makes them promising candidates for power transmission lines and other applications. Incorporating nano-carbon phases into metal-matrix composites is a promising strategy for enhancing electrical conductivity of metals. Here, we describe the manufacture of novel nano-carbon-aluminum composites (known as covetics) by an electro-charging assisted process (EAP) that show 5.6% increased electrical conductivity compared to the alloy matrix. We identify the important fabrication parameters of the EAP for a reaction system with a tapered graphite cathode. A high current density of 100 A/cm2, reaction time of 10 min, and reaction volume hemisphere of 4 mm radius around the electrode are responsible for the formation of graphitic nanostructures within the metal which contribute to the enhancement of electrical conductivity. The superior performance of these nano-carbon aluminum composites makes them promising candidates for power transmission lines and other conducting wires or cables in many applications. [Display omitted]