Design of high-performance Al₄C₃/Al matrix composites for electric conductor

Increased strength of Al matrix composites (AMCs) with a high electrical conductivity are in demand to replace copper conductors. In this study, a high-performance Al₄C₃/Al composite was synthesized in situ via the high-energy densification of uniform graphene oxide (GO)/Al powder combination; GO was completely transformed to monocrystalline Al₄C₃ nanorod structures, robustly bridging across the Al grain boundary. The formation mechanism of interfacial Al₄C₃ was illustrated by high-resolution transmission electron microscope observations. The Al₄C₃ nanorods were homogeneously dispersed and possessed an intimate and faceted interface with the matrix, resulting in the enhanced tensile strength of Al. Moreover, the Al₄C₃/Al composite retained the required electrical conductivity similar to that of pure Al, in addition to the stable interface at elevated temperatures and long-term service reliability in moist environment. The findings of this study will be significant in providing the basis of designing novel heat-resistant AMCs in electrical applications.