PNNL

Abstract

Aluminum-based alloys are highly sought after as lightweight alternatives in electric grid applications. Improving the electrical conductivity of aluminum alloys has the potential to increase the energy efficiency of power transport. We used a hot extrusion process to synthesize AA1100 alloy with low-cost reduced graphene oxide nanoparticles to manufacture ultra-conductive aluminum composites in this study. The effects of graphene content on the electrical and mechanical performance of the composites were evaluated. The macroscale AA1100/graphene wires demonstrated a 2.1% enhancement in electrical conductivity at 20 °C, while the ultimate tensile strength increased by 6.1%. A Zener-Hollomon model was used to confirm the in-process exfoliation of the agglomerated graphene nanoparticle feedstock into high electrical conductivity graphene-like flakes during extrusion. They may have provided high-velocity carrier pathways leading to the enhanced electrical performance of the alloy. Transmission electron microscopy at aluminum-graphene interfaces ensures the preclusion of detrimental carbide formation during composite synthesis while confirming the structure graphene-like flakes. The in-process exfoliation provides an economically viable technique to produce bulk scale graphinated aluminum composites for advanced application and can be applied more generally to other alloy systems.