Microstructural Characterization of Al 4 C 3 in Aluminum-Graphite Composite Prepared by Electron-Beam Melting
We prepared graphite infused aluminum composites by electron-beam vacuum melting and electromagnetic stirring with 0% and 4wt% graphite addition. Bulk density of 2.69 g/cm 3 was measured for samples with 0% graphite addition (AlCv0) and 2.66 g/cm 3 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, Al 4 C 3 , and graphite. Electron microscopy and energy dispersive X-ray spectroscopy revealed pockets of carbon rich phase of 10 to 50 μm in sizes dispersed in the Al matrix in AlCv4. Scanning transmission electron microscopy (STEM) showed that Al 4 C 3 crystallites of 1-2 μm sizes that 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.