Fabrication of Graphene Reinforced Aluminium Metal Matrix Composites for Advanced Tool Materials

In recognition of graphene’s exceptional qualities such as light weight yet superior thermal conductivity and elasticity (200 times stronger than steel), it has been established as a significant player in material science research. Despite its higher cost due to complex extraction and manufacturing processes, it is offered value as a reinforcement agent in more economical materials. The current research work focuses on developing metal matrix composites by reinforcing Aluminum with graphene. Nine distinct samples were manufactured, each containing varying percentages of graphene (0.5%, 1%, and 1.5%), along with copper powders (5%), SiC powders (2%), and Al powders by four steps: powder preparation, powder blending, compaction, and sintering. A Taguchi method with an L9 orthogonal array was utilized to design experiments and set process parameter levels for sample manufacturing, including compaction pressure (KPa), sintering temperature (°C), and sintering time (min.). Micro Vickers hardness (HMV-G21DT) testing revealed that hardness increased with lower sintering temperatures, durations, and medium compaction pressures. Additionally, a detailed study of the microstructure using scanning electron microscope of graphene-reinforced aluminum composites was conducted. Their primary application lies in fabricating tool electrodes for electrical discharge machines, aiming to reduce electrode wear rates.