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<p>Graphene-reinforced aluminum matrix composites (AMCs) with high yield strength and high electrical conductivity have attracted much attention, but current processing techniques still face challenges in meeting these performance requirements. In this study, a novel batch production process for aluminum matrix composites, named “in-situ exfoliation and dilution casting (ISEDC),” is systematically investigated. The ISEDC process innovatively uses flake graphite as the precursor of graphene and achieves in-situ exfoliation through continuous casting and rolling, successfully preparing graphene/aluminum composites (ISEDC-AMC). At a carbon content of 0.2 wt%, the ISEDC-AMC exhibits a tensile strength of 182.8&#xa0;MPa and an electrical conductivity of 65.36%, representing a 4.85% improvement in conductivity over the traditional powder metallurgy (PM) process, while maintaining comparable mechanical properties. Additionally, a life cycle assessment comparison analysis is conducted between the ISEDC and PM processes. The study takes the production of 1&#xa0;km of carbon aluminum composite conductive rods as the functional unit. The results show that the carbon dioxide emissions of the ISEDC process are reduced by 28% compared to the PM process. Economic analysis further indicates that the production cost of the ISEDC process is reduced by 57%. In conclusion, this study provides new ideas and technical support for the sustainable manufacturing of new high-performance aluminum matrix composites.</p> Graphical Abstract: <p></p>

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Sustainable Manufacturing of Graphene–Aluminum Composites: A Comparative Life Cycle Assessment

  • 期刊论文

  • 发表日期：

    2025年12月9日

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  • Xinwei Yang,
  • Qian Peng,
  • Changke Chen,
  • Qingcui Liu,
  • Yudai Huang

摘要

Graphene-reinforced aluminum matrix composites (AMCs) with high yield strength and high electrical conductivity have attracted much attention, but current processing techniques still face challenges in meeting these performance requirements. In this study, a novel batch production process for aluminum matrix composites, named “in-situ exfoliation and dilution casting (ISEDC),” is systematically investigated. The ISEDC process innovatively uses flake graphite as the precursor of graphene and achieves in-situ exfoliation through continuous casting and rolling, successfully preparing graphene/aluminum composites (ISEDC-AMC). At a carbon content of 0.2 wt%, the ISEDC-AMC exhibits a tensile strength of 182.8 MPa and an electrical conductivity of 65.36%, representing a 4.85% improvement in conductivity over the traditional powder metallurgy (PM) process, while maintaining comparable mechanical properties. Additionally, a life cycle assessment comparison analysis is conducted between the ISEDC and PM processes. The study takes the production of 1 km of carbon aluminum composite conductive rods as the functional unit. The results show that the carbon dioxide emissions of the ISEDC process are reduced by 28% compared to the PM process. Economic analysis further indicates that the production cost of the ISEDC process is reduced by 57%. In conclusion, this study provides new ideas and technical support for the sustainable manufacturing of new high-performance aluminum matrix composites.

Graphical Abstract: