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<p>High-conductivity AA1060 aluminum alloys suffer from low mechanical strength, limiting their applications in structural-functional sectors such as power transmission. Graphene nanoplates (GNP) were selected as reinforcements due to their unique 2D geometry, ultrahigh strength and superior electrical conductivity. However, critical challenges regarding poor wettability and floating persist. This study establishes a systematic preform-assisted stir-ultrasonic casting route to overcome these density-mismatch issues. GNP/1060 Al composites were fabricated using ball-milled and cold-pressed preforms, followed by stir-ultrasonic regulation. Results indicate that optimal comprehensive properties were achieved with 0.5&#xa0;wt.% GNP and 360&#xa0;W ultrasonic power: Under these conditions, the Vickers hardness, ultimate tensile strength, elongation, and electrical conductivity reached 24.65 HV, 63.05&#xa0;MPa, 60.08%, and 38.65% IACS, representing improvements of 32.4%, 63.9%, 52.3%, and 15.7% over the matrix, respectively. Distinct from studies focusing solely on parameter optimization, this work reveals a critical interfacial refinement mechanism, where specific ultrasonic energy regulates the reaction products (Al<sub>4</sub>C<sub>3</sub>) to the nanoscale. This mechanism effectively mitigates the strength-ductility trade-off while preserving electrical conductivity, providing a scientifically grounded strategy for manufacturing high-performance conductive aluminum composites.</p>

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Effect of Stir-Ultrasonic Integrated Casting on Microstructure and Properties of Graphene Nanoplate/AA1060 Composites

  • 期刊论文

  • 发表日期：

    2026年4月10日

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  • Linzhe He,
  • Ripeng Jiang,
  • Ruiqing Li,
  • Renjun Hu,
  • Aolei Fu

摘要

High-conductivity AA1060 aluminum alloys suffer from low mechanical strength, limiting their applications in structural-functional sectors such as power transmission. Graphene nanoplates (GNP) were selected as reinforcements due to their unique 2D geometry, ultrahigh strength and superior electrical conductivity. However, critical challenges regarding poor wettability and floating persist. This study establishes a systematic preform-assisted stir-ultrasonic casting route to overcome these density-mismatch issues. GNP/1060 Al composites were fabricated using ball-milled and cold-pressed preforms, followed by stir-ultrasonic regulation. Results indicate that optimal comprehensive properties were achieved with 0.5 wt.% GNP and 360 W ultrasonic power: Under these conditions, the Vickers hardness, ultimate tensile strength, elongation, and electrical conductivity reached 24.65 HV, 63.05 MPa, 60.08%, and 38.65% IACS, representing improvements of 32.4%, 63.9%, 52.3%, and 15.7% over the matrix, respectively. Distinct from studies focusing solely on parameter optimization, this work reveals a critical interfacial refinement mechanism, where specific ultrasonic energy regulates the reaction products (Al4C3) to the nanoscale. This mechanism effectively mitigates the strength-ductility trade-off while preserving electrical conductivity, providing a scientifically grounded strategy for manufacturing high-performance conductive aluminum composites.