Microstructure, microhardness and thermal expansion of CNT/Al composites prepared by flake powder metallurgy

Carbon nanotube/aluminum (CNT/Al) composites are prepared by a combination of flake powder metallurgy and hot-isostatic-pressing. The specimens are investigated by several techniques including Raman spectroscopy, optical microscopy, scanning- and transmission electron microscopy. The composites show a layered-microstructure with a stacking of CNT/Al flakes with a CNT-rich layer between two flakes. The individual Al grains forming the flakes are about 500 nm in size. The CNTs are well dispersed within a flake and they bridge the micro-cracks. The results reveal that the coefficient of thermal expansion (CTE) decreases markedly upon the increase in carbon content, reaching 15.4 × 10−6 K−1 for the specimen with a carbon content of 2.0 wt% (2.9 vol%), i.e. a 30% decrease compared to the CTE of pure Al. This could arise from the layered-microstructure resulting from the utilization of Al flakes as opposed to rounded particles.