To improve the thermophysical properties of Al alloy for thermal management materials, the Cu-coated carbon fibers (CFs) were used as reinforcement to improve the thermal conductivity (TC) and the coefficient of thermal expansion (CTE) of Al-12Si. The CFs reinforced Al matrix (CFs/Al) composites with different CFs contents were prepared by stir casting. The effects of the CFs volume fraction and Cu coating on the microstructure, component, TC and CTE of CFs/Al composites were investigated by scanning electron microscopy with EDS, X-ray diffraction, thermal dilatometer and thermal dilatometer. The results show that the Cu coating can effectively improve the interface between CFs and the Al-12Si matrix, and the Cu coating becomes Al2Cu with Al matrix after stir casting. The CFs/Al composites have a relative density greater than 95% when the volume fraction of CFs is less than 8% because the CFs uniform dispersion without agglomeration in the matrix can be achieved by stir casting. The TC and CTE of CFs/Al composites are further improved with the increased CFs volume fraction, respectively. When the volume fraction of CFs is 8%, the CFs/Al composite has the best thermophysical properties; the TC is 169.25 W/mK, and the CTE is 15.28 × 10– 6/K. The excellent thermophysical properties of CFs and good interface bonding are the main reasons for improving the thermophysical properties of composites. The research is expected to improve the application of Al matrix composites in heat dissipation neighborhoods and provide certain theoretical foundations.

There is increasing demand for the development of a new material with high strength, high stiffness, and good electrical conductivity that can be used for high-voltage direct current cables. In this study, we develop aluminumbased composites containing C60 fullerenes, carbon nanotubes, or graphene using a powder metallurgical route and evaluate their strength, stiffness, coefficient of thermal expansion, and electrical conductivity. By optimizing the process conditions, a material with a tensile strength of 800 MPa, an elastic modulus of 90 GPa, and an electrical conductivity of 40% IACS is obtained, which may replace iron-core cables. Furthermore, by designing the type and volume fraction of the reinforcement, a material with a tensile strength of 380 MPa, elastic modulus of 80 GPa, and electrical conductivity of 54% IACS is obtained, which may compete with AA 6201 aluminum alloys for use in all-aluminum conductor cables.

Intermetallic compound matrix composites have been expected to be established as high temperature structural components. Ni3Al is a representative intermetallic alloy, which has excellent ductility even at room temperature by adding certain alloying elements. Ni3Al matrix composites with aluminum oxide particles, which are formed by the in-situ reaction between the alloy and aluminum borate whiskers, are fabricated by a powder metallurgical method. The addition of aluminum borate whiskers disperses the synthetic aluminum oxide particles during sintering and dramatically increases the strength of the composite. The uniform dispersion of reaction synthesized aluminum oxide particles and the uniform solution of boron in the matrix seem to play an important role in the improvement in strength. There is a dramatic increase in strength with the addition of the whisker, and the maximum value is obtained at a 10 vol% addition of whisker. The Ni3Al composite with 10 vol% aluminum oxide particles 0.3 μm in size and with 0.1 wt% boron powder fabricated by the conventional powder metallurgical process does not have such high strength because of inhomogeneous distribution of aluminum oxide particles and of boron. The tensile strength of the Ni3Al with a 10 vol% aluminum borate whisker reaches more than twice the value, 930 MPa, of the parent alloy. No third phase is observed between the aluminum oxide and the matrix.

The type, volume fraction, size, shape and arrangement of embedded particles influence the mechanical properties of the particle reinforced metal matrix composites. This presents the investigation of the SiC particle and porosity distributions in various aluminum matrix composites produced by cold- and hot-pressing. The microstructures were characterized by optical microscopy and stereological parameters. SiC and porosity volume fractions, and the anisotropy distribution function were measured to establish the influence of the consolidation method.

This paper presents a new approach for analyzing the microstructure of -reinforced aluminum matrix composites from digital images. Various samples of aluminum matrix composite were fabricated by hot pressing the powder mixtures with certain volume and size combinations of pure Al and SiC particles. Microstructures of the samples were analyzed by computer-based image processing methods. Since the conventional methods are not suitable for separating phases of such complex microstructures, some new algorithms have been developed for the improved recognition and characterization of the particles in the metal matrix composites.