Using graphene for the development of novel aluminum alloys with high thermal conductivityand mechanical properties

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Technological innovation relies on the availability of materials capable of sustaining diverse mechanical, thermal, cyclic or environmental conditions. There is a global shift in the transportation industries towards electrification of vehicles. To support this innovation, however, novel alloys with currently unavailable mechanical, electrical and thermal properties are required. In this NSERC-Alliance program, a novel multi-process approach based on advanced powder metallurgy process (Spark Plasma Sintering, SPS) will be combined with a traditional metalcasting process to develop castable Al alloys with graphene-based additives. The proposed research builds on a strong partnership between researchers from The University of British Columbia, Nemak Canada (supplier of aluminum (Al) castings to the automotive market) and ZEN Graphene Solutions Ltd. (mining company and producer of graphene compounds). Graphene is known to have superb mechanical and thermo-electrical properties. However, its integration (much like other nanomaterials) into large-scale castings has not been successful to-date. Recent work by the proponents showed, that if the SPS technology is used, graphene-based additives can be efficiently integrated into aluminum castings. As a result, this research program focuses on pioneering industry-driven research consisting of: 1) Identifying optimal graphene additives (e.g., graphene oxide (GO), reduced-GO, pure graphene), 2) SPS processing of graphene containing master alloys, 3) Lab-scale metalcasting experimentation to determine optimal addition levels, casting conditions and blending procedures, and finally, 4) Full-scale manufacture of engine blocks and cylinder heads with graphene-based additives. This research has the potential to fundamentally transform the materials used in the transportation industries. By developing ultralight Al alloys with superb mechanical and thermo-electric properties, Nemak and ZEN will spearhead the Canadian manufacturing and mining sectors in technological innovation, and support the inevitable global shift in the transportation industries towards electric modes of transport.