Reviews on formation and tailoring of interfacial Al4C3 phase in carbon/aluminum composites

Graphene, carbon nanotube, and carbon fiber applied as reinforcements have poor wettability and weak bonding with aluminum matrix, which limit the function utilization of these carbon materials. The reaction between carbon and aluminum transforms the bonding of carbon/aluminum interface into partial reaction bonding, thereby enhance availably the interface strength and its efficiency of load and function transfers. Unfortunately, a large amount of brittle Al4C3 is readily formed by the interface reaction under high temperatures, leading to obvious damages of the carbon reinforcements. Aiming the tailoring of Al4C3 phase, the nucleation and growth mechanisms of Al4C3 and its effects on the interface bonding and performance of carbon/aluminum composites were introduced in this paper. Subsequently, the studies on the tailoring of Al4C3 amount and morphology, and the achieved results were reviewed from the aspects such as surface coating and nanoparticle decoration of carbon reinforcements, alloying of aluminum matrix, and optimizations of fabrication, hot working and treatment processes. The investigation focuses on the interface and performance of the composites were proposed finally. The maximum reinforcing potentials of graphene, carbon nanotube, and carbon fiber on aluminum matrix would be explored via multi-scaled designing of these carbon reinforcements and tailoring of the interface configurations. © 2024 Central South University of Technology. All rights reserved.