Abstract
The Al4C3-containing diamond/Al composites encounter a severe hydrolysis problem in moist environment. A 450 nm thick Zr layer was coated onto diamond particles by magnetron sputtering and was transformed to ZrC layer by subsequent heat treatment at 1050 °C. The ZrC-coated diamond particles were then incorporated into Al matrix to prepare diamond(ZrC)/Al composite by gas pressure infiltration. Although Al4C3 is still formed outside the ZrC layer in the diamond(ZrC)/Al composite, the amount of Al4C3 is greatly reduced compared with the unmodified diamond/Al composite. The thermal conductivity declines from 709 W/mK for the unmodified diamond/Al composite to 572 W/mK for the diamond(ZrC)/Al composite, which is attributed to the intrinsically low thermal conductivity of the ZrC layer. This work suggests an optional way of reducing undesirable hydrolytic Al4C3 but maintaining acceptable thermal conductivity in diamond/Al composites by coating ZrC layer onto diamond particles.
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