Synthesis of core-shell Al/Al2O3 composite through aluminum powder oxidation in hot water and its characterization

Abstract

Simple and potentially energy efficient way for synthesis of Al/Al2O3 composites is described. Synthesis method is based on aluminum powder oxidation in water at 100-200 °C and following drying and calcination at 600 °C. Aluminum powder with average size of about 40 urn that is currently applied in additive manufacturing was used. Present work was devoted to the study of oxidation degree of aluminum and so the propagation depth and structure of Al2O3 shell in composite’s matrix. AI/Al2O3 composites were produced in different regimes with different maximum temperature and duration of the process of aluminium oxidation in water. Aluminum oxidation degree and aluminium content in obtained Al/Al2O3 were changed in the range from 5.5 % and 90.1 % to 21.3 % and 66.2 % respectively. The size of single crystals of Al2O3 in shell was changed from about 6 nm to 200 nm and the thickness of Al2O3 shell was changed from about 400 nm to 1000 nm by changing the regime for Al/Al2O3 composite production. Experimental results showed that Al2O3 shell was well clutched with aluminum core. Shell structure had cracks aroused by calcination process. Size distribution for obtained composites was very close for that of initial aluminum powder. All of these characteristics recommend the obtained Al/Al2O3 composites for additive manufacturing.