Sara Huerta, ” Synthesis and Characterization of Graphene-Reinforced Al-8Ce-10Mg Nanocomposites via Additive Manufacturing Techniques”
Mentor: Pradeep Rohatgi, Materials Science & Engineering
Poster #64

The integration of graphene into metal matrices holds promise for enhancing mechanical properties, yet its effective incorporation remains a challenge. This study presents the synthesis and characterization of Graphene-reinforced Al-8Ce-10Mg alloy composites through an additive manufacturing technique. The aim was to augment the mechanical properties of the base alloy by introducing 0.5 wt% graphene. Gas atomized Al-8Ce-10Mg powder (Eck Industries) and high-quality graphene (Graphite Central, USA) were mixed with toluene in an Attritor mill at 230 rpm for 120 minutes. Stainless steel balls (5 and 10 mm diameter, 8:1 ball-to-powder ratio) were used for milling, with 20-minute cycles and 10-minute breaks. The powder underwent vacuum oven drying at 70°C and was then placed in an anti-static container filled with Argon gas, followed by additive manufacturing. Successfully fabricated cylindrical structures (with 8 mm in diameter and approximately 4 mm in height) were achieved. using a laser powder bed fusion (LPBF) system (SLM 125HL), with two sets of parameters: 200W laser power with scan speeds of 200-1200 mm/s and 350W laser power with scan speeds of 900-2600 mm/s. Relative densities were analyzed via Image Analysis and absolute densities using Archimedes’ method. Phase analysis using X-ray diffraction (XRD) and microstructural evaluations and elemental mapping analysis (optical microscopy, SEM/EDS, and HRTEM) were performed. Raman spectroscopy to prove the presence of graphene in the microstructure and particle size analysis (Mastersizer 3000) were conducted.  Microhardness testing examined mechanical properties of the cylindrical composite samples compared to additively manufactured Al-8Ce-10Mg alloy with similar parameters. This methodology aimed to optimize graphene incorporation into composites via LPBF while characterizing their structural and mechanical properties for potential industrial applications. The methodology demonstrated not only the feasibility of incorporating graphene into Al-8Ce-10Mg alloy matrices via additive manufacturing (LPBF) but also underscored the potential for microstructural evolution and improvement of mechanical properties. This work lays the foundation for further research in advanced materials engineering and industrial applications.