Influence of diamond particle size on the properties of diamond/Al composites fabricated by filtration extrusion

High-content diamond/Al composites have great potential for application as heat dissipation substrates in high-power electronic devices due to their superior thermal properties. This study addresses the persistent challenge of efficiently and economically preparing high-content diamond/Al composites. The filtration extrusion technique as a novel approach for fabricating these composites and explore the critical impact of diamond particle size on the extrusion process and the resulting microstructures. Our findings reveal that extrusion force remains minimal at the onset of the process but escalates sharply with an increase in diamond content, peaking upon completion of extrusion. Notably, larger diamond particles precipitate a more abrupt rise in extrusion force during displacement. The composites' density and thermal conductivity exhibit an initial increase followed by a decline as the diamond particle size is incremented, while the thermal expansion coefficient shows a progressive rise with size enlargement. These insights are pivotal for optimizing the fabrication parameters to achieve high-performance diamond/Al composites for thermal management applications.