A novel approach to improving the interfacial strength of 3D printed Al–GNP composites by modifying GNP with MgO

In this study, the MgO-coated graphene nanoplatelets (GNP)-reinforced aluminum matrix AlSi10Mg composites are fabricated by mechanical alloying and a 3D printing process. The interfacial structure of GNPs–Al has been investigated using high-resolution transmission electron microscopy, and their strengthening mechanism has been analyzed. A weak amorphous Al2O3 was found at the GNP–Al interface area in the composites made with uncoated GNPs. The structure of amorphous Al2O3 becomes distorted when load transfer is initiated, causing the detachment of GNPs from the matrix. This results in quick failure at the interface between uncoated GNPs and aluminum, restricting its overall strength. Once GNPs are coated with MgO, an Al/C mixing zone forms at the contact area, resulting in increased interface strength. The MgO coating on the GNP serves as a protective barrier, preventing the creation of a weaker amorphous Al2O3 layer at the interface and facilitating direct interaction between the GNP and Al matrix. The stress–strain curve demonstrates a 27.5% enhancement in tensile strength in the MgO-coated GNP–Al composite compared to the composite with uncoated GNPs. The strength is increased while maintaining toughness through load transmission of GNPs, bridging, and enhancing dislocation storage capacity by the Mg-rich phase. This study offers a new reference for strengthening 3D-printed aluminum alloys using GNPs.