Synergistic crack inhibition by lamellar structure and graphene nanoplatelets in 2024 Al-GNPs/TC4 laminated metal composites

Al/Ti laminated metal composites (LMCs) benefit from a bionic laminate structure that allows for simultaneous strength and plasticity enhancement. However, the Al layer with lower strength is always the first to crack under stress, resulting in declining mechanical properties of the Al/Ti LMCs. In this study, 2024 Al-GNPs/TC4 LMCs were prepared by replacing the conventional Al or Al alloy layers with 2024 Al-GNPs composites. Its ultimate tensile strength of 757 MPa surpasses that of almost all other Al/Ti LMCs. The lamellar structure and GNPs were found to have a synergistic effect in enhancing the mechanical properties by inhibiting crack extension across and within the layers, respectively. The hindrance of crack extension by the lamellar structure is primarily due to strain delocalization in TC4, as confirmed by phase-field-crystal simulation. On the other hand, GNPs impede crack extension through passivation and deflection, which was revealed by molecular dynamics to be attributed to dislocation hindrance and load transfer. Furthermore, it was confirmed that the main factors affecting the formation of intermetallic compounds are diffusion coefficient and solid solubility. This work provides new insights for breaking the performance limits of LMCs.