Novel metal-matrix composites with integrally-bound nanoscale carbon

We characterized the chemical, thermophysical, and mechanical properties of nanomaterials with up to 5 wt% nanocarbon (aka "covetics") in aluminum and copper metals. The nanocarbon is detectable by EDS and XPS but not by analytical methods such as LECO and GDMS. Nanocarbon raises the melting point and significantly alters surface tension, and thus porosity, during solidification. Open questions remain about the observation of higher density than would be predicted by the rule of mixtures. In aluminum alloys, we observed an increase in as-rolled strength and hardness with increasing amounts of nanocarbon. In copper, thermal conductivity was anisotropic: up to 50% higher in the extrusion direction and at least 25% lower in the transverse direction, and was different between transient and steady state test conditions. In aluminum, we observed a significant increase in electrical conductivity with nanocarbon, from 47 to 67% IACS. These materials are commercially promising because they are produced by conversion of inexpensive carbon powder to nanocarbon in the melt - paving the way for the production of nanomaterials in pyrometallurgical operations with economies of scale.