Direct Observation of Induced Graphene and SiC Strengthening in Al–Ni Alloy via the Hot Pressing Technique

In this study, Al/5 Ni/0.2 GNPs/x SiC (x = 5, 10, 15, and 20 wt%) nanocomposites were constituted using the powder metallurgy–hot pressing technique. The SiC particles and GNPs were coated with 3 wt% Ag using the electroless deposition technique then mixed with an Al matrix and 5% Ni using ball milling. The investigated powders were hot-pressed at 550 °C and 600 °C and 800 Mpa. The produced samples were evaluated by studying their densification, microstructure, phase, chemical composition, hardness, compressive strength, wear resistance, and thermal expansion. A new intermetallic compound formed between Al and Ni, which is aluminum nickel (Al3Ni). Graphene reacted with the Ni and formed the nickel carbide Ni3C. Additionally, it reacted with the SiC and formed the nickel–silicon composite Ni31Si12 at different percentages. A proper distribution for Ni, GNs, and SiC particles and excellent adhesion were observed. No grain boundaries between the Al matrix particles were discovered. Slight increases in the density values and quite high convergence were revealed. The addition of 0.2 wt% GNs to Al-5Ni increased the hardness value by 47.38% and, by adding SiC-Ag to the Al-5Ni-0.2GNs, the hardness increased gradually. The 20 wt% sample recorded 121.6 HV with a 56.29% increment. The 15 wt% SiC sample recorded the highest compressive strength, and the 20 wt% SiC sample recorded the lowest thermal expansion at the different temperatures. The five Al-Ni-Gr-SiC samples were tested as an electrode for electro-analysis processes. A zinc oxide thin film was successfully prepared by electrodeposition onto samples using a zinc nitrate aqueous solution at 25 °C. The electrodeposition was performed using the linear sweep voltammetric and potentiostatic technique. The effect of the substrate type on the deposition current was fully studied. Additionally, the ohmic resistance polarization values were recorded for the tested samples in a zinc nitrate medium. The results show that the sample containing the Al-5 Ni-0.2 GNs-10% SiC composite is the most acceptable sample for these purposes.