High-performance graphene/aluminum composites: progress and challenges from an industrial perspective

Graphene/aluminum (Gr/Al) composites are regarded as a promising class of lightweight, high-performance materials for aerospace, automotive, and electronics applications. Graphene's exceptional mechanical, thermal, and electrical properties are integrated with aluminum's favorable density and formability. From an industrial perspective, different methods for producing graphene are analyzed, and graphene/aluminum composites are discussed. The industrialization bottlenecks and path strategies for high-performance Gr/Al composites are analyzed. The major bottlenecks are uniform dispersion of graphene in Al matrix, suppression of the harmful Al₄C₃ interfacial phase, and cost control for large-scale production. The former two problems are addressed by the development of low-cost graphene surface modification technology. The latter problem can be solved by combining different composite technologies, such as spark plasma sintering and casting, which enables excellent microstructure controllability and efficiency. This dual-path framework is provided as a practical reference for the commercialization of Gr/Al composites.