Ton-scale metal–carbon nanotube composite: The mechanism of strengthening while retaining tensile ductility

One-dimensional carbon nanotubes (CNT), which are mechanically strong and flexible, enhance strength of the host metal matrix. However, the reduction of ductility is often a serious drawback. Here, we report significantly enhanced plastic flow strength, while preventing tensile ductility reduction, by uniformly dispersing CNTs in Al matrix. Nanoscale plasticity and rupturing processes near CNTs were observed by in-situ mechanical tests inside Transmission Electron Microscope (TEM). CNTs act like forest dislocations and have comparable density (∼10¹⁴/m²), and such 1D nano-dispersion hardening is studied in detail by in situ TEM and molecular dynamics simulations. Rupture-front blunting and branching are seen with in situ TEM, which corroborates the result from macro-scale tension tests that our Al+CNT nanocomposite is quite damage- and fault-tolerant. We propose a modified shear-lag model called “Taylor-dispersion” hardening model to highlight the dual roles of CNTs as load-bearing fillers and “forest dislocations” equivalent that harden the metal matrix, for the plastic strength of metal+CNT nanocomposite.