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Synthesis of Al/Cu core–shell particles through optimization of galvanic replacement method in alkaline solution

Rashid Ali, Fahad Ali, Aqib Zahoor, Rub Nawaz Shahid, Naeem ul HaqTariq, Saad Ullah, Arshad Mahmood, Attaullah Shah and Hasan Bin Awais


In this work, Al/Cu core–shell particles were successfully synthesized through an optimized galvanic replacement method. For this purpose, a uniform and dense copper layer was deposited on aluminum particles in an alkaline solution. The effects of four deposition factors, i. e. (i) molar ratio EDTA-2Na/CuSO4 · 5H2O, (ii) molar ratio CuCl2/Al powder, (iii) pH and (iv) temperature were systematically studied and optimized using the Taguchi orthogonal (L9) method. It was observed that molar ratio EDTA-2Na/CuSO4 · 5H2O and temperature are the most affecting factors in the deposition process. By increasing their levels, copper deposition increases within a specified time. The X-ray diffraction and scanning electron microscopy/ energy-dispersive X-ray spectroscopy results revealed the formation of homogeneous nanostructured Cu shells around Al particles. The results revealed that to achieve maximum copper deposition on Al powder; molar ratio EDTA-2Na. 2H2O/CuSO4. 5H2O, molar ratio CuCl2/Al powder, pH and temperature of the deposition bath should be 2.0, 0.05, 8.8 and 55 °C, respectively.

Prof. Dr. Fahad Ali Department of Metallurgy and Materials Engineering Pakistan Institute of Engineering and Applied Sciences (PIEAS) 45650, Islamabad Pakistan


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Received: 2020-11-30
Accepted: 2021-02-22
Published Online: 2021-05-08
Published in Print: 2021-05-31

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