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This paper concerns the development of a metal composite containing aluminium as phase change material (PCM) and alumina as structural supporting material (SSM) by the cold compression-hot sintering (CCHS) approach. The microstructural characteristics, thermal and mechanical properties and thermal performance of the proposed composite are characterized. For comparison, a salt composite made of NaLiCO3 as PCM and MgO as SSM with the same melting temperature as the proposed composite is also prepared and investigated. The results indicate that the alumina is wettable with liquid aluminium at elevated temperature, establishing confidence in fabrication of such aluminium composite through CCHS technique. The composite has good chemical compatibility with the melting temperature around 660.C, and 45% alumina gives the composite optimal formulation at which a thermal conductivity of 3.75 W/m.K, a mechanical strength of 33 MPa and a thermal energy storage density of 400 kJ/kg over temperature range of 500-700 degrees C can be achieved. The results also indicate that the aluminium composite presents a higher thermal performance than the salt composite. At the same working conditions, the aluminium composite thermal conductivity is over twice as high as that the salt composite while maintaining a similar thermal energy storage density with salt composite.
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