Development of novel cellular copper–aluminum composite materials: The advantage of powder metallurgy and mechanical milling approach for lighter heat exchanger

Abstract

Herein, a precise approach for the fabrication of cellular Cu–Al composite materials with favorable physical properties was developed. Hence, the obvious characteristics of cellular Cu-based materials were markedly improved by the incorporation of light metal of Al in Cu matrix using a ball milling method and polyethylene glycol as a space holder. Porous copper-aluminum composite materials were manufactured with uniform pore size distribution with porosity percentages of 37%–88% and pore sizes within the range of 50–200 μm. Two prominent types of Cu–Al cellular composite materials were produced. The first type showed an open-cell microstructure with polyhedral pores, high volume porosity of 88%, yield strength of 0.5 MPa, superior thermal conductivity (42 W/m.k), and outstanding electrical conductivity (0.057 × 10 8 (Ω−1. m−1)). The second type with a semi-open cell microstructure and spherical pore shape exhibited a favorable yield strength of 42 MPa, a good elastic modulus of 183 MPa, and an acceptable ductility of 35%. This process contributes to the development of cellular copper-based materials used in industrial applications such as filters, fuel cells, and heat exchangers. This research also lays the groundwork for the production of different types of cellular composite materials with varied characteristics and applications.