Synergistic performance evaluation of copper–WC-graphene composites: Microstructure, mechanical properties, corrosion, and wear behavior under microwave sintering

Abstract

This study investigates the synergistic performance of copper–WC–graphene composites fabricated using microwave sintering. Optical Microstructure analysis demonstrated a uniform distribution of reinforcing elements (WC and graphene) within the copper matrix across various compositions (Cu - 5 wt % WC, Cu - 5 wt % WC – 2.5 wt % Graphene, Cu - 5 wt % WC – 5 wt % Graphene, Cu - 5 wt % WC – 7.5 wt % Graphene). The SEM images further revealed controlled porosity and crack-free surfaces. Interfacial bond strength among WC, graphene, and copper was evidenced through SEM and wettability results, affirming successful phase integration. Mechanical property assessments unveiled substantial improvements in compressive strength (31.76%) and hardness (67.21%) after incorporating 5 wt % WC and 7.5 wt % graphene. Corrosion resistance was affirmed through minimal weight loss (0.201 mg) in a 3.5 wt % NaCl solution over 120 h. Wear tests exhibited a noteworthy 81.25% reduction in wear rate for Cu - 5 wt % WC – 7.5 wt % Graphene, emphasizing enhanced wear resistance. The coefficient of friction is determined to be 0.265. XRD analysis validates the composite's composition, featuring copper, copper oxide, copper carbide, tungsten carbide, and carbon phases.