Copper-based Metal Matrix Research Articles

A comprehensive review of processing techniques, reinforcement effects, and performance characteristics in copper-based metal matrix composites

A comprehensive review of processing techniques, reinforcement effects, and performance characteristics in copper-based metal matrix composites

Sol-Gel Derived Alumina Particles for the Reinforcement of Copper Films on Brass Substrates.

The aim of this study is to provide tailored alumina particles suitable for reinforcing the metal matrix film. The sol-gel method was chosen to prepare particles of submicron size and to control crystal structure by calcination. In this study, copper-based metal matrix composite (MMC) films are developed on brass substrates with different electrodeposition times and alumina concentrations. Scanning electron microscopy (FE-SEM) with energy-dispersive spectroscopy (EDS), TEM, and X-ray diffraction (XRD) were used to characterize the reinforcing phase. The MMC Cu-Al2O3 films were synthesized electrochemically using the co-electrodeposition method. Microstructural and topographical analyses of pure (alumina-free) Cu films and the Cu films with incorporated Al2O3 particles were performed using FE-SEM/EDS and AFM, respectively. Hardness and adhesion resistance were investigated using the Vickers microindentation test and evaluated by applying the Chen-Gao (C-G) mathematical model. The sessile drop method was used for measuring contact angles for water. The microhardness and adhesion of the MMC Cu-Al2O3 films are improved when Al2O3 is added. The concentration of alumina particles in the electrolyte correlates with an increase in absolute film hardness in the way that 1.0 wt.% of alumina in electrolytes results in a 9.96% increase compared to the pure copper film, and the improvement is maximal in the film obtained from electrolytes containing 3.0 wt.% alumina giving the film 2.128 GPa, a 134% hardness value of that of the pure copper film. The surface roughness of the MMC film increased from 2.8 to 6.9 times compared to the Cu film without particles. The decrease in the water contact angle of Cu films with incorporated alumina particles relative to the pure Cu films was from 84.94° to 58.78°.

Development and Characterizations of Microwave Sintered (Al2O3+MoS2) Reinforced Copper-Based Metal Matrix Hybrid composites

Development and Characterizations of Microwave Sintered (Al2O3+MoS2) Reinforced Copper-Based Metal Matrix Hybrid composites

Effect of Hot Rolling on Friction and Wear Characteristics of TiC Reinforced Copper-Based Metal Matrix Composites

The current study examines the effect of titanium carbide reinforcement (TiC) on the tribological behavior of copper metal matrix composites. The stir-casting process followed by hot rolling was employed to fabricate the composite parts. Hot rolling was performed at 510°C temperature with a 90% reduction ratio. An optical microscope, scanning electron microscope with energy dispersion spectroscopy, and Brinell hardness tester were used to investigate the microstructure, reinforcement particle distribution, and hardness. The microstructural investigations witness the uniform distribution of titanium carbide reinforcing agents along with the excellent binding with the copper matrix. The hardness was improved with the addition of titanium carbide content in both casting and rolling specimens. Dry sliding friction and wear tests were employed on a pin-on-disk setup with load values ranging from 30 to 120 N and sliding velocity values ranging from 0.628–2.512 m/s. In both casting and rolling conditions, the composites have a less coefficient of friction and wear rate than the matrix element. Wear rates of the unreinforced and reinforced cast and hot rolled alloys were enhanced as load and sliding velocity was raised. The incorporation of titanium carbide lowered the coefficient of friction and wear rate. In comparison to the unreinforced cast and rolled alloys, the coefficient of friction and wear of cast and rolled copper metal matrix composites was significantly reduced. Scanning electron microscopy was employed to investigate the worn surfaces and wear debris to confirm the possible wear mechanisms.

Investigation of the Dwelling Time and Compaction Pressure Effect on Mechanical Properties and Microstructure of the Cu-Sn Composite

Powder metallurgy has become a compatible alternative method in term of manufacturing complex component, such as frangible bullet. A bullet with frangible properties can be manufactured by using copper-based metal matrix composite with tin as the reinforce. During compaction process, the applied load and dwelling time are considered as substantial factor which affect the final product. Therefore, the aim of the present work study is to observe the pressure and the holding time during the compacting process (dwelling time) which has an impact on the mechanical properties of the Cu-Sn composite product. The green component or pressed product is tested with various compaction pressure variables, namely 500, 600, and 700 MPa with 0, 5, 15, 30, 45 minutes dwelling time, respectively. The sintering process is performed at 260°C for 30 minutes in the horizontal furnace. The result shows that the surface contact area was increased along with the compaction load upsurge which led to low porosity green compact. The 700 MPa compaction pressure with 15 minutes dwelling time has the optimum density, hardness, and compressive strength, which had 8,454 gr/cm3, 87 HRF and 349.74 MPa in value. The compacting product has been tested on Scanning Electron Microscope (SEM) and showed that 700 MPa compaction pressure had the best powder densification process.

Copper Based Powder Metallurgy Composite for Electrical Applications

This paper discusses Copper Metal Matrix Composites. It is obvious that copper matrix composites have been heavily relied upon by many industries because of their high wear resistance, corrosion resistance, excellent electrocatalytic properties, and high strength. The excellent electrical conductivity of copper-based materials also enables these materials to function as lubricants and anti-frictional materials. These materials were widely used in transportation, electrical contact transmission, and aerospace. Copper-based metal matrix composites have wide application due to their excellent mechanical, electrical, and thermal characteristics. Copper based metal matrix composites are also corrosion resistant and have a high strength. A contemporary study evaluated the effects of different parameters on powder metallurgy fabricated copper matrix metal composites. The focus was on understanding the applications and mechanical properties of copper-based composite materials.

Investigation on mechanical properties and deformation behavior of copper-based three-phase metal matrix composite: Experimental and micro-macro-mechanical finite element analysis

The present study involved development of copper-based metal matrix composite, reinforced with waste EN 31 steel chips and TiB2 ceramic particles. Waste EN 31 steel chips and TiB2 ceramic particles were ball-milled for 100 h to obtain a single entity. The composite material was produced with a stir-casting technique, followed by a squeeze pressure process. The addition of Cu + 10 wt% of waste steel chips + 5 wt% of TiB2 improved the tensile strength of the copper matrix by about 68.35%. Furthermore, the addition of Cu + 5 wt% of waste steel chips + 10 wt% of TiB2 and Cu + 12.5 wt% of waste steel chips + 2.5 wt% of TiB2 increased the hardness and toughness of the copper matrix by about 133.33% and 28.57%, respectively. The addition of Cu + 10 wt% waste steel chips + 5 wt% of TiB2 ensured minimal corrosion weight loss in the metal matrix composite as a result of low porosity and a strong bond between the molecules. Further, representative volume element (size: 225 × 225 × 225 nm)-based finite element analysis was done to explain the micro-mechanical deformation, interfacial strength of matrix-particle interaction and damage behavior of Cu + 10 wt% of waste steel chips + 5 wt% of TiB2 metal matrix composite. A user material sub-routine model was also written and implemented with the help of FORTRAN subroutines to simulate the macro-mechanical tension test process of Cu + 10 wt% waste steel chips + 5 wt%TiB2 metal matrix composite. The results revealed a good agreement between the micro-mechanical and macro-mechanical finite element analysis models on the one hand and the experimental results on the other. Further, the representative volume element (with matrix and particles) showed about 59% and 66.5% higher tensile strength compared to the matrix–particle interface and the matrix (without particles), respectively. The percentage difference between the micro-mechanical finite element analysis and the experiments as well as the macro-mechanical finite element analysis and the experiments was found to be 5.58% and 9.64%, respectively. The finite element analysis results established that the waste steel chip powder particles exhibited greater stress than the TiB2 powder particles.

Studies on wear behaviour of silicon carbide and fly ash reinforced copper based metal matrix composites

Metal Matrix Composites (MMC) are engineering materials which combines two or more dissimilar materials to attain improved properties. In the present investigation, copper and Silicon Carbide (SiC) - Fly ash are used as the matrix and reinforcements phases respectively. The MMCs are produced by powder metallurgy. Two composites where prepared with Cu (95%) and SiC (5%), Cu (90%), and SiC (5%) and Fly Ash (5%) is mixed for reinforcements. By using Scanning Electron Microscope (SEM), the microstructural analysis is done to assess the distribution of reinforcement particulates in the copper matrix phase. Dry sliding wear characteristics was studied by pin on disc tribometer.

A Re-investigation: Effect of various parameter on mechanical properties of copper matrix composite fabricated by powder metallurgy

In this study, a re-investigation on metal matrix composite fabricated by powder metallurgy route has been done. Copper based metal matrix composite has the wide applications because of their good electrical, thermal and mechanical properties. Copper has good strength and resistance to corrosion. But in order to increase the properties of copper, copper matrix composite has been fabricated by powder metallurgy process. The composites materials fabricate by powder metallurgy process has various property such as hardness, tensile strength, compressive strength, toughness, fatigue strength. These properties depend on some parameter such as reinforcement, pressure during powder compaction, temperature of sintering, holding time at sintering temperature, particle size, volume fraction of reinforcement etc. This study shows investigation of effect of various parameter on mechanical property of copper-based metal matrix composites. It has shown that due to presence of secondary phase hard particle like alumina, SiC, titanium carbide, TiO2 in copper metal matrix increase hardness, strength and reduce density. Reduction in density is very important in order to fabrication of automobile and aircraft parts. The strength and hardness increase with addition of SiC but ductility is reduced. It is shown that sintering temperature and sintering time is most important parameter because it highly influences hardness and strength.

Effect of xGnP/MWCNT reinforcement on mechanical, wear behavior and crystallographic texture of copper-based metal matrix composite

In the present investigation, Cu-based MMCs have been developed by PM route using exfoliated graphite nanoplatelets (xGnP) and MWCNTs as nanofillers and their influence on mechanical properties as well as crystallographic texture have been studied. xGnP possesses fine particle size as well as less disorder as compared to MWCNTs. Relative density, hardness and wear resistance found to be increased with the addition of nanofillers upto 2 wt% xGnP/MWCNTs, whereas porosity found to decrease with the addition of nanofillers upto 2 wt%. The hardness of Cu-2 wt% xGnP composite was found to be 560 MPa, which is about 1.6 times higher than that of the pure Cu sample (350 MPa) and 1.2 times greater than Cu-2 wt% MWCNTs composite (475 MPa). The wear mechanism was found to involve a combination of abrasion, ploughing, delamination, microcracks, deep grooves and pullout of nanofillers in all the composites. The tensile strength of the various Cu-xGnP composites shows an improvement upto the addition of 2 wt% xGnP. The maximum tensile strength of 130 MPa was achieved in the case of Cu-2 wt% xGnP composite, which is about 1.7 times higher than that of the pure sintered Cu sample (76 MPa). However, the tensile strength of the various Cu-MWCNT composites continuously decreases with the addition of MWCNTs. The homogenous distribution of xGnP, as well as good bonding of xGnP with Cu matrix, has been observed in SEM and TEM images of composites, which is found to be more dominant as compared to MWCNTs distribution in Cu-matrix. The residual stress in the various composites was found to be compressive in nature, and it shows a similar trend as that of the other properties like hardness and wear behaviour of the composites. The addition of nanofillers also altered the crystallographic texture of the composites. xGnP leads to weaker texture as well as decrees in the volume fraction of 〈011〉 fiber as compared to MWCNTs in Cu-based MMCs, which leads to having superior mechanical properties as compared to MWCNTs composites.

Enhancing the mechanical, wear behaviour of copper matrix composite with 2V-Gr as reinforcement

In the present study, copper along with secondary hybrid reinforcements like Vanadium (V) and Graphene-L (Gr-L) with various proportions like pure Cu, Cu-2V, Cu-2V-0.5Gr, Cu-2V-1Gr, Cu-2V-1.5Gr are added to evaluate the behaviour of Copper Matrix Composite. The evenly dispersion of heterogeneous Copper Matrix Composite is achieved by the economical stir casting process. The heterogeneous mixture with metallic materials is a promising strategy to improve the properties of CMC. The prepared specimen is subjected to various testing processes to test the properties like Tensile strength, hardness, Yield strength, Impact strength and wear behaviours. The grain formation of hybrid CMC is also studied using an optical microscope to see the relationship between strength and grain size. The characterization of hybrid CMC is done by X-ray diffraction, Fourier Transform Infrared Spectroscopy and Energy Dispersive X-ray Spectroscopy. Fractography is also done to investigate the debonding mechanism of heterogeneous composites. The wear behavior of the hybrid composite is examined by Pin-on-disc tribometer. The results obtained, shows that, there is a reduction in grain size with the increase in addition of vanadium and graphene-L. The decrease in grain size has directly contributed to the improvement of mechanical properties of CMC. There is also an enhancement in wear behavior such as improvement in co-efficient of friction and wear resistance with increase in hybrid composition. This paves a new strategy and acts as a reliable reinforcement to improve the behaviour of copper based metal matrix composites.

Evaluation of the slurry erosion resistance of the body materials of oil & gas drill bits with a modified abrasive waterjet

Fixed-cutter drill bit is a key component of the whole drilling system. Its quality and service life greatly depend on the erosion resistance of the bit body. A limitation to the successful development of improved erosion resistant materials is the lack of a meaningful, and standardized test method. In this work, a slurry erosion test method has been developed to fill this technical void, which incorporates environmental aspects of fixed-cutter drill bits and is capable of closely simulating the downhole conditions. Wear resistant materials that form the body of a drill-bit are created either by a liquid metal infiltration of copper-based metal matrix composite or through the deposition of a hardfacing layer on a hardened and tempered steel. Examples of both materials are described herein, where laboratory testing correlates to the downhole conditions, validating that the developed slurry erosion test is appropriate and meaningful.

Study of Dry-Sliding Wear Behaviour of Cu-SiCp Metal Matrix Composites

Abstract The present paper reported the mechanical properties and wear behaviour of copper-based metal matrix composites reinforced with silicon carbide (SiC). Copper -SiC (5%) and Copper-SiC (10%) and Copper-SiC (15%) metal matrix composites were prepared by stir casting route. The wear characteristics of the composites were assessed by dry sliding wear tests using pin-on-steel disc tribometer at different loads, speeds and times.

Tribological investigation of copper and AISI 304 steel during dry sliding wear

Copper-based metal matrix (CBMM) composite is used in ball bearings and other tribological components due to significant improvement in thermal and mechanical properties. However, copper alloys based bearings are likely to fail due to severe surface fatigue wear in rolling/sliding condition. To understand the fatigue wear of copper-alloy which is dominated by the evolution of asperity characteristics, the study of topography evolution in dry sliding condition is essential. The purpose of this study is to study the tribological behavior of copper-steel material combination in dry sliding condition. The tribological properties of copper are also compared with AISI 304 steel. Experiments are performed on pin-on-disc tribometer. The AISI 52100 steel disc is used as a counter body during the experiments on AISI 304 and copper pin materials. The effect of normal load on friction coefficient and wear is studied. Surface topographies of the worn surfaces are measured using a 3D optical profiler. Scale-sensitive fractal analysis (SSFA) is performed on worn surfaces to analyze the complexity of the surface. It is found that surface complexity increases with an increase in normal load. At low scale, worn surfaces are rough and can be simplified by applying fractal theory. At lower load, an oxide layer is formed on the copper surface which reduces the direct asperity contacts. At higher load, distortion in the shape of autocorrelation is observed due to an increase in adhesion and plowing wear.

An experimental study of tribological behaviours of aluminium- and copper-based metal matrix composites for bearing applications

To improve the tribological properties for journal bearing materials, composites have been developed in this work. Copper-aluminium (Cu-Al), copper-phosphorous (Cu-P), aluminium-flyash (Al-F), and copper-lead (Cu-Pb) composites were produced with stir casting method. Pin on disc experiments were performed in a starved lubrication condition for the evaluation of wear and coefficient of friction between the composite pins and mild steel disc. Scanning electron microscopy (SEM) images were obtained for the worn composite samples to study the wear behaviour. In this experimental study, copper-phosphorous exhibits better tribological properties as compared to the conventional copper-lead. however, the aluminium-flyash composite resulted in the lowest coefficient of friction and highest wear among all considered composite materials.

An experimental study of tribological behaviours of aluminium- and copper-based metal matrix composites for bearing applications

An experimental study of tribological behaviours of aluminium- and copper-based metal matrix composites for bearing applications

Enhanced tribological properties of SiC reinforced copper metal matrix composites

Copper based metal matrix composite (CMMC) attracts the multiple applications due to their good electrical, thermal and mechanical properties. In the present study, new composite of Cu–SiC for different compositions were fabricated at sintering temperature of 950°C by using powder metallurgy technique followed by characterization of physical, mechanical and metallurgical properties of the fabricated composites. Tribological study was carried out using a pin-on-disc tribometer to determine wear and coefficient of friction. The composite samples ‘(1-x) Cu - xSiC’ were prepared by powder metallurgy technique with x = 10, 15 and 20% volume fraction of SiC. Anti-wear properties were tested under the varying loads of 10-30N and sliding speed of 0.5 m s−1-1.5 m s−1. The hardness and tensile strength of the samples was found to increase by 48% and 24% respectively by adding 20% of SiC. The experimental results revealed some interesting facts on the tribological behavior of fabricated composite against steel disk including oxidative wear, abrasive wear and presence of mechanically mixed layer. Wear is reduced from 45% to 77%, whereas friction reduced to 25% to 44%, due to the addition of SiC from 10% to 20% respectively. Therefore the results indicate that the SiC reinforcement enhances the wear resistance capacity and reduces the coefficient of friction in Cu–SiC composite.

Thermal, corrosion and wear analysis of copper based metal matrix composites reinforced with alumina and graphite

Abstract The wear and corrosion resistances are important in marine applications, especially when it comes to structural support components like bearings, bushes and blocks. The copper hybrid metal matrix components are the new avenues explored in this front. A novel combination of alumina and graphite were considered as the reinforcements in a copper base for the development of a metal matrix composite. Power metallurgical techniques were used for the development of the MMC. The Vickers's hardness value of 64.9Hv has been observed by increasing the volume of alumina. Thermogravimetric analyses were carried out on material samples to estimate the exact sintering temperature and identified that 450–700 °C would be conducive. The TGA curves shows two step decomposition exists between 4300C 460 °C. FT-IR analysis was done to confirm the peak values of the materials. FTIR exposed the peak value of 1600 cm−1 for alumina where as for Copper and graphite peak values have been 2840 cm−1 and 17260 cm−1 respectively. The potentio dynamic analysis was done to estimate the rate of corrosion on the samples. The sample with nano and micro reinforcements offered intensive resistance to corrosion. The presence of graphite minimized the weight loss of the samples during the corrosion test. Finally the wear rates of the samples were estimated using the Pin On Disc experimental setup. The samples with nano material reinforcement and with a maximum proportion of graphite exhibited a better wear rate of 1.52 × 10−12 m2/kg under maximum load conditions.

Mechanical and corrosion behaviors of developed copper-based metal matrix composites

This work investigates mechanical properties and corrosion resistances of cast copper-tungsten carbide (WC) metal matrix composites (MMCs). Copper matrix composites have been developed by stir casting technique. Different sizes of micro and nano particles of WC particles are utilized as reinforcement to prepare two copper-based composites, however, nano size of WC particles are prepared by high-energy ball milling. XRD (X-rays diffraction) characterize the materials for involvement of different phases. The mechanical behavior of composites has been studied by Vickers hardness test and compression test; while the corrosion behavior of developed composites is investigated by electrochemical impedance spectroscopy in 0.5 M H2SO4 solutions. The results show that hardness, compressive strength and corrosion resistance of copper matrix composites are very high in comparison to that of copper matrix, which attributed to the microstructural changes occurred during composite formation. SEM (Scanning electron microscopy) reveals the morphology of the corroded surfaces.

Fabrication of Cu-SiC Composites using Powder Metallurgy Technique

Copper based metal matrix composites are gaining interest for multiple applications because of their good electrical, thermal and mechanical properties. In the present study, composite of Cu-SiC with different compositions are fabricated by using powder metallurgy technique. Three different volumetric fractional combination of composites are made namely Cu90%-SiC10%, Cu85%-SiC15% and Cu80%-SiC20% along with Cu100% sample. V-shape blender is used for blending the powder. Hydraulic press is used to compact the powder at a pressure of 250Mpa to achieve the solid structure. To obtain better results, sintering is performed at a temperature of 950°C and a holding time of 60 min. An attempt has been made to study the characteristics of fabricated copper based metal matrix composites. The study revealed that the addition of SiC as a reinforcement in Cu; improves the mechanical properties. Scanning Electron Microscope (SEM) is used to analyse the surface morphology of the sintered samples. Microstructural study of the metal matrix composite shows the homogeneous distribution of SiC particles in the metal matrix.