article · Results in Engineering
Conventional fabrication of hybrid metal composites often suffers from particle clumping and uneven reinforcement dispersion. A sequential addition method combined with optimised ball milling addresses this issue when producing copper matrix composites reinforced with silicon carbide and multi-walled carbon nanotubes. Introducing the reinforcements sequentially while controlling milling parameters yields a composite with a relative density of 98.88 per cent and an elevated surface hardness of 104.78 HV. Furthermore, the material demonstrates notable improvements in physical performance, achieving a 16 per cent rise in thermal conductivity to 390 W/m·K and an 8.5 per cent gain in electrical conductivity. Wear resistance also improves markedly, showing a 15 per cent reduction in wear rate due to the development of an effective tribolayer that supports material durability.
Copper is widely utilised for conducting heat and electricity, but unreinforced metal often lacks sufficient hardness and wear resistance for demanding environments. By successfully integrating carbon nanotubes and silicon carbide without clumping, this processing approach yields a denser, harder material that conducts heat and electrical current more effectively while resisting wear, potentially extending the operating life of high-performance components.
This work represents early-stage, laboratory-tested materials research demonstrating enhanced mechanical and conductive properties. While the combination of high thermal transfer, electrical conductivity, and reduced wear rate is relevant for high-performance thermal and electrical components, the abstract does not indicate a specific commercialisation pathway, target end-users, or a timeline for industrial adoption.
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• The sequential milling (Cu+MWCNTs/SiC) composite achieved a remarkable relative density of 98.88%. • The sequential milling (Cu+MWCNTs/SiC) composite exhibited superior wear behavior among the tested composites. • The thermal conductivity of the sequentially milled composite was superior to that of the pre-milled composites, along with improved electrical conductivity. Agglomeration and poor dispersion of reinforcements are common problems in conventional composite fabrication techniques, especially in hybrid composites. This study presents a novel technique, sequential reinforcement addition method combined with optimized ball milling, to produce copper (Cu) matrix composites reinforced with silicon carbide (SiC) and multi-walled carbon nanotubes (MWCNTs). By carefully controlling the milling parameters and introducing reinforcements sequentially, the study demonstrates substantial improvements in the mechanical, thermal, and electrical properties of Cu-based composites. The Cu+MWCNTs/SiC composite fabricated through this method exhibited a notable relative density of 98.88%, alongside a significant increase in surface hardness to 104.78 HV. Additionally, thermal conductivity improved by 16%, reaching 390 W/m·K, while electrical conductivity showed an 8.5% enhancement, achieving 17.53 × 10 5 S/m. The wear rate of the composite was reduced by 15%, attributed to the formation of an effective tribolayer that significantly enhances wear resistance, contributing to the overall durability of the material.
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DOI: 10.1016/j.rineng.2024.103471
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