Comprehensive studies for evaluating promising properties of Cu/graphene/fly ash nanocomposites

Copper (Cu)'s electrical conductivity makes it attractive for industrial usage. Due to its inferior mechanical characteristics, thermal expansion, and wear resistance, its applications are limited. This manuscript solves these issues while retaining its major feature, excellent electrical conductivity. In this regard, different quantities of graphene (Gr) and fly ash (FA) nanoparticles were combined with Cu in a planetary ball mill at 440 rpm for 20 h using powder metallurgy (PM). The microstructure of the generated powders was characterized using X-ray diffraction technique and transmission electron microscopy. The powders underwent compression and were then subjected to firing at three distinct temperature levels, reaching a maximum of 850 °C. In addition, an analysis was conducted on the microstructure, mechanical properties, wear resistance, thermal expansion behaviour, and electrical conductivity of the sintered samples. Based on the findings, the inclusion of a hybrid of Gr and FA ceramics effectively led to a reduction in particle sizes. The bulk density slightly decreases with the addition of hybrid ceramic while increasing with the rise in sintering temperature. The hybrid composited Cu/0.8 vol.% Gr/8 vol.% FA recorded an increase in the microhardness, ultimate stress, and Young's modulus of 25, 20, and 50%, respectively, relative to the Cu matrix. Furthermore, the wear rate and coefficient of thermal expansion for the same sample decreased by 67 and 30%, respectively. Finally, increasing the sintering temperature showed a clear improvement in the mechanical, electrical, and corrosion properties. Based on the results obtained, it can be concluded that the prepared hybrid nanocomposites can be used in power generation, power transmission, electronic circuits, and other applications.