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Correlation Between Manufacturing Conditions, Microstructure, and Electrical-Mechanical Properties of Cu Matrix

Marko Simić1, Emilija Nidžović1, Svetlana Butulija1

  • 1"Vinča" Institute of Nuclear Sciences-National Institute of the Republic of Serbia, University of Belgrade, 11001 Belgrade, Serbia.

Materials (Basel, Switzerland)
|April 14, 2026
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Summary

Mechanical alloying and consolidation methods significantly impact copper-zirconium-boron composites. Spark plasma sintering and hot pressing yield superior hardness and electrical properties compared to conventional cold pressing.

Keywords:
Cu–matrix compositesconductivitymechanical alloyingmechanical propertiespowder metallurgy

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Area of Science:

  • Materials Science
  • Metallurgy
  • Composite Materials

Background:

  • Advanced composite materials are crucial for high-performance applications requiring superior mechanical and electrical properties.
  • Copper matrix composites are being explored to meet these demands.

Purpose of the Study:

  • To investigate the influence of mechanical alloying (MA) conditions and consolidation methods on the properties of Cu-2Zr-0.6B (wt.%) composites.
  • To evaluate the formation of in situ ZrB2 reinforcements and their effect on material characteristics.

Main Methods:

  • Cu-2Zr-0.6B powder mixtures were mechanically alloyed at ball-to-powder weight ratios (BPR) of 10:1 and 15:1.
  • Milled powders were consolidated using conventional cold pressing followed by sintering (CPS), hot pressing (HP), and spark plasma sintering (SPS).

Main Results:

  • Higher dislocation densities were observed in powders milled with a 15:1 BPR, leading to increased hardness in bulk materials.
  • In situ formation of ZrB2 reinforcements significantly enhanced hardness and structural stability.
  • Spark plasma sintering (SPS) and hot pressing (HP) provided better control over grain growth and porosity reduction compared to CPS.
  • SPS and HP compacts exhibited significantly higher electrical conductivity (~38-39% IACS) and hardness (~155-173 HV1) than CPS compacts (~21% IACS, ~80 HV1).

Conclusions:

  • Mechanical alloying parameters and consolidation techniques critically influence the properties of Cu-ZrB2 composites.
  • SPS and HP are superior consolidation methods for achieving enhanced mechanical and electrical properties in these composites.
  • The in situ formation of ZrB2 reinforcements is key to improving the performance of copper matrix composites.