Synthesis and Experimental Investigation of Copper Matrix Hybrid Composite Reinforced with Sic/Gr/Cr and Optimization of Extrusion Parameter for Further Property Enhancement

Abstract

Copper matrix composites (CuMMC) overcome the constraints of pure copper by providing high strength, wear resistance, and corrosion resistance while maintaining excellent electrical and thermal conductivity. CuMMC is thus a promising material for a wide range of applications including heat exchangers, resistance welding electrodes, and maritime components. This study was aimed to fabricate silicon carbide reinforced copper matrix hybrid composite with addition of 1%Gr and 2%Cr to enhance good wettability between molten copper and solid reinforcement. Five samples were synthesized using stir casting with varying weight percentage of silicon carbide (0,3, 6, 9 and 12 wt.%) at 500rpm stirring speed, 30-minute stirring time and 1200 stirring temperature. Porosity percentage, hardness, electrical conductivity, compression strength and corrosion resistance properties of fabricated samples were investigated and analyzed. Test results demonstrated that the addition of SiC-Gr-Cr improved hardness and corrosion resistance when compared to commercial copper, however increasing the amount of reinforcement lowered electrical conductivity. The addition of SiC-Gr-Cr up to 12%wt enhanced compression strength, although when the amount of reinforcement approaches 15% wt., the compressive strength of the composite decreased due to an increased in brittleness. Cu-6SiC-2Cr-1Gr with overall enhanced properties was selected using Grey Relational analysis (GRA) technique for secondary process for further enhancement of properties. DEFORM 3D was employed for numerical simulation of hot extrusion at varying extrusion ratio (2,3,4 and 5), ram speed (1,2,3 and 4 mm/s) and billet temperature (800, 850, 900 and 950℃). Damage percentage and extrusion load were measured and analyzed as single response characteristics using Taguchi's S/N ratio and as multi-response characteristics using Hybrid Taguchi Grey Relational Analysis (HTGRA). The findings revealed that both damage and extrusion load was increased with increasing extrusion ratio of cosine dieCu-6SiC-2Cr-1Gr composite was finally extruded with optimum combination of parameter using extruder machine. Finding obtained after extrusion shows that porosity percentage was decreased from 2.71% to 1.57% when compared to sample before extrusion. Compression strength and hardness of Cu-6SiC 2Cr-1Gr were improved by 21.4% and 17.4% following extrusion although electrical conductivity showed slight decrement. This research work is expected to help all industries and researchers working in this area of focus.Copper Matrix Composites (Cummc) Overcome The Constraints Of Pure Copper By Providing High Strength, Wear Resistance, And Corrosion Resistance While Maintaining Excellent Electrical And Thermal Conductivity. Cummc Is Thus A Promising Material For A Wide Range Of Applications Including Heat Exchangers, Resistance Welding Electrodes, And Maritime Components. This Study Was Aimed To Fabricate Silicon Carbide Reinforced Copper Matrix Hybrid Composite With Addition Of 1%Gr And 2%Cr To Enhance Good Wettability Between Molten Copper And Solid Reinforcement. Five Samples Were Synthesized Using Stir Casting With Varying Weight Percentage Of Silicon Carbide (0,3, 6, 9 And 12 Wt.%) At 500rpm Stirring Speed, 30-Minute Stirring Time And 1200 Stirring Temperature. Porosity Percentage, Hardness, Electrical Conductivity, Compression Strength And Corrosion Resistance Properties Of Fabricated Samples Were Investigated And Analyzed. Test Results Demonstrated That The Addition Of Sic-Gr-Cr Improved Hardness And Corrosion Resistance When Compared To Commercial Copper, However Increasing The Amount Of Reinforcement Lowered Electrical Conductivity. The Addition Of Sic-Gr-Cr Up To 12%Wt Enhanced Compression Strength, Although When The Amount Of Reinforcement Approaches 15% Wt., The Compressive Strength Of The Composite Decreased Due To An Increased In Brittleness. Cu-6sic-2cr-1gr With Overall Enhanced Properties Was Selected Using Grey Relational Analysis (Gra) Technique For Secondary Process For Further Enhancement Of Properties. Deform 3d Was Employed For Numerical Simulation Of Hot Extrusion At Varying Extrusion Ratio (2,3,4 And 5), Ram Speed (1,2,3 And 4 Mm/S) And Billet Temperature (800, 850, 900 And 950???). Damage Percentage And Extrusion Load Were Measured And Analyzed As Single Response Characteristics Using Taguchi's S/N Ratio And As Multi-Response Characteristics Using Hybrid Taguchi Grey Relational Analysis (Htgra). The Findings Revealed That Both Damage And Extrusion Load Was Increased With Increasing Extrusion Ratio Of Cosine Diecu-6sic-2cr-1gr Composite Was Finally Extruded With Optimum Combination Of Parameter Using Extruder Machine. Finding Obtained After Extrusion Shows That Porosity Percentage Was Decreased From 2.71% To 1.57% When Compared To Sample Before Extrusion. Compression Strength And Hardness Of Cu-6sic 2cr-1gr Were Improved By 21.4% And 17.4% Following Extrusion Although Electrical Conductivity Showed Slight Decrement. This Research Work Is Expected To Help All Industries And Researchers Working In This Area Of Focus.