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org (E-ISSN 2348-1269, P- ISSN 2349-5138)

PHYSICAL AND MECHANICAL PROPERTIES

OF CERAMIC REINFORCED COPPER METAL
MATRIX HYBRID COMPOSITES
1
Akhil Manhas, 2Sunil Kumar Katheria, 3Dr. Manvandra Kumar Singh
1
M.Tech student, 2Assistant Professor, 3Assistant Professor
1
Department of Mechanical Engineering,
1
Mewar University, Chittorgarh, India

Abstract: This work is focussed to investigate the physical and mechanical properties of copper based metal matrix hybrid
composites developed by using powder metallurgy (P/M) technique. In this research, we have taken pure copper as matrix
and alumina (Al2O3), zirconia (ZrO2), molybdenum disulphide (MoS2) and chromium (Cr) are used as reinforcement.
Relative density is evaluated from the density which is measured by Archimedes principle. Lower relative density of
developed hybrid composites (HC) is observed as compare to pure copper due to development of some porosity. The
electrical conductivity of the developed hybrid composites is also evaluated by four probe technique where the electrical
conductivity of hybrid composite is comparatively lower than the pure copper due to the addition of low conducting nature of
ceramic reinforcements. However, the vickers hardness of developed hybrid composites is higher as compared to pure
copper. It is attributted to the reinforcement of harder cermaics like- alumina and zirconia in the copper matrix.

Index Terms – Metal matrix hybrid composite, Relative density, Vickers hardness, Electrical conductivity, Powder metallurgy
(P/M).
I. INTRODUCTION
Powder metallurgy (PM) has become an important processing method to develop the advance materials such as metal matrix
composites (MMCs). Such materials have uniform properties, fine grain structures and chemical homogeneity with less density
compare to its theoretical density due to presence of some micro porosity [1, 2]. A composite material can be defined as amalgamation
of the two or more materials that gives the better properties than those of individual components used alone. In contrast to the metallic
alloys, each of the material keeps its separate physical, chemical, and mechanical properties. The benefits of the composite materials
are of having a high hardness, tensile strength and toughness combined with the low density when it has been compared with the
classical materials. Recently, automobile industries are in trend due to increasing environmental concern, and technologies for
reducing fuel consumption have been rapidly developed, such as light weight technology engine downsizing for environmentally
friendly vehicles etc [3].
Hybrid MMCs were formed by reinforcing the base matrix with more than one reinforcement having different properties. The
composites which have a combination of two or more reinforcement of particles are capable of enhancing the mechanical
characteristic of the composite materials [4]. The performance of hybrid composites is a collective effect of the individual constituents
in which there is a better balance between the inbuilt advantages and disadvantages. The Silicon carbide material (SiC), aluminum
(Al2O3), boron carbide material (B4C), tungsten carbide (WC), graphite (Gr), single or multi types of carbon nanotubes (CNT) and
silica (SiO2) and are a few of the reinforcements which are used . But, here in the current research work alumina, zirconia,
molybdenum disulfide and chromium are characteristically used as reinforcements in the copper matrix to develop copper metal
matrix hybrid composites by using powder metallurgy technique. The developed copper hybrid composites are characterized for
relative density, porosity, hardness and electrical conductivity measurement with standard techniques and instruments.
II. EXPERIMENTAL PROCEDURE
a. DEVELOPMENT OF MATERIALS
In the current research work, the copper based hybrid composites were developed by using the powder metallurgy
technique as per the compositional details reported in Table 1.
The following processing steps were mainly involved to develop the hybrid composites:
(i) Weighing of the powders in their appropriate content was done using electronic weighing machine with accuracy of 0.0001g.
(ii) After weighing, the mixing of powders was done using planetary ball mill with 10:1 ball to powder weight ratio to obtain a
homogenous mixture of the powders. Zinc stearate was also added in the mixture to increase the flowability of mixtures.
(iii) Then homogenous mixture of powders was compacted at 60KN load and room temperature using the hydraulic press machine.
(iv) The compaction was followed by the sintering process, was performed using microwave sintering furnace at elevated temperature
of 850 0C for 30 min and at atmospheric pressure under inert environment of argon to avoid any kind of impure phase
development.

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The designation of the developed materials are reported in the table 1
Table.1: Compositional detail of the developed copper based hybrid composites

S. No. Types of materials Compositions Weight (%) Weight (g)

Pure copper (Cu)
1. Cu 100 50
94Cu-2ZrO2-2Al2O3-2Cr Cu 94.0 47
2. Hybrid composite (HC) ZrO2 2.0 1.0
Al2O3 2.0 1.0
Cr 2.0 1.0
Cu 89 44.5
ZrO2 2.0 1.0
89Cu-2ZrO2-2Al2O3-5MoS2- 2Cr
3. Al2O3 2.0 1.0
Self lubricated hybrid composite-1 (SLHC-1)
MoS2 5.0 2.5
Cr 2.0 1.0
Cu 84.0 42.0
ZrO2 2.0 1.0
84Cu-2ZrO2-2Al2O3-10MoS2- 2Cr
4. Al2O3 2.0 1.0
Self lubricated hybrid composite-2 (SLHC-2)
MoS2 10 5.0
Cr 2.0 1.0
Cu 79.0 39.5
79Cu-2ZrO2-2Al2O3-15MoS2- 2Cr ZrO2 2.0 1.0
5.
Self lubricated hybrid composite-3 (SLHC-3) Al2O3 2.0 1.0
MoS2 15 7.5
Cr 2.0 1.0

b. RELATIVE DENSITY AND POROSITY MEASUREMENT

The density is an important physical property of the product developed by powder metallurgy and normally increases with
increasing sintering temperature. Here in this work the density of the sintered product was measured by the Archimedes’ principle.
Subsequently, the relative density and porosity of the developed hybrid composites including copper matrix were evaluated by using
the measured density.
c. HARDNESS TEST

The hardness of the developed materials was measured using Vickers hardness test in which the indentation on materials was
given with a diamond indenter. The indenter was in the shape of pyramid with square base and having an angle of 136º between
opposite faces. The test samples were subjected to a load of 0.5 kgf for 10 seconds. Due to application of load, an impression of
indenter appeared on sample’s surfaces. The two diagonals of this indentation (d1 and d2) were measured with the help of a
microscope and arithmetic of these two used in the formula. Hardness is a measure of the resistance of a material to plastic
deformation induced by applied forces. Vickers hardness (HV) was calculated using the formula HV= 0.1891× F/d2; Where d, is the
average of the two diagonals of the imprint and F is the applied load.
d. MEASUREMENT OF ELECTRICAL CONDUCTIVITY

Four probe apparatus was used to measure the electrical resistance of the developed materials; it is one of the standard and
most widely used apparatus for the measurement of resistivity of the materials. In this technique, it consisted of four probe arranged
linearly in a straight line at equal distance from each other. A constant current is passed through the two probes and the potential drop
across the middle two probes was measured at room temperature, the resistance, R of a materials is proportional to its length L and
inversely proportional to its area of cross section A and it was evaluated by the formula R=ρ(L/A), where ρ is the resistivity of the
materials and its unit is ohmmeter. Subsequently, the electrical conductivity of the materials could be evaluated with help of the
evaluated resistance value.
III. RESULTS AND DISCUSSION
a. RELATIVE DENSITY

Fig.1 shows the variation of the realative density of the materials. It is noted that the realtive density of the copper is higher
as compare to other hybrid composites. Fig.1 also shows the relative density of the copper is 95 ± 0.48 % where as the HC, SLHC-1,
SLHC-2, SLHC-3 have 91 ± 0.3, 89 ± 0.35, 87± 0.45, 85 ± 0.5 %, respectively. The relative density of the SLHC-3 is least among all
the developed materials. It is also observed that the relative density of material is continuously decreasing on increasing the weight
percentage of molybdenum disulfide with the constant weight percentage of zirconia and alumina including chromium in the copper
matrix. Relative desity of copper is maximum due to least porosity and better bonding between atoms of pure copper and on the other
hand lowering in the relative density of the developed hybrid composites is mainly due to two reasons first, addition of lower dense
molybdenum disulfide in the matrix, second increase in the porosity in the developed hybrid composites [5, 6] as shown in Fig.2. The
percentage decrease in the relative density of HC, SSLHC-1, SLHC-2 and SLHC-3 is 4.21, 6.31, 8.42 and 10.52 % respectively as
compared to pure copper.

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Fig.1. Variation of the relative density of the materials

b. POROSITY

Fig.2 displays the variation of the porosity of materials. From the figure, it is noticed that SLHC-3 have highest porosity
among all the developed compositions. The porosity percentage of SLHC-3 is 15 ± 0.5 % whereas the porosity of Cu, HC, SLHC-1
and SLHC-2 is 5 ± 0.48, 9 ± 0.3, 11 ± 0.35 and 13 ± 0.45 %, respectively. It is also observed that on addition of different
reinforcement such as molybdenum disulfide, zirconia, alumina and chromium in hybrid composites the porosity increases. This
increase in porosity of the developed hybrid composites is attributed to the irregular shape, structure and size of the reinforcing
particle used in copper matrix. Thus the different crystal structure of different size of reinforcing partice may lead porosity in the
matrix [7, 8] where, the crystal structure of reinforcements such as molybdenum disulfide, zirconia, alumina and chromium are
hexagonal, monoclinic, trigonal and bcc, respeectively.

Fig.2. Variation of the porosity of the materials

c. HARDNESS

Fig.3 represents the variation of the vickers hardness of materials. It is observed that the vickers hardness of HC is highest
and Cu is least among all the developed materials. The vickers hardness of HC is 122 ± 7 however, the vickers hardness of Cu,
SLHC-1, SLHC-2 and SLHC-3 have 89 ± 5, 115 ± 7, 111 ± 8 and 105 ± 6, respectively. This increase in the hardness of the hybrid
composites is attributed to the high interfacial bonding strength at matrix and reinforcement and homogeneous distribution of
reinforcement within matrix which restricts the grain growth (Singh and Gautam, 2017) [7]. In addition to this increase in the
hardness of the hybrid composites may also due to the addition of harder ceramic reinforcement in copper matrix, their presence leads
to a higher hardness of the composites (Singh and Gautam, 2019 and Samal et al., 2013) [7, 9]. The advancement in such hardness of
hybrid composites may also be possible by dislocations locking mechanism due to the significant atomic size mismatch of reinforcing
particles and copper, possible segregation of reinforcing atom in stacking faults of copper may be another reason of hardness
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improvement ( Singh and Gautam, 2019, Bagheri, 2016) [7, 10]. It is observed that among hybrid composites, the vickers hardness
decreases from 122 ± 7 to 105 ± 6 HV on the addition of MoS 2 from 0 to 15 wt % with the constant wt % of Al 2O3, ZrO2 and Cr in
the copper matrix (Singh and Gautam, 2019 and Rajmohan et al., 2013) [7, 11]. This decrease in hardness of selflubricated hybrid
composites is due to addition of softer MoS2 in copper matrix.

Fig.3. Variation of the vickers hardness of the materials

d. ELECTRICAL CONDUCTIVITY

Fig.4 depicts the variation of the electrical conductivity of materials. The electrical conductivity of the material is evaluated by
four probe technique. It is observed that electrical conductivity of copper is highest among all the developed materials. The electrical
conductivity of copper is 88 ± 7 % IACS however HC, SLHC-1, SLHC-2 and SLHC-3 have 55 ± 8, 43 ± 9, and 38 ± 8 and 33 ± 7 %
IACS respectively. The least electrical conductivity is observed in SLHC-3. It is also observed that electrical conductivity is
continuously decreasing on increasing the weight percentage of molybdenum disulphide by 5-15 % at constant wt. % of Al2O3, ZrO2
and Cr. The electrical conductivity decreases from 95% (of pure copper) to 65% (of HC) with addition of 2 wt. % of Al 2O3, 2 wt. % of
ZrO2, 2 wt. % of Cr and zero wt. % of MoS2. Moreover, the electrical conductivity also decreases from 55 ± 8 % IACS (of HC) to 43
± 9 % IACS (of SLHC-1) when MoS2 increases from 0-5 wt. %, with same amount of Al2O3, ZrO2 and Cr. Also, decrease in electrical
conductivity from 43 ± 9 to 38 ± 8 % IACS from SLHC-1 to SLHC-2 and 38 ± 8 to 33 ± 7 % IACS from SLHC-2 to SLHC-3
respectively, when the wt. % of MoS2 increases from 5 to 10 and 10 to 15 with similar amount of Al 2O3, ZrO2 and Cr. Here the self
lubricated hybrid composite are showing less electrical conductivity as compare to hybrid composite and pure copper. Such lowering
in the conductivity of hybrid composites is attributed to the reinforcement of the non-conducting ceramic materials, such as Al2O3,
ZrO2, Cr and MoS2 into the copper matrix (Singh and Gautam, 2018; V.A. Nadkarni and E.J. Synk, 1984). [5, 12] In addition,
decrease in electrical conductivity of the hybrid composites may also be attributed to the presence of porosity in the developed hybrid
materials. The presence of conductive materials is essential for achieving high electrical conductivity. Particle to particle contact
develops within the developed hybrid composite materials in the network of conductive path. With the addition of higher amount of
ceramic reinforcement into copper matrix, porosity developed in the developed hybrid composites, which disturb the contact
continuity in the conductivity region. [5, 13, 14].

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Fig.4. Variation of the electrical conductivity of the materials

IV. CONCLUSION

1. Copper based metal matrix hybrid composite were successfully developed by using powder metallurgy technique, where
molybdenum disulphide (MoS2), with constant weight percentage alumina (Al2O3), zirconia (ZrO2) and chromium (Cr) were
used as reinforcements.
2. The relative density of developed hybrid composites is lower as compare to that of copper is 95 ± 0.48 %. The percentage
decrease in the relative density of HC, SLHC-1, SLHC-2 and SLHC-3 is 4.21, 6.31, 8.42 and 10.52 % respectively as
compared to pure copper.
3. It is observed that the porosity of developed hybrid composites is higher as compared to pure copper. The porosity percentage
of SLHC-3 is highest among all materials that is 15 ± 0.5 % whereas the porosity of Cu, HC, SLHC-1 and SLHC-2 is 5 ±
0.48, 9 ± 0.3, 11 ± 0.35 and 13 ± 0.45 %, respectively.
4. It is also observed that the vickers hardness ofdeveloped hybrid composites is very high as compared to pure copper. It is
attributted to the reinforcement of harder cermaics like- alumina and zirconia in the copper matrix. The vickers hardness of
HC is 122 ± 7 however, the vickers hardness of SLHC-1, SLHC-2, SLHC-3 and Cu have 115 ± 7, 111 ± 8 and 105 ± 6, 89 ±
5, respectively.
5. The electrical conductivity of the developed hybrid composites is evaluated by four probe technique. The electrical
conductivity of hybrid composites is comparatively lower than the pure copper. This lowering in electrical conductivity of
hybrid composite is due to addition of non conducting reinforcement in copper matrix. The electrical conductivity of copper is
88 ± 7 % IACS however HC, SLHC-1, SLHC-2 and SLHC-3 have 55 ± 8, 43 ± 9, and 38 ± 8 and 33 ± 7 % IACS
respectively.

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