Comparative Microstructural, Mechanical, and Tribological Evaluation of Cu Matrix Composites Reinforced with B4C, B, Cr, Co, Al2O3, and Graphite via Powder Metallurgy

Abstract

Copper and its alloys are widely used in electrical, automotive, aerospace, and energy applications because of their excellent thermal and electrical conductivity. However, the low hardness and poor wear resistance of pure Cu limit its use under tribologically demanding sliding conditions. In this study, Cu matrix composites reinforced with 1 wt.% boron carbide (B4C), boron (B), chromium (Cr), cobalt (Co), alumina (Al2O3), and graphite (Gr) were fabricated by powder metallurgy and comparatively evaluated under identical processing and testing conditions. Phase constitution and microstructural characteristics were analyzed by XRD, SEM, and EDS, while mechanical and tribological behavior was assessed by Vickers hardness and dry sliding wear tests. All reinforcements improved the hardness of the Cu matrix compared with unreinforced Cu. The hardness increase followed the order Cu-B4C (68.91%) > Cu-B (66.43%) > Cu-Gr (63.97%) > Cu-Al2O3 (61.79%) > Cu-Cr (42.69%) > Cu-Co (36.04%). Dry sliding wear tests, performed under a 10 N normal load, 0.05 m s(-1) sliding speed, and 1000 m sliding distance against a 316L stainless-steel ball, showed that all reinforced composites exhibited lower mass loss and more stable sliding behavior than pure Cu. Among all samples, Cu-B4C displayed the best wear performance, with a 154.8% improvement in wear resistance relative to pure Cu. SEM analysis of the worn surfaces revealed that reinforcement addition reduced severe plastic deformation, groove formation, and delamination, leading to a more stable wear regime. Graphite- and boron-containing composites benefited from interfacial lubrication and contact stabilization, whereas B4C and Al2O3 improved wear resistance through rigid-particle strengthening and enhanced load-bearing capacity. By comparing ceramic, metalloid, metallic, oxide, and solid-lubricating reinforcements at the same low addition level and under identical processing and testing conditions, this study provides a reinforcement-selection framework for Cu-based composites requiring improved hardness and dry-sliding durability.