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FABRICATION OF COPPER - BORON CARBIDE METAL
MATRIX COMPOSITE BY POWDER METALLURGY
P. K. Prajapati, D. Chaira
Department of Metallurgical and Materials Engineering
National Institute of Technology Rourkela
Rourkela, Odisha-769008, India
APMA 2019, 19th -21st February 2019, Pune 1
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Motivation
2
Copper based ceramic reinforced metal matrix composites (MMCs)
have been the subject of extensive research due to their good
mechanical, thermal and tribological properties.
Boron carbide (B4C) has excellent chemical and thermal stability,
high hardness and low density.
Boron carbide (B4C) cermets and boron carbide-based composites
serve as promising materials for a variety of applications that require
elevated mechanical properties, high neutron absorption cross
section, high melting point, good wear and corrosion resistance.
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B4C based cermets and composites are widely used for various
high technology applications, such as light-duty bulletproof
armors, neutron absorber in liquid–metal- cooled fast breeder
reactors, wear-proof parts, and cutting tools.
B4C coating is applied on copper and steel using various methods
which are extensively used in nuclear industries.
One drawback of the boron carbide is lower thermal and electrical
conductivity.
Copper are one of the most important materials for thermal and
electronic applications due to its higher electrical and thermal
conductivities.
The use of B4C particles as reinforcements in copper based
composites is considered very attractive to overcome the drawback
of boron carbide.
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Objectives
Fabrication of Cu-B4C MMC by cold compaction
followed by conventional sintering.
To study the effect of B4C content in the
composite.
Microstructural characterization, physical,
mechanical and electrical conductivity study of
fabricated composite.
To study interface between Cu-B4C.
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Experimental Details Blending of Cu and B₄C powder (5, 10 and 15 wt. %)
Cold compaction under pressure of 600 MPa
Conventional sintering at 900o C for 1 hour under Ar gas
Microstructure
analysis Phase Mechanical
property
XRD
Hardness
Electrical
conductivity
Optical
SEM
FESEM
Compressive strength
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Characterization of as received powder
(a) FESEM micrograph of Cu (b) FESEM micrograph of B4C
(a) (b) • Cu-dendritic shape,
electrolytic grade
• B4C-irregular shape
with sharp edge.
• Particles size of B4C
varies from 48 µm to
214 µm.
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Flowability and density of as received powder
• Compressibility index
(CI)=𝑇𝑎𝑝 𝑑𝑒𝑛𝑠𝑖𝑡𝑦−𝑏𝑢𝑙𝑘 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑥100
𝑇𝑎𝑝 𝑑𝑒𝑛𝑠𝑖𝑡𝑦
• 𝐻𝑎𝑢𝑠𝑛𝑒𝑟 𝑟𝑎𝑡𝑖𝑜 𝐻𝑅 =𝑇𝑎𝑝 𝑑𝑒𝑛𝑠𝑖𝑡𝑦
𝐵𝑢𝑙𝑘 𝑑𝑒𝑛𝑠𝑖𝑡𝑦
• 𝐴𝑛𝑔𝑙𝑒 𝑜𝑓 𝑟𝑒𝑝𝑜𝑠𝑒 𝜃 =
tan−1 𝑒𝑖𝑔𝑡 𝑜𝑓 𝑐𝑜𝑛𝑒 𝑓𝑜𝑟𝑚𝑒𝑑
𝑟𝑎𝑑𝑖𝑢𝑠 𝑜𝑓 𝑑𝑖𝑠𝑐 𝑓𝑜𝑟𝑚𝑒𝑑
7
Powder Bulk density (gm/cc) Tap density (gm/cc) Compressibility
index (CI)
Hausner ratio (HR)
Copper 1.05 1.28 18.03 1.22
B4C 1.13 1.46 12.90 1.35
• As received copper and B4C powder exhibit angle of repose as 25.770 and 39.200.
• Copper exhibits higher flow ability than B4C.
• Copper shows higher compressibility than B4C.
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Pure Cu
5 wt. %B4C
10 wt. %B4C
15 wt. %B4C
Characterization of fabricated Cu-B4C MMC
• Presence of weak peak of
Cu2O with strong peaks of Cu
and B4C
• Uniform distribution of B4C
particles in the Cu matrix.
Optical micrographs
of Cu-B4C composites
sintered at 900 C for
1 hour
XRD spectra of Cu-B4C composites
sintered at 900 C for 1 hour
8
Annealing twins
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B4C Pores
Cu
B4C
Copper matrix
Cu -B4C interface
(a) (b)
(c) (d) (e)
SEM micrographs of (a) Cu-10 wt. % B4C composite (b) Cu and B₄C
interface of Cu-10 wt. % B4C composite (c) Cu- 5wt. % B4C (d) Cu-10 wt.%
B4C (e) Cu-15wt.% B4C
• Uniform distribution of B4C reinforcements in Cu matrix.
• Good compatibility between Cu and B4C.
• No interfacial product has been formed at Cu-B4C interface.
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1 2 3 4 5 6 7 8
keV
0
2
4
6
8
10
12
14
cps/eV
Cu Cu
El AN Series unn. C norm. C Atom.
[wt.%] [wt.%] [at.%]
-------------------------------------
B 5 K-series 55.58 55.58 58.16
C 6 K-series 44.42 44.42 41.84
------------------------------
Total: 100.00 100.00 100.00
El AN Series unn. C norm. C Atom.
[wt.%] [wt.%] [at.%]
-------------------------------------
Cu 29 K-series 74.52 100.00 100.00
-------------------------------------
Total: 74.52 100.00 100.00
0.20 0.40 0.60 0.80 1.00 1.20 1.40 1.60 1.80
keV
0
1
2
3
4
5
cps/eV
C B
EDS spectra and elemental composition of B4C
EDS spectra and elemental composition of Cu matrix
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Elemental mapping of Cu-10 wt. %
B4C composite
Line scan from B4C to Cu matrix
11
B4C
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Wt.% B4C Density
(g/cc)
Relative
density
(%)
5 7 82
10 6.70 81
15 6.26 78
Pure Cu 7 78
B4C (wt. %) Average Vickers
hardness (VHN)
0 37.88 ± 1.13
5 55.14 ± 1.6
10 65.64 ± 2.96
15 79.06 ± 5.2
Density and hardness study
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Compressive stress- strain graphs for pure
Cu, Cu-5 wt. % B4C, Cu-10 wt. % B4C and
Cu-15 wt. % B4C composites
Compressive strength study
Samples after
compressive test
Maximum compressive strength of 337
MPa is achieved for Cu-10 wt. % B4C
MMC
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Electrical conductivity for Cu-B4C composites
Electrical conductivity
P. K. Prajapati, D. Chaira, Fabrication and characterization of Cu–B4C metal matrix composite by powder metallurgy:
Effect of B4C on microstructure, mechanical properties and electrical conductivity, Trans Indian Inst. Met.,
https://doi.org/10.1007/s12666-018-1518-2 14
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Composition Processing method Density Hardness Strength
Al-5 wt. % Cu alloy
reinforced with B4C (2, 5, 7
wt. %) [9]
Stir casting process followed by
sqeeze casting and then ageing at
200 and 250 C
Average density 99 %
of theoretical
105 VHN for ageing at
250 C for 4 h (Al-5 wt.
% Cu-7 wt. % B4C)
Maximum compressive
strength 143 MPa (Al-5
wt. % Cu-7 wt. % B4C)
Al2024 matrix composites
reinforced by high volume
fraction of B4C (40:60) [10]
Mechanical milling and vacuum
hot pressing followed by hot
extrusion
-------------
----------
Maximum compressive
strength of 1115 MPa with
10 vol. % coarse grained
Al2024
Al-B4C composite (5, 10 , 15
wt. % B4C)[15]
Stir casting at 800 and 1000 C 2.8 g/cc casted at 1000
C
94.7 BHN (Al-15 5
B4C)
Maximum tensile strength
210 MPa
Cu-B4C composites (1, 2, 3
wt. % B4C)[11]
Powder metallurgy method;
sintering at 700 C for 2 h at
open atmosphere
90 % for 3 wt. % B4C 87.5 BHN for 3 wt. %
reinforced B4C
------------------
Cu-8 vol. % B4C surface
dispersion strengthened
composite [12]
Friction stir processing
-------------
99 VHN
-----------------
Cu-B4C composite [16] Friction stir welding ------------------ Average hardness 140
VHN
-----------------
A356-B4C composite [17] Friction stir processing
-------------------
Maximum hardness
74.98 VHN
Maximum tensile strength
399.42 MPa
C-B4C composite [Present
study]
Powder metallurgy; cold
compaction followed by
sintering at 900 C, 1 h
82 % of relative density 79.06 ± 5.2 VHN Maximum compressive
strength 337 MPa
A comparative studies of B4C reinforced composites fabricated by various researchers and the
present research work
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Conclusions • Cu-B4C metal matrix composites were successfully fabricated by using powder metallurgy
route taking different weight percentage of B4C powder.
• Optical, SEM and FESEM analysis of pure Cu, Cu-5wt. % B4C, Cu-10 wt. % B4C, and Cu-
15wt. %B4C show that there is uniform distribution of B4C particle in Cu matrix.
• A maximum relative density of 82 % achieved for Cu-5 wt. % B₄C composite. The relative
density decreases with addition of B4C and for 10 and 15 wt. % B4C it is found 80.4% and
78.33% respectively.
• Hardness value increases with addition of B4C in to pure Cu. The Vickers hardness value
for pure copper is 38 VHN, which increases to 79 VHN for 15 wt. % B4C.
• Compressive strength is improved with the addition of B4C powder in Cu matrix. The
maximum compressive strength is found for 10 wt. % B4C, which is 337 MPa. But further
addition of B4C in to Cu makes it brittle and strength decreases.
• Electrical conductivity of pure copper is found to be 4.5×106 S/m which decreases with
increase in B4C content in composites. Electrical conductivity of Cu-5wt.% B₄C is
1.92×106 S/m, Cu-10wt.% B₄C is .75×106 S/m, and Cu-15wt.%B₄C is .32×106 S/m.
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Acknowledgement
• M. Tech student, Pradeep Kumar Prajapati
• Dept. of Metallurgical & Materials Engineering,
NIT Rourkela, Odisha
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