SYNTHESIS, CHARACTERIZATION, AND MACHINABILITY OF COPPER MATRIX COMPOSITES REINFORCED WITH MICRO AND NANO-SIZED SI3N4 AND ALN PARTICLES
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The present study investigates the synthesis, characterization, and machinability evaluation of copper matrix compositesreinforced with silicon nitride (Si3N4) and aluminum nitride (AlN) particles in both micro and nano forms. Compositescontaining 5 wt.% of each reinforcement were fabricated using a powder metallurgy route involving ball milling, coldcompaction, and sintering at 800 °C. The resulting composites were characterized for density, porosity, and microhardnessin accordance with ASTM standards. SEM and EDS analyses confirmed uniform distribution and high purity of thereinforcements without evidence of interfacial reaction products. Among all compositions, the Si3N4 micro-particle reinforcedcomposite exhibited the highest hardness (68 HV) and density (6.24 g/cc), indicating superior particle-matrix bonding. Incontrast, AlN-reinforced samples exhibited better dispersion and ductility but lower mechanical strength, with densities around5.57 g/cc. Machinability was assessed using wire electrical discharge machining (WEDM), where Si3N4 based compositesdemonstrated finer surface finishes (minimum Ra ~2.5 μm), while AlN reinforced composites with micro particles exhibitedrougher surfaces and higher oxide formation. These findings highlighted the effectiveness of Si3N4 micro-particle reinforcementin enhancing the mechanical and machining performance, making it suitable for copper composites to be utilized in frictionaland structural applications.
Abstract
The present study investigates the synthesis, characterization, and machinability evaluation of copper matrix compositesreinforced with silicon nitride (Si3N4) and aluminum nitride (AlN) particles in both micro and nano forms. Compositescontaining 5 wt.% of each reinforcement were fabricated using a powder metallurgy route involving ball milling, coldcompaction, and sintering at 800 °C. The resulting composites were characterized for density, porosity, and microhardnessin accordance with ASTM standards. SEM and EDS analyses confirmed uniform distribution and high purity of thereinforcements without evidence of interfacial reaction products. Among all compositions, the Si3N4 micro-particle reinforcedcomposite exhibited the highest hardness (68 HV) and density (6.24 g/cc), indicating superior particle-matrix bonding. Incontrast, AlN-reinforced samples exhibited better dispersion and ductility but lower mechanical strength, with densities around5.57 g/cc. Machinability was assessed using wire electrical discharge machining (WEDM), where Si3N4 based compositesdemonstrated finer surface finishes (minimum Ra ~2.5 μm), while AlN reinforced composites with micro particles exhibitedrougher surfaces and higher oxide formation. These findings highlighted the effectiveness of Si3N4 micro-particle reinforcementin enhancing the mechanical and machining performance, making it suitable for copper composites to be utilized in frictionaland structural applications.