Optimized ball milling and sequential addition of SiC and MWCNTs reinforcements for enhanced performance of copper hybrid composites

Agglomeration and poor dispersion of reinforcements are common problems in conventional composite fabrication techniques, especially in hybrid composites. This study presents a novel technique, sequential reinforcement addition method combined with optimized ball milling, to produce copper (Cu) matrix composites reinforced with silicon carbide (SiC) and multi-walled carbon nanotubes (MWCNTs). By carefully controlling the milling parameters and introducing reinforcements sequentially, the study demonstrates substantial improvements in the mechanical, thermal, and electrical properties of Cu-based composites. The Cu+MWCNTs/SiC composite fabricated through this method exhibited a notable relative density of 98.88%, alongside a significant increase in surface hardness to 104.78 HV. Additionally, thermal conductivity improved by 16%, reaching 390 W/m·K, while electrical conductivity showed an 8.5% enhancement, achieving 17.53 × 10⁵ S/m. The wear rate of the composite was reduced by 15%, attributed to the formation of an effective tribolayer that significantly enhances wear resistance, contributing to the overall durability of the material.