Correlation Between Manufacturing Conditions, Microstructure, and Electrical–Mechanical Properties of Cu Matrix Composites

The continuous demand for advanced composite materials with superior mechanical and electrical properties has driven the exploration of copper matrix composites for high-performance applications. The Cu–2Zr–0.6B (wt.%) powder mixtures were mechanically alloyed (MA) using two different ball-to-powder weight ratios (BPR: 10:1 and 15:1) to investigate the influence of milling conditions on the final composite material’s properties. MA powders milled with BPR 15:1 exhibited the highest values of dislocation densities, which induce higher hardness of Cu–ZrB2 bulk materials. The MA powders were consolidated using three different methods: conventional cold pressing followed by sintering (CPS), hot pressing (HP), and spark plasma sintering (SPS). The in situ forming of ZrB2 (3.5 vol.%) reinforcements during consolidation processes in Cu matrix proved to have a major impact on enhancing the hardness and structural stability, while the use of SPS and HP offered superior control over grain growth and porosity reduction compared to CPS. Main findings related to electrical and mechanical properties showed similar values for SPS (~38% IACS, ~173 HV1) and HP compacts (~39% IACS, ~155 HV1) but proved to be much higher compared to values of CPS compacts (~21% IACS, ~80 HV1).