G. F. C. EFE et al.: FABRICATION AND PROPERTIES OF SiC REINFORCED COPPER-MATRIX-COMPOSITE ...
585–590
FABRICATION AND PROPERTIES OF SiC REINFORCED
COPPER-MATRIX-COMPOSITE CONTACT MATERIAL
IZDELAVA IN LASTNOSTI S SiC UTRJENEGA KOMPOZITNEGA
MATERIALA NA OSNOVI BAKRA
Gozde Fatma Celebi Efe1,2, Mediha Ýpek1, Sakin Zeytin1, Cuma Bindal1,2
1Sakarya University, Faculty of Engineering, Department of Metallurgy and Materials Engineering, Esentepe Campus, 54187 Sakarya, Turkey
2Sakarya University, Biomedical, Magnetic and Semi Conductive Materials Research Center (BIMAS-RC), Esentepe Campus, 54187 Sakarya, Turkey
gcelebi@sakarya.edu.tr
Prejem rokopisa – received: 2015-07-01; sprejem za objavo – accepted for publication: 2015-07-28
doi:10.17222/mit.2015.175
This study aims at improving mechanical properties of electrical contacts through copper and copper-matrix silicon-carbide-
reinforced composites produced with powder metallurgy. Copper powder was produced with the cementation method. Pure
copper and mixtures of copper with 3 % of mass fraction of SiC powder were pressed with a uniaxial pressure of 280 MPa and
sintered at 700 °C for 2 h in an atmospheric environment. After the sintering, these compacts were immediately pressed at a load
of 850 MPa while the samples were hot. The characterization of the samples was made with microstructural investigations,
relative-density experiments, electrical-conductivity and hardness measurements. XRD analyses revealed that there are no other
phases besides Cu and SiC in the sintered samples. Electrical conductivity of pure copper was reduced from 91.7±1.8 % IACS
to 66.4±0.9 % IACS but the hardness of pure copper was increased from 127±1.2 HVN to 142±6.0 HVN with the addition of
3 % of mass fraction of SiC. Contact-count experiments were made with these samples to determine the contact performance for
(3000, 6000, 9000, 12.000 and 21.000) turns-on/off. The loss of the contact material increased with the increasing number of
turn-ons, related with the increased copper oxide amount formed on the contact surfaces.
Keywords: Cu-SiC composite, hardness, relative density, electrical conductivity, IACS, contacts test
Namen {tudije je izbolj{anje mehanskih lastnosti elektri~nih kontaktov iz bakra in kompozita bakra, oja~anega z delci silicije-
vega karbida, izdelanih iz prahov. Prah bakra je bil izdelan z metodo cementacije. ^isti baker in me{anice bakra s 3 masnimi
odstotki SiC so bili enoosno stiskani s tlakom 280 MPa in sintrani 2 h na 700 °C v atmosferskem okolju. Po sintranju so bili
vzorci {e vro~i stisnjeni z obte`bo 850 MPa. Vzorci so bili karakterizirani s preiskavo mikrostrukture, z eksperimenti relativne
gostote, z meritvijo elektri~ne prevodnosti in z meritvijo trdote. Rentgenska difrakcija je odkrila, da v sintranih vzorcih ni
drugih faz, razen Cu in SiC. Elektri~na prevodnost ~istega bakra se je zmanj{ala iz 91,7±1,8 % IACS na 66,4±0,9 % IACS,
trdota ~istega bakra se je pove~ala iz 127±1,2 HVN na 142±6,0 HVN z dodatkom 3 masnih odstotkov SiC. Preizkusi {tevila
kontaktov so bili izvedeni s temi vzorci za dolo~itev zmogljivosti kotaktov pri (3.000, 6.000, 9.000, 12.000 in 21.000) vklopih in
izklopih. Izguba materiala kontakta se pove~uje s pove~anjem {tevila vklopov, kar je posledica pove~anega obsega tvorbe oksida
bakra na kontaktni povr{ini.
Klju~ne besede: Cu-SiC kompozit, trdota, relativna gostota, elektri~na prevodnost, IACS, preizkus kontaktov
1 INTRODUCTION
There are many electrical contact materials subject to
relative motions and used in a variety of applications,
such as electrical switches, contactors, circuit breakers,
connectors, relays, chips in cards, voltage regulators, arc-
ing tips and switch gears.1,2 Electrical contact materials
used in these applications must have a good combination
of wear strength, high electrical conductivity, and ero-
sion and welding resistance. On the contrary, low electri-
cal conductivity and wear resistance cause poor contact
and arcing, and thus the contacts erode. An electric arc is
the form of an electric discharge with the highest current
density that takes place when contacts are in the process
of establishing a current flow interrupting the flow of the
current. Depending on high temperature and mass flow
on the contact material surface, an erratic contact resis-
tance and a material loss occur, thus the contact material
surface is severely corroded and eroded. Hence, a contact
material should have a high resistance to corrosion as
well as a high arc-erosion resistance to maintain the con-
tact integrity by having high electrical and thermal
conductivity, a high melting point and also a certain
strength.2,3 As copper has a high thermal conductivity, a
low electrical resistance, a lower coefficient of thermal
expansion (CTE) than aluminum and can easily be
formed or machined into complicated lead frames or
base plates, it is extensively used for cables, wires, elec-
trical contacts and a wide variety of other parts that are
required to pass electrical current.4,5
Cu-based composites were feasible to be used as
electrical-contact materials in relays, contactors, switches,
circuit breaks and other switch-gear components.6 As
SiC has a high thermal conductivity and offers good
availability, low price and possible machinability, it can
be used as a reinforcement in copper-based composites
for high-performance heat-sink materials and packages.
Dispersion of fine SiC particles improve the copper-
matrix strength through impeding the dislocation move-
ment and also prevent the grain growth of the copper
Materiali in tehnologije / Materials and technology 50 (2016) 4, 585–590 585
UDK 67.017:661.665.1:691.73 ISSN 1580-2949
Original scientific article/Izvirni znanstveni ~lanek MTAEC9, 50(4)585(2016)
matrix at high temperature so that the composites can
maintain a relatively high strength at elevated tempera-
ture.3,7–9 In the present work, the effects of SiC particles
on the electrical, mechanical and also contact perfor-
mance of Cu-SiC composites were investigated.
2 EXPERIMENTAL DETAILS
The copper powder used in this study was produced,
with the cementation method, from CuSO4 solutions
using metallic-iron powder. Cemented Cu powder and
3 % mass fractions of SiC powder with a 99.5 % purity
and a 1 μm particle size were mechanically mixed and
cold pressed. The sintering of pure copper and copper
3 % mass fraction of SiC was performed at 700 °C for
2 h, embedded in the graphite powder. In order to
increase the relative density and mechanical properties of
test samples, they were hot pressed after the sintering.
The presence of the phases formed within the sintered
samples was determined with X-ray diffraction using
Cu-K radiation with a wavelength of 1.5418 A over a 2
range of 10–90°. The relative densities of the composites
were measured with a method based on Archimedes’
law.
The microstructure analysis of the composites was
performed with a JEOL JSM-5600 model scanning
electron microscope (SEM). The microhardness of both
pure copper and the composite was measured with a
Leica WMHT-Mod model Vickers-hardness instrument
under an applied load of 50 g. The measurements of
electrical conductivity of the specimens were performed
with a GE-model electrical-resistivity measurement
instrument. The experimental set-up for the contact test
consisted of a square 555-wave oscillator turning on/off
the contactor, a counter and a contactor, on which the
samples were mounted. The contact counter was ad-
justed to the desired number (3000, 6000, 9000, 12.000
and 21.000) before the experiment. When the selected
count number was reached, the operation was automa-
tically ended. The electrical load over the counter was
1600 W (at 220 V) for all the experiments. The experi-
mental set-up used in this study is shown in Figure 1.
The weight loss of the samples was determined. Subse-
quently, surface and oxide evaluations of the samples
were carried out with SEM-EDS.
3 RESULTS AND DISCUSSION
SEM micrographs of Cu and the SiC reinforcement
agent used in the experimental studies and the sintered
Cu-3 % of mass fractions of SiC composite are given in
Figure 2. It is seen from Figure 2a that copper powder
has a spherical shape and a particle size of 5 μm; and it is
seen from Figure 2b that SiC particles have an angular
and irregular shape, and a diameter of 1 μm. In Figure
2c light-grey areas indicate the Cu matrix and dark-grey
and cornered shapes indicate the SiC reinforcement com-
ponent.
XRD patterns of the Cu-3 % of mass fractions of SiC
composite consist of copper and SiC peaks (Figure 3).
No oxide peak was observed in the XRD analysis of the
Cu-3 % of mass fractions of SiC composite sintered at
700 °C for 2 h. The relative density, hardness and %
IACS (the international annealed copper standard) of the
samples are given in Table 1. The relative density of the
sintered samples decreased with the addition of SiC
because SiC particles behave as an obstacle for the Cu
atom diffusion. On the contrary, the hardness was found
to increase with the SiC addition. The SiC addition
strongly impeded the plastic flow, causing the hardness
of the Cu-SiC composite to increase with the amount of
reinforcing particles. It is known that the higher the
relative density the higher is the electrical conductivity.
G. F. C. EFE et al.: FABRICATION AND PROPERTIES OF SiC REINFORCED COPPER-MATRIX-COMPOSITE ...
586 Materiali in tehnologije / Materials and technology 50 (2016) 4, 585–590
Figure 1: Images of: a) experimental set-up, b) contactor, on which
samples were fixed, and contacts, c) dynamic contacts
Slika 1: Posnetki: a) eksperimentalnega sestava, b) kontaktorja, na
katerem so pritrjeni vzorci in kontakti, c) dinami~nih kontaktov
The electrical conductivity of the composites decreased
with the increment in the SiC content because
ceramic-based SiC forms a barrier to the motion of
copper electrons, providing electrical conductivity.
Generally, the weight loss increased with the in-
creasing contact count for both Cu and Cu-3 % of mass
fractions of SiC composite. But it is obvious that the
material loss of the Cu-3 % of mass fractions of SiC
composite is higher than that of pure Cu (Figure 4).
Table 1: Relative density, hardness and electrical-conductivity values
of Cu and Cu-3 % of mass fractions of SiC composite sintered at 700
°C for 2 h
Tabela 1: Relativna gostota, trdota in elektri~na prevodnost Cu in
kompozita Cu-3 % masnega dele`a SiC, 2 h sintranega na 700 °C
Samples Relative density(%)
Hardness
(HV) % IACS
Cu 97.5 ± 0.8 127 ± 1.2 91.7 ± 1.8
Cu-3% of mass
fractions of SiC 92.3 ± 1.1 142 ± 6 66.4 ± 0.9
SEM photographs of the sample surfaces after (3000,
6000 and 9000) turns-on/off are given in Figures 5 and
6. When SiC reinforced contact materials heat up, they
have to absorb heat, cool down the contact and delay the
arc formation; thus, their material loss is lower than that
of pure copper.2 But it can be seen from the SEM micro-
graphs that the surface of the Cu-3 % of mass fractions
of SiC composite is destroyed to a larger extent than the
surface of pure Cu; in addition, spherical formations,
which got smaller with the increasing contact count
number, were detected on the contact surfaces. With the
increasing contact count number, deformed regions
G. F. C. EFE et al.: FABRICATION AND PROPERTIES OF SiC REINFORCED COPPER-MATRIX-COMPOSITE ...
Materiali in tehnologije / Materials and technology 50 (2016) 4, 585–590 587
Figure 3: XRD patterns of Cu-3 % of mass fractions of SiC composite
sintered at 700 °C for 2 h
Slika 3: Rentgenogram kompozita Cu-3 % masnega dele`a SiC,
sintranega 2 h na 700 °C
Figure 2: SEM micrographs of: a) copper powder, b) SiC particles
and c) Cu-3 % of mass fractions of SiC composite
Slika 2: SEM-posnetki: a) prah bakra, b) delci SiC in c) kompozit
Cu-3 % masnega dele`a SiC
Figure 4: Weight loss of the contact via the contact count number
Slika 4: Zmanj{anje te`e kontakta v odvisnosti od {tevila vklopov
increased and local melting and smearing areas were
formed.
EDS result taken from the surfaces of the contact
samples are given in Figures 7 and 8. It was found that
the weight loss increased with the increasing number of
turns on/off in the contact-count experiments. Surface
evaluations showed that oxide increased when the num-
ber of turns on/off increased and the arc formation got
easier. O. Guler and E. Evin2 claimed that an increased
copper oxide amount simplifies the arc formation bet-
ween the contacts by increasing the contact resistance.
An increasing arc or a high resistance on a contact-mate-
rial surface during a turn on/off heats up the contact
surfaces. When the contact number is increased, particles
on the surface become coarser. Brittle oxide layers on the
contact material are broken by the impact force formed
during turns on/off and removed from the surface. This
causes a mass loss. This situation continues with a feed-
back mechanism.2 The EDS analysis of the sphere for-
mations on the pure Cu surface after 9000 contacts show
that these regions are O- and Cu-rich areas (Figure 7).
The EDS analysis shows that many Cu-rich regions
G. F. C. EFE et al.: FABRICATION AND PROPERTIES OF SiC REINFORCED COPPER-MATRIX-COMPOSITE ...
588 Materiali in tehnologije / Materials and technology 50 (2016) 4, 585–590
Figure 5: SEM micrographs of Cu and Cu-3 % of mass fractions of SiC composite at a low magnification after 3000, 6000 and 9000 turns on/off
Slika 5: SEM-posnetki Cu in kompozita Cu-3 % masnega dele`a SiC pri majhni pove~avi, po 3000, 6000 in 9000 vklopih in izklopih
Figure 6: SEM micrographs of Cu and Cu-3 % of mass fractions of SiC composite after 3000, 6000 and 9000 turns on/off
Slika 6: SEM-posnetki Cu in kompozita Cu-3 % masnega dele`a SiC po 3000, 6000 in 9000 vklopih in izklopih
remain intact because they are under the average contact
level. The remaining Cu-rich areas show that the contact
material can resist more turn on/off cycles.
In Figure 8, glassy regions rich with silicon, verified
with the EDS analysis, are obvious. SiC particles
probably oxidized with the increasing arc, the heat effect
and/or the Cu and Si compounds formed. A. K. Kang
and S. B. Kang10 indicated that SiC particles decompose
into Si and C and merge with Cu. T. Schubert et al.5
claimed that SiC is not stable at elevated temperatures
and forms Cu-Si solid solutions due to its decompo-
sition. In Figure 8, Si-rich areas indicated with arrows
have some bubbles and pores. These pores may result
from gas reactions. It is thought that the gases in these
bubbles leak towards the surface with the increasing
heat/arc and bulge on the material surface. During the
contact test, decomposed C reacts with O, which results
in CO2 and CO gas formations.10 The microcracks in the
micrographs indicate that the contact surfaces are brittle
and may be coated with a thin oxide film (Figure 8b).
4 CONCLUSIONS
A cemented Cu-SiC composite was manufactured
successfully with the powder-metallurgy method. The
presence of Cu and SiC was verified with an XRD
analysis. All of the samples manufactured had a remark-
ably high relative density. The hardness of the composite
was increased with added SiC. It was observed that the
electrical conductivity of the Cu-SiC composite is in
good agreement with the literature. During the contact-
count experiments, the weight loss and oxidation
increased with the increasing number of turns on/off for
both samples. Also, the surface of the Cu-3 % of mass
fractions of SiC composite was destroyed to a larger
extent than the surface of pure Cu.
Acknowledgment
The authors thank expert Fuat Kayis for performing
the XRD and SEM-EDS studies and special thanks are
G. F. C. EFE et al.: FABRICATION AND PROPERTIES OF SiC REINFORCED COPPER-MATRIX-COMPOSITE ...
Materiali in tehnologije / Materials and technology 50 (2016) 4, 585–590 589
Figure 7: SEM micrograph and EDS analysis of Cu contact after 9000
turns on/off
Slika 7: SEM-posnetek in EDS-analiza Cu kontakta po 9000 vklopih
in izklopih
w/%
Marks
1 2 3 4 5 6
C 15.66
O 16.25 17.68 23.900 20.87 17.87 1.641
S 0.328
Fe 1.181 0.845 1.035 1.158 0.765 0.510
Cu 82.56 65.79 74.737 77.96 81.35 97.85
Figure 8: EDS analysis of Cu-3 % of mass fractions of SiC composite
after: a) 3000, b) 9000 turns on/off
Slika 8: EDS-analiza kompozita Cu-3 % masnega dele`a SiC po:
a) 3000 in b) 9000 vklopih in izklopih
w/%
Marks
1 2 3 4 5 6 7
C 2.364
O 8.36 42.1 16.9 39.4 31.9 24.0 21.8
Si 16.1 4.39 17.8 11.9 6.00 11.2
Fe 0.86 4.08 0.83 5.86 2.90 1.83 5.85
Cu 88.4 37.6 77.8 36.8 53.1 68.1 60.9
w/%
Marks
1 2 3 4 5 6
O 42.05 7.707 8.085 49.89 51.44 11.06
Si 17.77 0.939 1.630 15.83 14.76 0.219
Fe 8.527 1.152 1.024 6.112 5.813 0.226
Cu 31.64 90.20 89.26 28.15 27.97 35.09
extended to technician Ersan Demir of the Sakarya Uni-
versity for assisting with the experimental studies. This
work was conducted as a project supported by TUBI-
TAK, with the contract number of 106M118.
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G. F. C. EFE et al.: FABRICATION AND PROPERTIES OF SiC REINFORCED COPPER-MATRIX-COMPOSITE ...
590 Materiali in tehnologije / Materials and technology 50 (2016) 4, 585–590