Microstructure and Wear Performance of Fly Ash-Reinforced Copper Matrix Composites Prepared via Powder Metallurgy

This research work investigated the role of fly ash particles (0, 5, 10, 15 and 20 wt.%) on the microstructural evolution and the wear resistance under dry sliding conditions of copper matrix composites (CMCs), prepared through powder metallurgy (PM) route. Copper and fly ash particles were initially mixed in a twin-shell blender, compacted in a die and sintered in a protected muffle furnace. Proper dispersion of fly ash particles was obtained. XRD plots did not show the formation of any other compounds or oxides. The increase in fly ash content increased porosity content. EBSD images of the composites revealed grain refinement due to the incorporation of fly ash particles. Fly ash reinforcement particles enhanced the resistance to wear and lowered the values of the coefficient of friction (COF). The wear mechanism shifted to abrasive wear from microcutting at particle content exceeding 10 wt.%. The electrical conductivity of the prepared CMCs was negatively affected by fly ash particles.