applied

sciences
Article
Effect of SiC and WC Reinforcements on Microstructural and
Mechanical Characteristics of Copper Alloy-Based Metal Matrix
Composites Using Stir Casting Route
Priyaranjan Samal 1, * , Harihar Tarai 2 , Arabinda Meher 3, * , B. Surekha 4 and Pandu R. Vundavilli 2

1 Department of Mechanical Engineering, Koneru Lakshmaiah Education Foundation,

Vaddeswaram 522302, India
2 School of Mechanical Sciences, Indian Institute of Technology, Bhubaneswar 752050, India
3 Department of Mechanical Engineering and University Centre for Research & Development, Chandigarh
University, Mohali 140413, India
4 School of Mechanical Engineering, KIIT deemed to be University, Bhubaneswar 751024, India
* Correspondence: [email protected] (P.S.); [email protected] (A.M.)

Abstract: This study focuses on a comparative analysis of mechanical behavior and microstructural
characteristics of Cu matrix (C87600) based hybrid composites reinforced with SiC-Grp and WC-Grp
fabricated by the stir casting process. The graphite particle percentage was kept constant, whereas the
content of SiC and WC in the respective composites was varied to analyze the mechanical properties
of the fabricated composites. The morphological observation was carried out by field emission
scanning electron microscope (FESEM), which revealed uniform dispersion of the reinforced particles
in the hybrid composites. Clear phases of SiC and WC along with the Cu alloy were identified by the
x-ray diffractometer (XRD). Further, a comparative study was conducted to analyze the mechanical
behavior of the Cu-SiC-Gr and Cu-WC-Gr hybrid composites. With the addition of the hard ceramic
materials, the tensile behavior and microhardness of both the Cu-based MMCs were improved. The
WC-Gr reinforced composites exhibited higher mechanical properties than the SiC-Gr reinforced
Citation: Samal, P.; Tarai, H.; Meher, hybrid composites. Further, the fracture surfaces were also characterized to study the tensile behavior
A.; Surekha, B.; Vundavilli, P.R. Effect of the fabricated copper-based hybrid composites, which shows that ductile fracture was mainly
of SiC and WC Reinforcements on associated with both hybrid composites.
Microstructural and Mechanical
Characteristics of Copper Keywords: metal matrix composites; copper; stir casting; tensile strength; mechanical behavior
Alloy-Based Metal Matrix
Composites Using Stir Casting Route.
Appl. Sci. 2023, 13, 1754. https://
doi.org/10.3390/app13031754
1. Introduction
Academic Editor: Anthony William Metal matrix composites (MMCs) are the most promising materials and find their
Coleman
usage in a wide range of industrial applications such as automotive, aerospace, defense,
Received: 12 December 2022 marine, electronics, etc. Moreover, MMCs do not lose their basic behavior even in critical
Revised: 21 January 2023 environmental conditions. Further, MMCs exhibit superior properties over monolithic
Accepted: 24 January 2023 materials in terms of higher stiffness, strength, specific weight, excellent wear and corrosion
Published: 30 January 2023 resistance, etc. [1–3]. Still, issues and the possibility of amalgamation of several matrices
and reinforcements are present in the development of MMCs. Copper alloy matrix-based
composites are widely utilized in different automobile and electronics components owing
to their exceptional corrosion and wear resistance, high weldability, high thermal conduc-
Copyright: © 2023 by the authors. tivity, etc. [4,5]. Xiao et al. [6] studied the tensile and tribological properties of Cu matrix
Licensee MDPI, Basel, Switzerland. composites as brake pad materials for high-speed trains, in which the copper composites
This article is an open access article
exhibited excellent mechanical and frictional behavior.
distributed under the terms and
The characteristics of various copper composites can be enhanced with proper con-
conditions of the Creative Commons
sideration of the ceramic reinforcement particles. Wang et al. [7] reported the usage of
Attribution (CC BY) license (https://
Al2 O3 particulates as reinforcement in the Cu-based composite, where grain refinement
creativecommons.org/licenses/by/
strengthening was found to be superior to particle dispersion strengthening. Similarly,
4.0/).

Appl. Sci. 2023, 13, 1754. https://doi.org/10.3390/app13031754 https://www.mdpi.com/journal/applsci

Appl. Sci. 2023, 13, 1754 2 of 18

Ramesh et al. [8] examined the mechanical characteristics of Cu-based hybrid composites.
The tensile properties and hardness of the hybrid composites were enhanced due to the
synergistic effect of the reinforcement particulates along with their interfacial bonding
with the matrix alloy. Singh et al. [9] reported the mechanical properties of pure copper
matrix composites incorporated with WC-Al2 O3 -Cr and WC-ZrO2 -Cr reinforcements using
the stir-casting process. They reported that the alumina particulate reinforced composites
exhibited enhanced properties than zirconia owing to the load transfer effect and particle
strengthening. Similarly, Liang et al. [10] fabricated copper matrix-based composites with
TiB2 particles and TiB whiskers as reinforcements using in-situ casting followed by rolling
and annealing. With the combined influence of whiskers and particles, the hybrid compos-
ites exhibited enhanced strength. Further, Zhang et al. [11] investigated the mechanical
and microstructural characterization of Cu alloy composites reinforced with ZrB2 by the
in-situ synthesis process. The effects of cryo-rolling and aging treatment resulted in an
increment in the tensile properties with the help of precipitation and dislocation strength-
ening mechanisms. Sap et al. [12] produced Cu-SiC-Ti-B hybrid composites following
the powder metallurgy method, where the homogenous interface with the matrix was
observed. Further, the bending and tensile strength were also improved by incorporating
hybrid reinforcements.
Furthermore, Yin et al. [13] reported the mechanical characteristics of Cu-TiB2 -TiN
hybrid composites prepared by high-temperature self-propagating reaction synthesis fol-
lowed by the hot pressing process. The strengthening effect resulted from the higher
load-carrying ability of the ceramic particulates yielded better tensile strength of the copper
composites. Nageswaran et al. [14] investigated the tensile behavior of the copper hybrid
composites reinforced with titanium dioxide and graphite particles synthesized by the stir
casting method. Homogenous dispersion along with a reduction in grain size gave rise to
refinement in the copper phase, which in turn strengthened the copper-based composites.
Singh et al. [15] studied the mechanical characteristics of Copper/WC hybrid composites
with highly strained stainless steel chips fabricated through the liquid metallurgy process.
The ultimate tensile strength and micro-hardness of the MMCs were enhanced consid-
erably along with the corrosion resistance as related to the base copper alloy. Further,
TiC-reinforced copper alloy composites were produced by the in-situ reaction method,
where the mechanical behavior of the composites was enhanced considerably with a decline
in electrical conductivity [16].
It can be evident from the literature that most of the studies related to copper-based
metal matrix composites utilize pure copper as the matrix phase. Further, very few works
have been reported on Cu-based hybrid composites where the Silicon brass alloy has
not yet been used as a matrix material. In this research, an effort is made to fabricate
the silicon brass copper alloy (C87600) hybrid composites by using a low-cost stir-casting
process. Furthermore, an attempt is made to study a comparative analysis of the mechanical
behavior between SiC-Gr and WC-Gr particulate-reinforced composites. The comparative
analysis was formulated in terms of tensile strength and hardness, along with the tensile
fractography behavior of the hybrid composites.

2. Materials and Methodology

In this study, commercially available silicon-brass Copper alloy, also termed C87600
alloy was considered as the matrix phase for the composites, where zinc and silicon are the
primary alloying element with traces of iron and magnesium. The elemental composition
of the C87600 alloy (as received) is presented in Table 1. This alloy exhibits high wear and
corrosion resistance behavior along with excellent conductivity. The copper alloy C87600
does not respond to heat treatment. It is usually used in marine shafting, architectural
appliances, etc., due to its exceptional wear resistance, corrosion resistance, and electrical
conductivity. Table 2 presents the physical properties of the C87600 alloy. To fabricate
the hybrid composites, SiC, WC, and Gr micro-particulates with 99% purity were bought
from Vision Casting Pvt. Ltd., Hyderabad. Besides the base matrix alloy, two sets of
Appl. Sci. 2023, 13, 1754 3 of 18

copper hybrid composites were fabricated considering SiC-Gr and WC-Gr composites. The
graphite particle being considered as secondary reinforcement, its content in the hybrid
composites was kept constant at 1 wt.%, whereas the weight percentages of SiC and
WC varied at 3 wt.%, 6 wt.%, and 9 wt.%, respectively. These hard ceramic constituents
were selected as the reinforcing phase as these materials tend to enhance the physical
characteristics to a significant extent [17,18]. The copper-based hybrid composite materials
were fabricated through the stir casting process due to their cost-effectiveness and favorable
for mass production [19].

Table 1. Elemental composition of silicon-brass Copper (C87600) alloy.

Element Zn Si Mg Fe Cu
Weight% 4.5 5.5 0.04 0.02 Remaining

Table 2. Physical properties of C87600 alloy.

Properties Values
Density 8.3 g/cm3
Hardness 120 HV
Tensile strength 350–415 MPa
Elastic modulus 110–115 GPa
Thermal conductivity 28.4 W/m.K
Melting point 1050 ◦ C

Firstly, the copper alloy (C87600) ingots were kept in a high-temperature sustaining
graphite crucible and heated in an electric furnace at a temperature of 1200 ◦ C, which
is above its melting limit. After the ingots reached a fully molten state, the pre-heated
reinforcements (heated at a temperature of 600 ◦ C for 1 h) were introduced to the copper
melt for the manufacture of the composites. Pre-heating the reinforcement is necessary
to remove any moisture content. In this stage, the reinforcements were either SiC or WC
particles as per the compositions. The mechanical stirrer was attached to the furnace, which
was uninterruptedly stirred at 400 rpm for 15 min to obtain the homogenous distribution
of the reinforcement particles. Thereafter, the graphite particles of 1 wt.% content were
introduced to the copper melt for the development of hybrid MMCs. The stirring action
was continued for another 15 min with the same speed to effectively distribute the rein-
forcements in the molten copper alloy. The complete process was conducted with argon gas
shielding to evade any contamination of the molten metals with atmospheric gases. Further,
the degasser (C2 Cl6 ) was added to the molten alloy to get rid of any dissolved hydrogen
gas existing in it. After removing the slag from the surface, the molten metals were poured
into a metallic split die, which was preheated at a temperature of 600 ◦ C. Pre-heating the
die was necessary to minimize the temperature gradient and shun the chilling effect while
pouring the molten metals. Moreover, the pre-heating process also removes the moisture
and oil present on the exposed faces, thus avoiding any surface porosity defects. Figure 1
represents the schematic representation of the stir casting setup used for the manufacturing
of the copper-based hybrid MMCs. Different compositions of the fabricated copper MMC
are presented in Table 3.
Appl. Sci. 2023, 13, 1754 4 of 18
Appl. Sci. 2023, 11, x FOR PEER REVIEW 4 of 19

Figure 1. Schematic representation of the stir casting setup for composite synthesis.
Figure 1. Schematic representation of the stir casting setup for composite synthesis.
Table 3. Compositions of the fabricated MMC.
Table 3. Compositions of the fabricated MMC.
Composites
Composition
Developed
Composites
CompositionBase Copper Alloy
Developed C0
Cu-3%SiC-1%Gr C1
Base Copper Alloy C0
Cu-6%SiC-1%Gr C2
Cu-3%SiC-1%GrCu-9%SiC-1%Gr C1 C3
Cu-6%SiC-1%GrCu-3%WC-1%Gr C2 C4
Cu-9%SiC-1%GrCu-6%WC-1%Gr C3 C5
Cu-3%WC-1%GrCu-9%WC-1%Gr C4 C6
Cu-6%WC-1%Gr C5
The fabricated copper composites were analyzed usingC6
Cu-9%WC-1%Gr FESEM and XRD to analyze
the microstructural and phase behavior. The specimen for microstructural examination
were cut with 10 mm × 10 mm dimension from the as-casted composites, and the surface
The fabricated copperwere
irregularities composites
removed bywerethe analyzed using machine.
dry belt grinding FESEM and XRD to analyze
The specimens were pol-
the microstructural and several
ished with phase grades
behavior. The paper
of emery specimen
(up tofor
1500microstructural
grade) followed examination
by velvet cloths
were cut with 10 mm ×by
polishing 10aerosol
mm dimension
and diamond from the as-casted
suspension. Further,composites, and the
a chemical etchant surfaceof
consisting
50 ml
irregularities were Nitric acid
removed byand
the50
drymlbelt
distilled water machine.
grinding was used forThethespecimens
etching process
weretopolished
reveal the
microstructure of the copper alloy composites. The compositional
with several grades of emery paper (up to 1500 grade) followed by velvet cloths polishing details along with mor-
phological analysis of the hybrid composites were obtained using a field emission scan-
by aerosol and diamond suspension. Further, a chemical etchant consisting of 50 mL Nitric
ning electron microscope (FESEM) coupled with an EDX detector (ZEISS Merlin Compact
acid and 50 mLGemini).
distilledX-ray
water was used for
diffractometer the etching
(BRUKER process towas
D8 ADVANCE) reveal the microstructure
utilized to characterize the
of the copper phase
alloy structure
composites.
analysis of the hybrid composites, which was carriedmorphological
The compositional details along with out in the 2θ inci-
analysis of the dent
hybrid composites
angle were[20].
range of 20°–90° obtained using a field
In the diffraction emission
process, scanning
Cu Kα radiation electron
with a wave-
length of 1.54 Å was generally used. An automatic Vickers
microscope (FESEM) coupled with an EDX detector (ZEISS Merlin Compact Gemini). hardness testing apparatus
(Zwick Roell
X-ray diffractometer Indentec)
(BRUKER D8was employed to was
ADVANCE) evaluate the micro-hardness
utilized to characterize of thethe
copper
phasecom-
posites, where the experiments were conducted at an indentation load of 500 gf with a 10
structure analysis of the hybrid composites, which was carried out in the 2θ incident angle
sec dwell time. Five sets of hardness values were measured at five different locations of
range of 20◦ –90 ◦ [20]. In the diffraction process, Cu K radiation with a wavelength of
the specimen, and the average value along withα the standard deviation was reported as
1.54 Å was generally used. An automatic
the ultimate hardness Vickers
value of the hardness
composites. testingthe
To evaluate apparatus (Zwick
tensile strength of Roell
the fab-
Indentec) was employed to evaluate the micro-hardness of the copper
ricated composites, the samples were machined by a wire-EDM machine from composites, where
the as-
the experiments werecomposites
casted conducted at an indentation
according to ASTM E8Mload of 500
standards gf with
which haveagauge
10 sec dwell
lengths of time.
25 mm
and width of 6 mm. The schematic diagram of the tensile sample is
Five sets of hardness values were measured at five different locations of the specimen, and shown in Figure 2. The
the average value along with the standard deviation was reported as the ultimate hardness
value of the composites. To evaluate the tensile strength of the fabricated composites, the
samples were machined by a wire-EDM machine from the as-casted composites according
to ASTM E8M standards which have gauge lengths of 25 mm and width of 6 mm. The
schematic diagram of the tensile sample is shown in Figure 2. The tensile tests were
conducted in a computerized universal testing machine (TUE-C-400) at room temperature
with an extension speed of 1 mm/min. Three experiments were performed for each
composition of the composite to have the average tensile strength value along with the
 Appl. Sci. 2023, 11, x FOR PEER REVIEW 5 of 19

Appl. Sci. 2023, 13, 1754 5 of 18

Appl. Sci. 2023, 11, x FOR PEER REVIEW 5 of 19
tensile tests were conducted in a computerized universal testing machine (TUE-C-400) at
room temperature with an extension speed of 1 mm/min. Three experiments were per-
formed fordeviation
standard each composition
presented.of the composite
The tensile to have the average
fractography wastensile strength value
also analyzed by the FESEM to
along with the tensile tests
standard were conducted
deviation presented.inThe
a computerized
tensile universalwas
fractography testing
alsomachine (TUE-C-400) at
analyzed
examine the fracture behavior of the composites. The experimental process
room temperature with an extension speed of 1 mm/min. Three experiments followed
were per-for
by the FESEM to examine the fracture behavior of the composites. The experimental pro-
the current study is shown
formed incomposition
for each Figure 3. of the composite to have the average tensile strength value
cess followed for the current study is shown in Figure 3.
along with the standard deviation presented. The tensile fractography was also analyzed
by the FESEM to examine the fracture behavior of the composites. The experimental pro-
cess followed for the current study is shown in Figure 3.

Figure 2. Schematic of the tensile test specimen.

Figure 2. Schematic of the tensile test specimen.
Figure 2. Schematic of the tensile test specimen.

Figure 3. Process flow chat3.for

Figure the current
Process research.
flow chat for the current research.
Figure 3. Process flow chat for the current research.
3. Results and Discussion
3. Results and Discussion
3. Results and Discussion
3.1.
3.1. Microstructural Microstructural Characterization
Characterization
3.1. Microstructural Characterization
The microstructure Theofmicrostructure
the as-received of the
baseas-received
copper alloybaseiscopper
shownalloy is shown
in Figure 4. Itincan
Figure 4. It can
The microstructure
be observed frombethe
observed offrom
the the
micrograph as-received
thatmicrograph base
the dendritic copper
thatstructure
the alloy
dendritic
of is shown
structure
the silicon of the
brass inalloy
Figure
silicon 4. It
isbrass canisbe
alloy
observed from clearly
the visible.
micrograph Similarly,
that the
the composition
dendritic of the
structurecopper
of alloy
the
clearly visible. Similarly, the composition of the copper alloy can also be confirmed from can
silicon also be
brass confirmed
alloy is from
clearly
the EDXshows
images, which shows the zinc and silicon element in the alloy. mi-
The FESEM mi-
visible. Similarly, the composition of the copper alloy can also be confirmed from the EDX
the EDX images, which the zinc and silicon element in the alloy. The FESEM
crostructure crostructure
of the Cu-SiC-Gr ofand
the Cu-WC-Gr
Cu-SiC-Gr and Cu-WC-Gr
hybrid hybrid
composites arecomposites
shown in are shown
Figures 5 in Figures 5
images, which shows the zinc
and 6, respectively.andThesilicon element
homogenous in the alloy.
distribution of the The FESEM
reinforcement microstructure
particulates could of
andCu-SiC-Gr
the 6, respectively.
and The homogenous
Cu-WC-Gr distribution of the are
reinforcement in particulates could
be visible from thehybrid composites
SEM micrographs, which wasshownthe result Figures 5 and
of the optimum 6, respectively.
stirring action
be visible from the SEM micrographs, which was the result of the optimum stirring action
The homogenous distribution of the reinforcement particulates could be visible from the
SEM micrographs, which was the result of the optimum stirring action throughout the
casting process. Moreover, the vortex formation due to the mechanical stirring within the
melt resulted in the uniform dispersion of the reinforcement phases during the stir-casting
process [21]. When the FESEM images were examined, it could be said that there were
no signs of agglomeration of the particles for both the hybrid composites. Pointed and
irregularly formed SiC could be easily observed from the microstructures, whereas the
spherical (round) shaped WC was observed for the respective composites. Moreover, there
were no shrinkage porosity defects which also demonstrates an effective stir-casting process.
Similarly, the intensity of the alloying elements as well as the reinforcing elements was also
 Appl. Sci. 2023, 11, x FOR PEER REVIEW 6 of 19

throughout the casting process. Moreover, the vortex formation due to the mechanical
Appl. Sci. 2023, 13, 1754 stirring within the melt resulted in the uniform dispersion of the reinforcement phases 6 of 18
during the stir-casting process [21]. When the FESEM images were examined, it could be
said that there were no signs of agglomeration of the particles for both the hybrid compo-
sites. Pointed and irregularly formed SiC could be easily observed from the microstruc-
observed in the tures, whereas
regional EDXthe spherical
analysis.(round) shaped
Several WC was observed
elements like Zn,for Si,
the respective
C, O, and compo-
W existed
sites. Moreover, there were no shrinkage porosity defects which also demonstrates an ef-
along with the copper matrix that established the development of the composites.
fective stir-casting process. Similarly, the intensity of the alloying elements as well as the The
micrographs also revealed
reinforcing that was
elements thealso
concentration
observed in theof the elements
regional in Several
EDX analysis. the base alloy was
elements
like Zn,
different from that of Si,
the C, composites,
O, and W existedwhich
along with the copper matrix
corresponds thatdifferent
to the established content
the devel- of the
opment of the composites. The micrographs also revealed that the concentration of the
reinforcements.elements
Further, the very low oxygen content, as shown in the EDX spectrum,
in the base alloy was different from that of the composites, which corresponds
revealed that substantially
to the different minimum
content of the oxidation
reinforcements.happened
Further, theduring
very lowthe fabrication
oxygen content, as as the
whole process was carried out under the argon atmosphere. This restrictedhappened
shown in the EDX spectrum, revealed that substantially minimum oxidation any possible
during the fabrication as the whole process was carried out under the argon atmosphere.
contamination with the outside oxide environment, which could have
This restricted any possible contamination with the outside oxide environment, which
deteriorated the
quality of the casting.
could have deteriorated the quality of the casting.

Figure 4. FESEM micrograph and EDX analysis of Cu alloy matrix.

Appl. Sci. 2023, 11, x FOR
Figure PEER REVIEW
4. FESEM micrograph and EDX analysis of Cu alloy matrix. 7 of 19

Figure 5. FESEM Figure 5. FESEM micrograph and EDX analysis of Cu-SiC-Gr hybrid composites with SiC variation
micrograph and EDX analysis of Cu-SiC-Gr hybrid composites with SiC variation
of (a) 3, (b) 6, and (c) 9 wt.%.
of (a) 3, (b) 6, and (c) 9 wt.%.
Appl. Sci. 2023, 13, 1754 7 of 18
Appl. Sci. 2023, 11, x FOR PEER REVIEW 8 of 19

Figure 6. FESEM
Figure 6. FESEM micrograph andmicrograph
EDX analysisand EDX analysis of hybrid
of Cu-SiC-Gr Cu-SiC-Gr hybrid composites
composites with WC with WC variation
variation
of (a) 3, (b) 6, and (c) 9 wt.%.
of (a) 3, (b) 6, and (c) 9 wt.%.

3.2. XRD Analysis3.2. XRD Analysis

The XRD spectrum of the fabricated Cu-SiC-Gr and Cu-WC-Gr hybrid composites
The XRD spectrum of the fabricated Cu-SiC-Gr and Cu-WC-Gr hybrid composites
are shown in Figures 7 and 8, respectively. The phase structure examination of the hybrid
are shown in Figures 7 andwas
composites 8, respectively.
conducted at aThe phase angle
diffraction structure
of 20° examination of the
to 90° by the x-ray hybrid Ma-
diffraction.
composites was jor conducted
diffractionat a diffraction
peaks of Cu wereangle found of 20◦base
in the to 90 ◦
alloybyas the
wellx-ray
as the diffraction.
composites. The
Major diffractionpeaks
peaks of Cu were
corresponding to found in the
the 2θ angle of base
34.4°, alloy as well
50.5°, and as the
74.1° refer composites.
to the copper peaks,
and the lattice
The peaks corresponding to planes
the 2θareangle 0 0),◦and
(1 1 1),of(234.4 (2 2◦ ,0),
, 50.5 and 74.1◦ refer
respectively. Similarly,
to theclean peaks of
copper
SiC were
peaks, and the lattice found
planes in (1
are Figure
1 1),5,(2whereas
0 0), andthe peaks
(2 2 0), of respectively.
WC can also beSimilarly,
observed inclean
Figure 6.
The very small peak of graphite can be visible in both the hybrid composites due to the
peaks of SiC were found in Figure 5, whereas the peaks of WC can also be observed in
small intensity as compared with the Cu peaks. The XRD pattern shows that there are no
Figure 6. The very small peak
intermediate of graphite
reactions betweencan be visible
Cu with SiC or WC in both the hybrid
and graphite that composites
can be confirmed
due to the small from
intensity as compared
the spectrum, whichwithshows theaCu peaks. casting
successful The XRD pattern
process. Theshows
absencethatof any
there are no intermediate reactions between Cu with SiC or WC and graphite that can be
confirmed from the spectrum, which shows a successful casting process. The absence of
any undesirable intermetallic reaction products in the composites was a good sign for the
hybrid composites, which otherwise would have adversely affected the properties. Sadeghi
et al. [22] fabricated nano-MMCs of Cu-reinforced in-situ TiC and carbon particles, and
they reported only diffraction peaks related to TiC and Cu without any other intermetallic
compounds. Moreover, the careful analysis revealed that the intensity of the peaks in
the case of the composites was changed with respect to the base alloy, which can be
 Appl. Sci. 2023, 11, x FOR PEER REVIEW 9 of 19

undesirable intermetallic reaction products in the composites was a good sign for the hy-
undesirable intermetallic
brid composites, reaction products
which otherwise would have in the composites
adversely wasthe
affected a good sign forSadeghi
properties. the hy-
Appl. Sci. 2023, 13, 1754 brid composites, which otherwise would have adversely affected the
et al. [22] fabricated nano-MMCs of Cu-reinforced in-situ TiC and carbon particles,properties. Sadeghi
8 ofand
18
et al.reported
they [22] fabricated nano-MMCs
only diffraction ofrelated
peaks Cu-reinforced in-situ
to TiC and TiC andany
Cu without carbon
otherparticles, and
intermetallic
they reportedMoreover,
compounds. only diffraction peaksanalysis
the careful related to TiC andthat
revealed Cuthe
without any of
intensity other
theintermetallic
peaks in the
compounds. Moreover,was
case of the composites thechanged
careful analysis revealed
with respect to thethat the
base intensity
alloy, whichofcan
thebepeaks in the
associated
associated with the reinforcement content for both the hybrid composites. Further, the
case
withofthethe composites was
reinforcement changed
content withthe
for both respect to composites.
hybrid the base alloy, which the
Further, canmajor
be associated
diffrac-
major diffraction peaks of the copper elements in the hybrid composites were shifted
with the reinforcement
tion peaks of the coppercontent
elementsforin
both
the the hybrid
hybrid composites.
composites wereFurther,
shifted the majoradiffrac-
towards higher
towards a higher two-theta angle compared to that of the base matrix, which also facilitated
tion peaksangle
two-theta of thecompared
copper elements
to that in
of the hybrid composites
base matrix, whichwere shifted towards
also facilitated a higher
the incorpora-
the incorporation of the ceramic reinforcements.
two-theta
tion of theangle compared
ceramic to that of the base matrix, which also facilitated the incorpora-
reinforcements.
tion of the ceramic reinforcements.

Figure7.7.XRD
Figure XRDphase
phaseanalysis
analysisofofCu
Cualloy
alloyand
andCu-(3,
Cu-(3,6,6,9)9)wt.%
wt.%SiC-Gr
SiC-Grhybrid
hybridcomposites.
composites.
Figure 7. XRD phase analysis of Cu alloy and Cu-(3, 6, 9) wt.% SiC-Gr hybrid composites.

Figure 8. XRD phase analysis of Cu alloy and Cu-(3, 6, 9) wt.% WC-Gr hybrid composites.
Figure8.8.XRD
Figure XRDphase
phaseanalysis
analysisofofCu
Cualloy
alloyand
andCu-(3,
Cu-(3,6,6,9)9)wt.%
wt.%WC-Gr
WC-Grhybrid
hybridcomposites.
composites.
3.3. Micro-Hardness Evaluation
3.3.
3.3.Micro-Hardness
Micro-Hardness Evaluation
The micro-hardnessEvaluation
values of behaviors of the Cu-SiC-Gr and Cu-WC-Gr hybrid
The micro-hardness
composites in comparisonvalues
The micro-hardness values
to theofofbehaviors
basebehaviors ofofthe
copper matrix Cu-SiC-Gr
theare
Cu-SiC-Gr
summarized and
andCu-WC-Gr
Figures 9hybrid
Cu-WC-Gr
in hybrid
and 10,
composites
composites in comparison
respectively.inItcomparison
was found to to the base
thethe
that basecopper matrix
copperofmatrix
addition are summarized
are summarized
hard and in Figures
in Figures
stiff reinforcements 99 and10,
and 10,
contributed
respectively.
respectively.It Itwas
to the improvement wasfound
foundthat
of the thethe
that addition
hardness of theofcopper
addition hard and
of hard stiffstiff
and reinforcements
composites. contributed
reinforcements to
contributed
The microhardness value
the
to improvement
the improvement of theofhardness of theof
the hardness copper composites.
the copper The microhardness
composites. value ofvalue
The microhardness the
base alloy was found to be 128 HV. It is important to note that the maximum hardness value
was observed in the case of 9 wt.% SiC-Gr and 9 wt.% WC-Gr composites in comparison to
the base matrix. However, WC-Gr reinforced hybrid composites had more hardness value
than the SiC-Gr composites. The Cu-9%SiC-1%Gr composites witnessed a microhardness
 of the base alloy was found to be 128 HV. It is important to note that the maximum hard
ness value was observed in the case of 9 wt.% SiC-Gr and 9 wt.% WC-Gr composites i
comparison to the base matrix. However, WC-Gr reinforced hybrid composites had mor
hardness value than the SiC-Gr composites. The Cu-9%SiC-1%Gr composites witnessed
Appl. Sci. 2023, 13, 1754
microhardness value of 164 HV, whereas the Cu-9%WC%-1%Gr composites exhibited
9 of 18
value of 174 HV. Further, the Cu-9%SiC-1%Gr composites revealed an increment of 28%
in comparison to the base alloy, whereas the Cu-9%WC-1%Gr had shown a 36% increas
in hardness
value of 164 HV,property.
whereas Both SiC and WC are composites
the Cu-9%WC%-1%Gr consideredexhibited
to be hard constituents,
a value of 174 HV.and the
further addition led to a significant enhancement of the
Further, the Cu-9%SiC-1%Gr composites revealed an increment of 28% in comparison hardness of the composites.
to the Var
iousalloy,
base factors resulted
whereas in the strengthening
the Cu-9%WC-1%Gr of theahybrid
had shown composites.
36% increase Primarily,
in hardness property. it is assoc
Both
atedSiC withandthe
WCuniform
are considered to be hard
distribution constituents,
of the ceramics and their further
particulates addition
in the led to matrix
soft copper
aSimilarly,
significant the
enhancement of the hardness
hard reinforcements of theresistance
caused composites. to Various factorsduring
deformation resultedthe in indenta
the strengthening of the hybrid composites. Primarily, it is associated
tion. Moreover, the interfacial strength of the SiC and WC with copper matrix improve with the uniform
distribution of the ceramics particulates in the soft copper matrix. Similarly, the hard
the hardness properties of the composites by transferring the load to the reinforcemen
reinforcements caused resistance to deformation during the indentation. Moreover, the
particles. The well-dispersed SiC and WC particles occupied the interstitial position in th
interfacial strength of the SiC and WC with copper matrix improved the hardness properties
ofcopper alloy, therefore,
the composites restricting
by transferring the loadthe local
to the deformation
reinforcement and crack
particles. growth in the compo
The well-dispersed
sites.
SiC andA WC
sample imageoccupied
particles of the indentation during
the interstitial the Vickers
position micro-hardness
in the copper testing is pre
alloy, therefore,
sented inthe
restricting Figure 11. Several and
local deformation previous worksinofthe
crack growth literature
composites. alsoAreported
sample image similarof result
Nageswaran et al. [14] examined the mechanical characteristics of the Copper hybrid com
the indentation during the Vickers micro-hardness testing is presented in Figure 11. Several
previous
posites works of literature
reinforced with also reported
titanium similarand
dioxide results. Nageswaran
graphite et al. [14]
produced examined
through stir casting
the mechanical characteristics of the Copper hybrid composites reinforced
which resulted in the enhancement of the hardness. Similarly, the Cu matrix reinforce with titanium
dioxide and graphite produced through stir casting, which resulted in the enhancement of
with TiB2 particulates exhibited higher hardness due to the homogeneity in distributio
the hardness. Similarly, the Cu matrix reinforced with TiB2 particulates exhibited higher
with less porosity in the composites [23]. Moreover, the 10 wt.% silicon carbide reinforce
hardness due to the homogeneity in distribution with less porosity in the composites [23].
Cu-Sn alloy
Moreover, composites
the 10 wt.% silicon witnessed the maximum
carbide reinforced Cu-Sn enhancement
alloy composites ofwitnessed
50% (approx.) the in th
hardness enhancement
maximum behavior dueofto 50%the(approx.)
Orowaninstrengthening and particle
the hardness behavior due to strengthening
the Orowan mecha
nism [24]. The
strengthening Orowan
and particlemechanism
strengthening is applicable
mechanismin the The
[24]. caseOrowan
of the MMCs,
mechanism where is the rein
forcements
applicable are case
in the nano of and sub-micron
the MMCs, wherelevels. Similarly, Meher
the reinforcements are nanoet al.
and[25] investigated th
sub-micron
levels.
hardness Similarly, Meherof
properties et copper
al. [25] investigated the hardness
hybrid composites properties
by powder of copper hybrid
metallurgy route. They re
composites by powder metallurgy route. They reported that
ported that the Orowan mechanism had contributed more to the increase in the the Orowan mechanism hadhardnes
contributed more to the increase in the hardness behavior of the composites due to the less
behavior of the composites due to the less inter-particle spacing for the fine reinforcemen
inter-particle spacing for the fine reinforcement particles.
particles.

Figure
Figure 9. 9. Variation
Variation of Vickers
of Vickers micro-hardness
micro-hardness Cuand
Cu alloy alloy and6,Cu-(3,
Cu-(3, 6, SiC-Gr
9) wt.% 9) wt.% SiC-Gr
hybrid hybrid compo
compos-
sites.
ites.
Appl. Sci. 2023, 11, x FOR PEER REVIEW 11

Appl. Sci. 2023, 13, 1754 10 of 18

Appl. Sci. 2023, 11, x FOR PEER REVIEW 11 of 19

Figure 10. Variation of Vickers micro-hardness Cu alloy and Cu-(3, 6, 9) wt.% WC-Gr hybrid com-
Figure 10. Variation of Vickers micro-hardness Cu alloy and Cu-(3, 6, 9) wt.% WC-Gr hybrid
posites. 10. Variation of Vickers micro-hardness Cu alloy and Cu-(3, 6, 9) wt.% WC-Gr hybrid
Figure
composites.
posites.

Figure 11. Pyramid indentation during Vickers micro-hardness test.

3.4. Tensile Strength Analysis

The effect of different reinforcements on copper alloy-based hybrid metal matrix
Figure11.11.
Figure Pyramid
Pyramid indentation
indentation duringduring
VickersVickers micro-hardness
micro-hardness test.
test. ambient
composite on tensile stress-strain behavior is analyzed under conditions. The ten-
sileTensile
3.4. properties of the
Strength developed hybrid composites are analyzed in comparison with the
Analysis
3.4.
baseTensile
copperStrength Analysis
C87600 alloy matrix. The typical image of the tensile specimens before and
The effect of different reinforcements on copper alloy-based hybrid metal matrix
after The effect of
their fracture differentinreinforcements
is presented on copper
Figure 12. The variation alloy-based
of tensile strength of hybrid
the Coppermetal m
composite on tensile stress-strain behavior is analyzed under ambient conditions. The
hybrid
composite composite with
on tensile the content
stress-strain of reinforcement
behavior is
is analyzed presented
under in Figures 13 and
ambient conditions. 14. The
tensile properties of the developed hybrid composites are analyzed in comparison with the
Bothproperties
sile the ultimateoftensile strength (UTS)
the developed and yield strength of theanalyzed
hybrid composites were wit
base copper C87600 alloy matrix. Thehybrid composites
typical image are
of the tensile specimens inbefore
comparison
and
measured and observed to be increased with an increase in the reinforcement content. The
after
basetheir fracture
copper is presented
C87600 alloy in Figure The
matrix. 12. The variation
typical image of tensile
of the strength
tensile of specimens
the Copper before
physical
hybrid and mechanical
composite with theproperties
content ofreinforcement
of the reinforcement is materialsin
presented significantly
Figures 13influence
and 14.
after their strength
fractureofis the
presented in material.
Figure 12. The variation of tensile strength of the Co
Both the ultimate tensile strength (UTS) and yield strength of the hybrid composites tensile
the tensile developed The graph shows that the ultimate were
hybrid composite
and yieldand strength with
of the the
copper content
C87600 of
alloyreinforcement
is 371.5 in MPa is presented in Figures 13 an
measured observed to be increased with an increase theand 243.6 MPa,content.
reinforcement respectively.
The
Both
physical the
The addition
andultimate
of SiCtensile
mechanical ceramic strength
particulate
properties (UTS)
of the by 3,and yield
6, and
reinforcement strength
9 wt.% along
materials of the1 hybrid
with wt.%
significantly composites
graphite
influence
increased
measured
the the yield strength
and observed
tensile strength by 6.5, 13.7,
to be increased
of the developed and 24%.
material.with In contrast,
an increase
The graph the
shows that ultimate
in the tensile
thereinforcementstrength
ultimate tensilecontent
is increased
physical and bymechanical
4.5, 13.4, andproperties
26%, respectively, compared with materials
of the reinforcement the base copper C87600 influ
significantly
alloy. It was found that the Cu-9%SiC-1%Gr hybrid composite displayed maximum yield
the tensile strength of the developed material. The graph shows that the ultimate te
and yield strength of the copper C87600 alloy is 371.5 MPa and 243.6 MPa, respecti
The addition of SiC ceramic particulate by 3, 6, and 9 wt.% along with 1 wt.% grap
 Appl. Sci. 2023, 13, 1754 11 of 18

and yield strength of the copper C87600 alloy is 371.5 MPa and 243.6 MPa, respectively.
The addition of SiC ceramic particulate by 3, 6, and 9 wt.% along with 1 wt.% graphite
Appl. Sci. 2023, 11, x FOR PEER REVIEW 12 of
increased the yield strength by 6.5, 13.7, and 24%. In contrast, the ultimate tensile strength
is increased by 4.5, 13.4, and 26%, respectively, compared with the base copper C87600
alloy. It was found that the Cu-9%SiC-1%Gr hybrid composite displayed maximum yield
strength
strengthof of
303303
MPa andand
MPa ultimate tensile
ultimate strength
tensile of 467 MPa.
strength of 467The ultimate
MPa. tensile strength
The ultimate tensile streng
and yield strength of the Cu-9%SiC-1%Gr hybrid composites are increased by 26% and
and yield strength of the Cu-9%SiC-1%Gr hybrid composites are increased by 26% an
24%, respectively, in comparison to the base copper alloy.
24%, respectively, in comparison to the base copper alloy.

Appl. Sci. 2023, 11, x FOR PEER REVIEW 13 of 19

In the present study, it was experienced that the addition of 9 wt.% of SiC along with 1
wt.% of graphite enhanced the ultimate tensile strength by 26%, and the addition of 9
wt.% of WC along with 1 wt.% of graphite enhanced the ultimate tensile strength by 30%.
Moreover, the thermal mismatch between the copper matrix and the ceramics reinforce-
ments would probably be another reason for improving the tensile properties. The mis-
match among the coefficients of thermal expansion (CTE) generates a rise in the disloca-
tion density in the composites. Therefore, it resulted in prismatic punching of the disloca-
tions at the interface, which led to the work-hardening of the composites [31]. The for-
mation of these dislocation densities is proportional to the surface area of the reinforce-
ment.
Figure
Figure
The
12.12.
homogenous
Tensile
Tensile specimen
specimen
dispersion
before
before andof
and after
thetensile
after
tensile
reinforcements tends to increase the surface
test. test.
area, resulting in higher work hardening in the fabricated composites.
In the present study, Cu-9%WC-1%Gr showed the highest tensile strength among th
developed composites. It is important to note that the tensile strength of WC-reinforce
composites had shown relatively higher strength than the SiC-reinforced hybrid comp
sites may be due to the better mechanical properties of the reinforcement used [26]. Th
ultimate tensile strength and yield strength of the materials increased by 30% and 28%
respectively, for the Cu-9%WC-1%Gr hybrid composites. Similarly, Cu-6%WC-1%Gr h
brid composites exhibited a 24% and 22% increment in the UTS, and yield strength wa
observed as compared with the base alloy. This improved mechanical strength of the h
brid composites is associated with excellent plastic strain-sustaining capability, which
increased by the higher interfacial bonding between the materials. Furthermore, addin
these reinforcements hampers the dislocation motion by repulsive or attractive intera
tions, which is linked to strain hardening [27]. The mechanical properties of the copp
hybrid composites consist of different concentrations of reinforcement, which are pr
sented in Table 4. From these mechanical results, it could be concluded that adding th
silicon carbide and tungsten carbide along with graphite particulates into the copper m
trix alloy holds promise for improved tensile properties. The improvement in the tensi
properties also indicates that the reinforcement particles exhibited great wettability wit
the molten copper alloy.
Figure13.
13.Variation
Variationof of yield
yield strength
strength and ultimate tensile strength
of Cuofalloy
Cu alloy and Cu-(3, 6, 9) wt.%
Figure
SiC-Gr
Ahybrid
significant increase
composites.
in and
the ultimate
strength tensile strength
of the materials and Cu-(3,
is observed 6, 9)to
due wt.%
the transf
SiC-Gr hybrid composites.
of tensile load from the ceramic reinforcement (SiC and WC) to the copper C87600 allo
matrix. Based on the continuum mechanics, the excellent bonding between the reinforc
ment and the matrix helps to enhance the tensile behavior of the materials. The yiel
strength of the materials is enhanced due to the discontinuously reinforced ceramic pa
ticulate based on the shear-lag model [28]. The theoretical yield strength of the develope
composite (𝜎 ) can be determined based on the theoretical strength of the matrix (𝜎
the volume fraction of the reinforcement (𝑣 ) and aspect ratio of the ceramic particula
(𝑠) shear-lag model, as shown in Equation (1) [29].

𝜎 =𝜎 [ 𝑣 1+ + (1 − 𝑣 ) ] (
Appl. Sci. 2023, 13, 1754 12 of 18
Figure 13. Variation of yield strength and ultimate tensile strength of Cu alloy and Cu-(3, 6, 9) wt.%
SiC-Gr hybrid composites.

Figure 14. Variation of yield strength and ultimate tensile strength of Cu alloy and Cu-(3, 6, 9) wt.%
Figure 14. Variation of yield strength and ultimate tensile strength of Cu alloy and Cu-(3, 6, 9) wt.%
WC-Gr hybrid composites.
WC-Gr hybrid composites.

In the present study, Cu-9%WC-1%Gr showed the highest tensile strength among the
developed composites. It is important to note that the tensile strength of WC-reinforced
composites had shown relatively higher strength than the SiC-reinforced hybrid composites
may be due to the better mechanical properties of the reinforcement used [26]. The ultimate
tensile strength and yield strength of the materials increased by 30% and 28%, respectively,
for the Cu-9%WC-1%Gr hybrid composites. Similarly, Cu-6%WC-1%Gr hybrid composites
exhibited a 24% and 22% increment in the UTS, and yield strength was observed as com-
pared with the base alloy. This improved mechanical strength of the hybrid composites
is associated with excellent plastic strain-sustaining capability, which is increased by the
higher interfacial bonding between the materials. Furthermore, adding these reinforce-
ments hampers the dislocation motion by repulsive or attractive interactions, which is
linked to strain hardening [27]. The mechanical properties of the copper hybrid composites
consist of different concentrations of reinforcement, which are presented in Table 4. From
these mechanical results, it could be concluded that adding the silicon carbide and tungsten
carbide along with graphite particulates into the copper matrix alloy holds promise for
improved tensile properties. The improvement in the tensile properties also indicates that
the reinforcement particles exhibited great wettability with the molten copper alloy.

Table 4. Mechanical Properties of Copper hybrid composites.

Ultimate
Composite Microhardness Yield Strength
Tensile Strength Elongation (%)
Specimen (HV) (MPa)
(MPa)
C0 128.1 371.5 243.6 18.2
C1 142.5 388.1 259.4 17.2
C2 149.4 421.4 277.1 16.5
C3 164.4 467.6 303.1 14.4
C4 156.7 401.5 268.5 15.1
C5 165.2 456.2 297.3 14.2
C6 174.1 485.7 312.1 11.5

A significant increase in the strength of the materials is observed due to the transfer of
tensile load from the ceramic reinforcement (SiC and WC) to the copper C87600 alloy matrix.
Appl. Sci. 2023, 13, 1754 13 of 18

Based on the continuum mechanics, the excellent bonding between the reinforcement and
the matrix helps to enhance the tensile behavior of the materials. The yield strength of the
materials is enhanced due to the discontinuously reinforced ceramic particulate based on
the shear-lag model [28]. The theoretical yield strength of the developed composite (σyc )
can be determined based on the theoretical strength of the matrix (σym ), the volume fraction
of the reinforcement (v p ) and aspect ratio of the ceramic particulate (s) shear-lag model, as
shown in Equation (1) [29].
n  s o

σyc = σym [ v p 1 + + 1 − vp ] (1)
2
The yield strength and UTS of the composite materials also increased due to the
presence of ceramic reinforcement acting as a resistance to plastic deformation and crack
propagation [30]. An earlier study by Fenghong et al. [26] indicated that adding 10 wt.%
SiC and 10 wt.% WC in the soft aluminum 6061 alloy matrix enhances the yield strength
and UTS by 30.76% and 38%, respectively, with the reduction of maximum ductility by
86%. In the present study, it was experienced that the addition of 9 wt.% of SiC along
with 1 wt.% of graphite enhanced the ultimate tensile strength by 26%, and the addition
of 9 wt.% of WC along with 1 wt.% of graphite enhanced the ultimate tensile strength
by 30%. Moreover, the thermal mismatch between the copper matrix and the ceramics
reinforcements would probably be another reason for improving the tensile properties.
The mismatch among the coefficients of thermal expansion (CTE) generates a rise in the
dislocation density in the composites. Therefore, it resulted in prismatic punching of
the dislocations at the interface, which led to the work-hardening of the composites [31].
The formation of these dislocation densities is proportional to the surface area of the
reinforcement. The homogenous dispersion of the reinforcements tends to increase the
surface area, resulting in higher work hardening in the fabricated composites.
The introduction of ceramic reinforcement like SiC and WC in the copper C87600
alloy matrix enhanced the tensile properties of the materials; however, the ductility of the
materials was reduced. The effect of ceramic reinforcement on the percentage elongation of
the developed copper-based hybrid metal matrix composites is shown in Figures 15 and 16.
The base copper C87600 alloy showed a percentage elongation of 18.2%; however, by
adding 9 wt.% SiC and 1 wt.% graphite to the copper matrix, the ductility of the materials
is reduced to 14.4%. Similarly, the ductility of the materials is decreased to 11.5% for
Cu-9%WC-1%Gr composites in comparison with the base copper alloy. The 9%SiC-1%Gr
reinforced copper composites had witnessed a 21% reduction in the elongation percentage
in comparison to the base alloy, whereas the decrease in the percentage elongation was
found to be 36% for the Cu-9%WC-1%Gr composites. The addition of these hard and stiff
particulates resulted in the increment of brittleness that subjected to the decline in the
ductility of the composite. A higher decrease in ductility was observed by the addition
of WC particulate as compared to SiC particulates. Similar results were also reported
by Mengqi et al. [32], where the elongation percentage of the copper hybrid MMCs was
linearly reduced with the higher reinforcement.
To characterize the tensile behavior, the fractured tensile surfaces of the Cu-SiC-Gr
and Cu-WC-Gr hybrid composites were also analyzed through FESEM micrographs and
are presented in Figures 17 and 18, respectively. Generally, the ductile mode of fracture is
characterized by the cup and cone structure, whereas a flat surface mechanism is associated
with the brittle mode of fracture. Most fractography in this study shows small-sized dimples
and micro-voids, indicating that the composites retained their ductile behavior up to a
significant extent [33,34]. The micro-voids were the primary reason for the tensile failure as
these became the crack initiation site during the testing. Moreover, the micro-voids were
formed as a result of the higher reinforcement content, which became stress-intensity sites.
As the tensile load gradually increased, these sites further experienced coalescence and
growth, resulting in the propagation of cracks. This might have happened due to the lack
of sites to release the strain energy. Moreover, there were not any signs of particle fracture
 rials is reduced to 14.4%. Similarly, the ductility of the materials is decreased to 11.5% for
Cu-9%WC-1%Gr composites in comparison with the base copper alloy. The 9%SiC-1%Gr
reinforced copper composites had witnessed a 21% reduction in the elongation percentage
in comparison to the base alloy, whereas the decrease in the percentage elongation was
Appl. Sci. 2023, 13, 1754 found to be 36% for the Cu-9%WC-1%Gr composites. The addition of these hard and 14 of stiff
18
particulates resulted in the increment of brittleness that subjected to the decline in the
ductility of the composite. A higher decrease in ductility was observed by the addition of
WC particulate as compared to SiC particulates. Similar results were also reported by
as observed in the micrographs. The hybrid composites didn’t exhibit any form of cleavage
Mengqi et al. [32], where the elongation percentage of the copper hybrid MMCs was lin-
facets that showed no or minimum quantity of brittle fracture.
early reduced with the higher reinforcement.

Appl. Sci. 2023, 11, x FOR PEER REVIEW 15 of 19

Figure 15. Variation % elongation of Cu alloy and Cu-(3, 6, 9) wt.% SiC-Gr hybrid composites.
Figure 15. Variation % elongation of Cu alloy and Cu-(3, 6, 9) wt.% SiC-Gr hybrid composites.

Figure 16. Variation % elongation of Cu alloy and Cu-(3, 6, 9) wt.% WC-Gr hybrid composites.
Figure 16. Variation % elongation of Cu alloy and Cu-(3, 6, 9) wt.% WC-Gr hybrid composites.

To characterize the tensile behavior, the fractured tensile surfaces of the Cu-SiC-Gr
and Cu-WC-Gr hybrid composites were also analyzed through FESEM micrographs and
are presented in Figures 17 and 18, respectively. Generally, the ductile mode of fracture is
characterized by the cup and cone structure, whereas a flat surface mechanism is associ-
ated with the brittle mode of fracture. Most fractography in this study shows small-sized
dimples and micro-voids, indicating that the composites retained their ductile behavior
up to a significant extent [33,34]. The micro-voids were the primary reason for the tensile
failure as these became the crack initiation site during the testing. Moreover, the micro-
voids were formed as a result of the higher reinforcement content, which became stress-
intensity sites. As the tensile load gradually increased, these sites further experienced co-
alescence and growth, resulting in the propagation of cracks. This might have happened
Appl. Sci. 2023, 13, 1754 15 of 18
Appl. Sci. 2023, 11, x FOR PEER REVIEW 16 of 19
Appl. Sci. 2023, 11, x FOR PEER REVIEW 16 of 19

Figure 17. FESEM of tensile fractography surface of Cu alloy and Cu-(3, 6, 9) wt.% SiC-Gr hybrid
Figure 17. FESEM of tensile fractography surface of Cu alloy and Cu-(3, 6, 9) wt.% SiC-Gr hybrid
composites.
Figure 17. FESEM of tensile fractography surface of Cu alloy and Cu-(3, 6, 9) wt.% SiC-Gr hybrid
composites.
composites.

Figure 18. FESEM of tensile fractography surface of Cu alloy and Cu-(3, 6, 9) wt.% WC-Gr hybrid
composites.
Figure 18. FESEM of tensile fractography surface of Cu alloy and Cu-(3, 6, 9) wt.% WC-Gr hybrid
Figure 18. FESEM of tensile fractography surface of Cu alloy and Cu-(3, 6, 9) wt.% WC-Gr hybrid
composites.
composites.
Appl. Sci. 2023, 13, 1754 16 of 18

4. Conclusions
Copper alloy (C87600) matrix hybrid composites were successfully fabricated by stir
casting using SiC-Gr and WC-Gr particles, from which the following conclusions are made:
i. Homogenously dispersion of the reinforcement particulates was observed with the
help of the optimum stirring action during the casting. Moreover, the elemental
composition of the hybrid composites was also analyzed through EDX analysis.
ii. Clear peaks of the SiC and WC were found along with the copper matrix from
the XRD spectrum, which also indicated the successfulness of the casting process.
Moreover, there were no intermetallic products observed between the copper and
ceramic reinforcements.
iii. The micro-hardness and tensile strength of copper hybrid MMCs were improved
significantly with the incorporation of the SiC and WC particles along with graphite,
which shows better interfacial bonding and wettability of the ceramic particulates
with molten alloy.
iv. The hybrid composites reinforced with WC particulates exhibited higher strength
compared to SiC-reinforced composites.
v. The tensile fractography was also characterized in the form of micro-dimples and
tear-ridges, which shows that the hybrid composites retained their ductility to a
significant extent.

Author Contributions: Conceptualization, P.S., H.T. and P.R.V.; methodology, P.S., H.T., A.M. and
P.R.V.; formal analysis, P.S., H.T. and A.M.; investigation, P.S., H.T. and P.R.V.; resources, B.S. and
P.R.V.; data curation, P.S. and H.T.; writing—original draft preparation, P.S., H.T. and A.M.; writing—
review and editing, B.S. and P.R.V.; supervision, P.R.V.; project administration, P.R.V.; funding
acquisition, A.M. All authors have read and agreed to the published version of the manuscript.
Funding: The authors declare that no funds, grants, or other support were received during the
preparation of this manuscript.
Institutional Review Board Statement: Not applicable.
Informed Consent Statement: Not applicable.
Data Availability Statement: The data presented in this study are available upon request from the
corresponding author.
Acknowledgments: The authors would like to express their great appreciation to the Head of the
School of Mechanical Sciences, IIT Bhubaneswar for providing the experimental facility for the
completion of this research work.
Conflicts of Interest: The authors declare no conflict of interest.

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