# Tailoring Microstructure and Performance of Cu/SiC Composites via Integrated Powder Metallurgy and Thermo-Compression Processing

## TL;DR

This paper shows how combining powder metallurgy with thermo-compression processing improves the strength and performance of copper-silicon carbide composites.

## Contribution

The study introduces thermo-compression processing as an effective post-sintering method to enhance Cu–SiC composite properties.

## Key findings

- TCP reduced porosity and improved reinforcement dispersion in Cu–SiC composites.
- The composite achieved ~209 MPa tensile strength, ~65 HRB hardness, and ~35 MJ/m3 toughness at 3 wt.% SiC.
- Improved performance resulted from uniform dispersion, better bonding, and microstructural refinement.

## Abstract

This study reports the fabrication and characterization of copper–silicon carbide (Cu–SiC) metal matrix composites produced using powder metallurgy (PM) combined with thermo-compression processing (TCP), a dual route that remains limited in Cu–SiC research. Micro-sized SiC particles (1–25 wt.%) were incorporated into Cu, compacted, sintered, and subsequently subjected to sequential forging and annealing. Unlike conventional PM-only processing, TCP significantly reduced porosity, promoted more uniform reinforcement dispersion, and relieved residual stresses, creating a strong synergy between densification and microstructural refinement. SEM, EDS, XRD, and Raman analyses confirmed phase stability, homogeneous reinforcement distribution, and the absence of deleterious interfacial phases. The integrated PM + TCP route achieved an ultimate tensile strength of ~209 MPa, hardness of ~65 HRB, and toughness of ~35 MJ/m3 at approximately 3 wt.% SiC. The superior performance at this composition resulted not from the lowest porosity but from the combined effects of uniform particle dispersion, improved particle–matrix bonding, and deformation-driven refinement. These findings establish TCP as an effective post-sintering strategy that overcomes intrinsic porosity and interfacial limitations in Cu–SiC composites. Overall, powder metallurgy combined with the thermo-compression processing is identified as a promising processing pathway for developing high-strength, thermally stable Cu–SiC materials for structural and thermal management applications.