OPTIMIZATION OF COPPER-GRAPHITE COMPOSITE MATERIALS THROUGH SPARK PLASMA SINTERING: IMPACT OF VARIED POWDER SIZES ON PHYSICAL, MECHANICAL, AND ELECTRICAL PROPERTIES

In this study, copper-graphite composite materials were meticulously prepared using spark plasma sintering (SPS), manipulating the size of graphite and copper powders to achieve an optimal ratio. The physical, mechanical, and electrical characteristics were found to be directly influenced by the initial powder sizes. Specifically, by selecting an optimal copper-graphite ratio (Cu-G) and employing different SPS sintering temperatures, samples were fabricated using graphite and electrolytic grade copper powder as source materials. Notably, when the particle size of the copper and graphite exceeded several microns, the resulting samples exhibited deteriorated mechanical and electrical properties, leading to a decline in overall quality. The fabricated composite samples underwent comprehensive examination using micro-hardness testing, Hall system analysis, density testing, optical microscopy, and FE-SEM to explore thermal, compositional, and structural parameters