Synergistic Effects of Graphene and E-Glass Fiber on the Mechanical and Wear Performance of Heat Treated Copper Matrix Composites.

This study investigates the mechanical and tribological properties of heat-treated copper-based hybrid composites reinforced with graphene (0.5–1.5 wt.%) and E-glass fiber (3–7wt.%), fabricated via stir casting. The composites were evaluated for tensile strength, hardness, and wear resistance to assess their suitability for high-performance applications. Tensile tests revealed a progressive enhancement in Ultimate Tensile Strength (UTS), with the optimal composite (7% E-glass fiber + 1.5% graphene) achieving 371.63 MPa, a 10.8%improvement over pure copper (335.34 MPa). This improvement is attributedtothesynergistic effect of graphene’s load-bearing capacity and E-glass fiber’s plasticity, further amplified by heat treatment. Hardness tests demonstrated a significant increase inBrinell Hardness Number (BHN) from 66 (pure copper) to 118 for the highest reinforcement content, owing to uniform dispersion and heat treatment. Tribological analysis using a Pin-on-Disc tribometer (ASTM G99-17) under varyingloads(10–30 N) and sliding speeds (200–600 RPM) showed that wear resistance improved with reinforcement content. The composite with 7% E-glass fiber and 1.5%graphene exhibited the lowest wear rate, as graphene reduced direct matrix contact and E-glass fiber mitigated severe wear. However, wear rates increased with higher loads and speeds due to frictional heating and plastic deformation. The study highlights the critical role of reinforcement composition and heat treatment in optimizing mechanical and tribological performance. These hybrid composites, combining superior tensile strength, hardness, and wear resistance, are promising for applications demanding exceptional durability, such as aerospace, automotive, and electronics.