Metals

Alumina (Al₂O₃) reinforced copper matrix composites are widely used in the electronic industry, rail transit, and other fields due to their excellent electrical conductivity, ductility, and wear resistance. However, due to problems such as non-wetting and thermal expansion differences between alumina and Cu, weak interfacial bonding can easily reduce physical and thermal properties. A uniform silver layer was deposited on Al₂O₃ via chemical plating to enhance interface bonding with copper. Al₂O₃@Ag/Cu composites with 1–3 wt.% Al₂O₃ were prepared by rapid hot-press sintering. The effects of plating temperature and Al₂O₃ content on microstructure and properties were investigated. The results show that the optimum coating temperature is 25 °C, and a thin and uniform silver coating can be formed. This effectively improved Al₂O₃–Cu interface bonding while maintaining 77.8% of copper’s thermal conductivity (320.7 W/(m·K)). The composites showed improved wear resistance with increasing Al₂O₃ content. At 3 wt.% Al₂O₃@Ag, the wear rate was 3.36 × 10⁻⁵ mm³/(N·m), 84.4% lower than pure copper, with plow groove wear as the main mechanism.

This study established a marine atmospheric corrosion prediction model by comparing the corrosion behavior of 7075 aluminum alloy in neutral salt spray tests and outdoor exposure tests conducted in the coastal atmosphere of Hainan. The results show that severe rusting occurred after 96 h of neutral salt spray testing, with loose white cluster-like corrosion products mainly composed of Al(OH)₃ and Al₂O₃. The thickening of the corrosion product layer slowed down the corrosion process, following a nonlinear power-law kinetic relationship. In the later stage, potential dropped sharply due to product layer spallation, and recovered as new corrosion products formed, confirming that the stability of the product layer is critical for protection. Under coastal atmospheric exposure, the composition of corrosion products was similar to that observed in the salt spray test, but the actual corrosion rate was affected by environmental dynamic equilibrium. The acceleration factor of the neutral salt spray test corresponding to the same corrosion amount in the Hainan marine atmosphere exhibited a declining trend, reflecting that differences in the protective nature of the corrosion product layer were influenced by environmental factors. Electrochemical analysis indicated that both tests showed similar current–potential synergistic variation mechanisms dominated by product layer stability. In summary, while the neutral salt spray test effectively simulates the chloride-induced corrosion mechanism in marine atmospheres, its kinetic model cannot directly predict real corrosion behavior through a simple acceleration factor, as environmental complexity must be considered.

A hot extrusion deformation test of sintered Cu-10wt%Mo composite was carried out under deformation conditions, with deformation temperatures ranging from 800 °C to 950 °C, and extrusion ratios ranging from 2.9 to 10.5. The hot extrusion process eliminated the original interfaces between copper powder particles in sintered Cu-10wt%Mo composite. While the copper phase experienced dynamic recrystallization, the molybdenum particles effectively pinned the boundaries and inhibited subsequent grain growth. As the extrusion ratio increased, the composite material’s tensile strength, elongation, and thermal conductivity first increased and then decreased. With the rise in hot extrusion deformation temperature, the composite material’s tensile strength, elongation, and thermal conductivity gradually increased, but stabilized after reaching 900 °C. Deformation during hot extrusion is confined to the copper phase, which undergoes dynamic recrystallization (DRX), with no significant deformation occurring in the molybdenum phase. The molybdenum phase promotes an increased local strain rate in the copper phase, resulting in the formation of a certain number of twin grains.