Optimization of Warm Compaction Process Parameters in Synthesizing Carbon-Copper Composite Using Taguchi Method

Abstract:

Carbon–copper composites are attractive materials used for electrical applications, such as brushes for engines and generators, slip rings, switches, relays, lugs, contactor and current collector. Various methods can be used to prepare Carbon-copper composite, such as infiltration, sintering, cold pressing, hot pressing or isostatic pressing. However, powder metallurgy route is seen to be most favorable due to its possibility of producing uniform microstructure and excellent net shape product. In this work, carbon-copper composite is prepared using powder metallurgy route with warm compaction process. The compaction pressure (A), compaction temperature (B), post baking temperature (C) and compaction time (D) were optimized by Taguchi method. Hardness and transverse rupture strength (TRS) were used to assess the effect of warm compaction process. The experimental design is according to the L9 (3⁴) orthogonal array. Signal to noise and analysis of variance (ANOVA) are employed to analyze the effect of warm compaction parameters. It is found that the best parameters and their levels are A3B2C3D2 for the main effect of hardness and the best parameters and their levels for TRS is A3B2C3D1. It is also notified that optimized parameters of A3, B2 and C3 are identical for hardness and TRS. However, for parameter D, the best level for hardness is D2 and for TRS is D1. The ANOVA analysis proved that compaction temperature parameter is significant to hardness and TRS value whereas the others parameters are not significant.

• Periodical: Key Engineering Materials (Volume 701)
• Pages: 112-116
• DOI: https://doi.org/10.4028/www.scientific.net/KEM.701.112
• Online since: July 2016
• Authors: Salina Budin*, Mohd Afiq Nurul Hadi, Talib Ria Jaafar, Mohd Asri Selamat
• Keywords: ANOVA, Carbon-Copper Composite, Hardness, Taguchi Method, Transverse Rupture Strength, Warm Compaction

References

[1] P. Queipo, M. Granda, R. Santamaria and R. Menendez, Preparation of pitch-based carbon-copper composites for electrical applications, Fuel. 83(2004) 1625-1634.

DOI: 10.1016/j.fuel.2004.02.014

[2] S.F. Moustafa, S.A. El-Badry, A.M. Sanad and B. Kieback, Friction and wear of copper–graphite composites made with Cu-coated and uncoated graphite powders, Wear. 253(2002) 699–710.

DOI: 10.1016/s0043-1648(02)00038-8

[3] H. Sarmadi, A.H. Kokabi and S.M. Seyed Reihani, Friction and wear performance of copper–graphite surface composites fabricated by friction stir processing (FSP), Wear. 304(2013) 1–12.

DOI: 10.1016/j.wear.2013.04.023

[4] K. Rajkumar and S. Aravindan, Microwave sintering of copper–graphite composites, Journal of Materials Processing Technology. 209(2009) 5601–5605.

DOI: 10.1016/j.jmatprotec.2009.05.017

[5] M.M. Rahman and S.S.M. Nor, An experimental investigation of metal powder compaction at elevated temperature, Mechanics of Materials. 41(2009) 553-560.

DOI: 10.1016/j.mechmat.2008.12.003

[6] Z.Y. Xiao, L. Fang, W. Zhang, M. Shao and Y.Y. Li, Fabrication of NbC, -Reinforced Iron Matrix Composites by PM Techniques and Its Warm Compaction, Sino Swedish Structural Materials Symposium. (2007) 66-69.

[7] Z.Y. Xiao, M.Y. Kea, L. Fang, M. Shao and Y.Y. Li, Die wall lubricated warm compacting and sintering behaviors of pre-mixed Fe–Ni–Cu–Mo–C powders, Journal of Materials Processing Technology. 209(2009) 4527–4530.

DOI: 10.1016/j.jmatprotec.2008.10.018

[8] A. Simchi and A.A. Nojoomi, Warm compaction of metallic powders, Advances in Powder Metallurgy. (2013) 86 108.

DOI: 10.1533/9780857098900.1.86

[9] S.S. Feng, H.R. Geng and Z.Q. Guo, Effect of lubricants on warm compaction process of Cu-based composite, Composites: Part B. 43(2012) 933–939.

DOI: 10.1016/j.compositesb.2011.09.004

[10] J.A. Ghani, I.A. Choudhury and H.H. Hassan. Application of Taguchi method in optimization of end milling parameters, Journal of Materials Processing Technology, 145(2004) 84 – 92.

DOI: 10.1016/s0924-0136(03)00865-3

[11] F.L. Zhang, M. Zhu and C.Y. Wang, Parameters optimization in the planetary ball millingt of nanostructured tungsten carbide/cobalt powder. International Journal of Refactory Metals and Hard Materials. 26 (2008) 329 – 333.

DOI: 10.1016/j.ijrmhm.2007.08.005

[12] Y.C. Lin, Y.F. Chen, D.A. Wang and H.S. Lee. Optimization of machining parameters in magnetic force assisted EDM based on Taguchi methods, Journal of Materials Processing Technology, 209(2009) 3374 – 3383.

DOI: 10.1016/j.jmatprotec.2008.07.052