Enhanced wetting and properties of carbon/carbon-Cu composites with Cr3C2 coatings by Cr-solution immersion method

doi:10.1016/j.jmst.2017.01.028

Abstract

Abstract:

A facile ammonium-dichromate solution immersion method was introduced to synthesize the copper-wettable Cr₃C₂ coating on and inside the carbon-carbon (C/C) preform. The formation mechanism and the microstructures of the Cr₃C₂ coatings were studied. The contact angle between molten copper and the C/C decreased from 140° to 60°, demonstrating the significant improvement in the wettability. The Cr₃C₂-coated C/C-Cu composite with only 4.2% porosity and 3.69 g cm^-3 density was manufactured through copper infiltration. As a result, the thermal and electrical conductivity of the modified C/C-Cu increased significantly due to the infiltrated copper. Also the mechanical properties of the composites including both the flexural and compressive strengths were enhanced by over 100%. The modified C/C-Cu composite exhibited lower friction coefficients and wear rates for different load levels than those of the commercial C/Cu composite. These results demonstrate the potential of the modified C/C-Cu material for use in electrical contacts.

Bo Kong, Jinming Ru, Hongdi Zhang, Tongxiang Fan. Enhanced wetting and properties of carbon/carbon-Cu composites with Cr₃C₂ coatings by Cr-solution immersion method[J]. J. Mater. Sci. Technol., 2018, 34(3): 458-465.

Figures/Tables 11

Fig. 1. Schematic diagram of procedure to prepare coated-C/C composites.

Fig. 2. Schematic drawing of infiltration procedure to manufacture C/C-Cu composites.

Fig. 3. (a) XRD patterns and (b) TG-DTG curves of the ammonium-dichromate-immersed C/C at different temperatures during modification procedure. (NH4)2Cr2O7→Cr2O3+4H2O+N2 (4)

Fig. 4. (a) Surface and (b) cross-section microstructures of Cr3C2-coated C/C substrates and (c, d) linear EDS analysis on the cross-section of the coated C/C.

Fig. 5. Contact angle curves as a function of time and morphologies of copper melt on (a) Cr3C2-coated C/C and (b) uncoated C/C.

Fig. 6. SEM micrographs of interface between copper and modified C/C with (a) low, (b) medium, and (c) high magnification and (d) elemental mapping of carbon, chromium and copper.

Fig. 7. Morphology (a), optical micrographs at low (b) and high (c) magnification of modified C/C-Cu and SEM micrographs (d, f) with linear EDS analysis (e, g) of modified C/C-Cu composite (d, e) and unmodified C/C-Cu (f, g).

Table 1 Density, porosity, conductivities and mechanical properties of the different composites (C/C-Cu #1 is uncoated C/C infiltrated by copper, C/C-Cu #2 is coated C/C infiltrated by copper).

Materials	Density (g cm^-3)	Porosity (%)	Thermal conductivity (W m^-1 K^-1)	Electrical resistivity (μΩ m)	Flexural strength (MPa)	Compressive strength (MPa)
C/C	1.45	30.2	39.6	40.1010	53.4	74.1
C/C-Cu #1	2.29	18.9	61.1	11.6070	69.2	106.2
C/C-Cu #2	3.69	4.2	168.6	0.0755	129.5	240.4

Fig. 8. Comparison of modified C/C-Cu and C/C-Cu composites with previous studies [13,15,24]: (a) thermal conductivity; (b) specific thermal conductivity; (c) bending strength improvement associated with infiltration; (d) electrical resistivity.

Table 2 Friction coefficients and wear rates of different composite materials under different loads.

Sample	Friction coefficient			Wear rate (10^-7 mm³ m^-1 N^-1)
	50 N	100 N	200 N	50 N	100 N	200 N
C-C	0.10	0.14	0.11	-	-	-
Modified C/C-Cu	0.09	0.12	0.10	32.4	35.9	43.16
C/Cu	0.12	0.2	0.2	136.0	152.5	171.6

Fig. 9. Microstructures of worn surface of modified C/C-Cu composite under loads of (a) 50 N, (b) 100 N and (c) 200 N with (d) the EDS linear analysis, (e) low and (f) high magnification of worn surface of C/C composite under load of 200 N, and modified C/C-Cu composite under loads of (g) 50 N, (h) 100 N and (i) 200 N.

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Enhanced wetting and properties of carbon/carbon-Cu composites with Cr₃C₂ coatings by Cr-solution immersion method

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