Synthesis of Bulk Nano-Al2O3 Dispersed Cu-Matrix Composite Using Ball Milled Precursor

Kinetics of solid-state reduction reaction during ball milling of CuO-Al and CuO-prealloyed Cu(Al) powder blends in dry and wet condition has been investigated by using X-ray diffraction (XRD), differential scanning calorimetry (DSC), and transmission electron microscopy (TEM) techniques. Direct reduction of CuO by Al has resulted into Al₂O₃ dispersed Cu-matrix composite through a self-propagating reaction only during milling in dry condition. However, indirect reduction of CuO by prealloyed Cu(Al) resulted into formation of nano-Al₂O₃ dispersed Cu-matrix composite either by continued ball milling in dry condition or by subsequent thermal treatment of wet milled powder precursor. The influence of milling conditions, that is, milling speed, and milling media, on the occurrence of reduction of CuO by elemental Al or Al in prealloyed Cu(Al) during ball milling have been explained by considering their effects on the rise of powder temperature due to collisions between balls and powder particles, and the rate of reduction of ignition temperature of the reaction due to microstructural refinement. TEM investigation has revealed that the size of Al₂O₃ particles in the composite power blend formed by the indirect reaction route (CuO-prealloyed Cu(Al)) is much finer than the same in case of direct reaction route (CuO-Al). It is suggested that the kinetics of the reduction reaction in the indirect reaction route is relatively sluggish in nature and amenable to processing of large amount of nano-Al₂O₃ dispersed Cu-matrix composite powder for industrial purpose.