Optimized ball milling and sequential addition of SiC and MWCNTs reinforcements for enhanced performance of copper hybrid composites

• The sequential milling (Cu+MWCNTs/SiC) composite achieved a remarkable relative density of 98.88%. • The sequential milling (Cu+MWCNTs/SiC) composite exhibited superior wear behavior among the tested composites. • The thermal conductivity of the sequentially milled composite was superior to that of the pre-milled composites, along with improved electrical conductivity. Agglomeration and poor dispersion of reinforcements are common problems in conventional composite fabrication techniques, especially in hybrid composites. This study presents a novel technique, sequential reinforcement addition method combined with optimized ball milling, to produce copper (Cu) matrix composites reinforced with silicon carbide (SiC) and multi-walled carbon nanotubes (MWCNTs). By carefully controlling the milling parameters and introducing reinforcements sequentially, the study demonstrates substantial improvements in the mechanical, thermal, and electrical properties of Cu-based composites. The Cu+MWCNTs/SiC composite fabricated through this method exhibited a notable relative density of 98.88%, alongside a significant increase in surface hardness to 104.78 HV. Additionally, thermal conductivity improved by 16%, reaching 390 W/m·K, while electrical conductivity showed an 8.5% enhancement, achieving 17.53 × 10 5 S/m. The wear rate of the composite was reduced by 15%, attributed to the formation of an effective tribolayer that significantly enhances wear resistance, contributing to the overall durability of the material.