Fabrication of copper composites containing 3D graphene-like carbon network

Simultaneously improving copper’s mechanical strength and electrical conductivity through alloying or compositing is challenging. Constructing a three-dimensional continuously conductive and reinforcing network has been considered an effective solution. In this study, we prepared copper matrix composites reinforced with a three-dimensional graphene-like structure by graphitizing sucrose-coated copper microparticles which are then densified using spark plasma sintering (SPS) technique. The study systematically investigated the key processing steps, including the deoxidation of the original copper powder, the carbonization, and the graphitization of sucrose-coated copper powder, along with the effect of hydrogen ratio on the structure of the carbon layer coated on the copper powder. By optimizing the SPS sintering temperature and pressure parameters, dense graphene-like reinforced copper matrix composites were obtained. The results indicate that the quality and structure of the carbon layer on the surface of copper microparticles significantly affect the densification, microstructure, and electrical properties of the composites. Through comprehensive optimization, we obtained graphene-like/copper matrix composites with conductivity approaching that of high-purity copper while maintaining high hardness. This research provides critical insights for guiding the mass production of graphene/copper matrix composites with ultra-high conductivity and superior mechanical properties. • 3D graphene-like structure formed by graphitizing sucrose-coated copper microparticles and densifying via SPS. • Morphological and structural evolution of copper microparticles during each processing stage. • Composites with high electrical conductivity and improved mechanical properties.