Fabrication and characterization of copper-alumina composite tubes via electroforming: Microstructure, mechanical properties, and corrosion resistance

This study fabricated Cu–Al 2 O 3 composite tubes via electroforming using a rotating stainless-steel cathode and copper anode. The research systematically investigated how Al 2 O 3 reinforcement particle concentrations (10, 15, 20, and 35 g/L in the electrolyte) influence microstructure, surface morphology, and mechanical properties. Comprehensive characterization included tensile, wear, and hardness testing, complemented by microstructural analysis via SEM-EDX and phase identification through XRD. Results demonstrated that Al 2 O 3 incorporation significantly enhanced mechanical performance. The optimal composite (includes 11.04 vol% Al 2 O 3 ), which was derived from an electrolyte concentration of 15 g/L Al 2 O 3 particles, achieved exceptional properties: yield strength (172.059 MPa), tensile strength (335.269 MPa), hardness (128.8 HV), wear resistance (mass loss: 2.1 mg), and friction coefficient (1.063). Compared to the pure copper tube, the optimal Cu–Al 2 O 3 composite tube demonstrates significantly enhanced properties: yield strength is more than doubled, ultimate tensile strength is boosted by 53 %, hardness is almost tripled (increased by 259 %), and wear resistance is increased by 70 %. However, this came with reduced ductility (63.33 % lower elongation) and semi-brittle fracture behavior. Electrochemical tests in corrosive environment (3.5 wt% NaCl solution) revealed improved corrosion resistance, attributed to Al 2 O 3 's barrier effect against pit propagation. XRD analysis confirmed particle dispersion without interfacial reactions, preserving matrix integrity. These findings highlight the composite's potential for high-strength applications, particularly in demanding sectors like power generation and HVAC systems, where balanced mechanical and corrosion-resistant properties are critical.