Synthesis of CuCr and CuCrAg alloys with extended solid solubility with nano-Al2O3 dispersion by mechanical alloying and consolidation by high pressure sintering

Cu-4.5Cr and Cu-4.5Cr-3Ag (wt%) alloys with nanocrystalline Al2O3 dispersion (5 or 10 wt%) were synthesized by mechanical alloying and consolidated by high pressure sintering at two different temperatures. Mechanical alloying/milling leads to formation of nanocrystalline matrix grains of about 40-60 nm after 25 h of milling with nanometric (< 20 nm) Al2O3 particles dispersed in it. After consolidation by high pressure sintering (8 GPa at 600-800 degrees C), the dispersoids nearly retain their ultrafine size and uniform distribution, while the alloyed matrix undergoes significant grain growth. Apparent density of the compacts is about 95% of the theoretical density of the corresponding compositions. 10 wt% Al2O3 dispersed Cu-4.5Cr-3Ag alloy consolidated at 800 degrees C shows maximum hardness (435 VHN) and wear resistance. High hardness at this material is due to fine grain structure with nano-dispersoids. The fine grained structure is generated due to dynamic recrystallization during high pressure sintering which has been observed through metallography as well as macro-/microtexture analysis. The electrical conductivity of the pellets without and with nano-Al2O3 dispersion is about 40-45% IACS (International Annealing Copper Standard) and 35% IACS, respectively. Thus, mechanical alloying followed by high pressure sintering seems a potential route for developing nano-Al2O3 dispersed Cu-Cr and Cu-Cr-Ag alloys for heavy duty electrical contacts. (C) 2012 Elsevier B.V. All rights reserved