Sintering microstructure and properties of copper powder prepared by electrolyzation and atomization

Abstract

The almost completely dense copper was prepared by ultrafine copper powder prepared with both methods of electrolysis and novel water-gas atomization through cold isostatic pressing (CIP) and sintering under atmospheric hydrogen. Fine copper powder possesses the higher sintering driving force, thereby promoting shrinkage and densification during the sintering process. The grain size of sintered samples by electrolytic copper powder is smaller than that prepared by the atomized copper powder, and the twin crystals are particularly prone to forming in the former sintered microstructure due to the raw powder with low oxygen content and high residual stress originating from the CIP process. The relative density of samples by electrolytic and atomized powder at 1000 °C sintering temperature achieves 99.3% and 97.4%, respectively, significantly higher than that of the powder metallurgy copper parts reported in the literature. Correspondingly, the ultimate tensile strength and yield strength of samples by both kinds of copper powder are approximately similar, while the elongation of the sintered sample by the electrolytic powder (60%) is apparently higher than the atomized powder (44%). The superior performance of samples fabricated by electrolytic powder is inferred from the full density and low oxygen level for there is no cuprous oxide in the grain boundaries.

Keywords

copper powder / electrolyzation / gas-water combined atomization / sintered microstructure / property

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