High thermal and mechanical properties of carbon fiber network reinforced copper matrix composites achieved by configuration design and interface engineering

Constructing three-dimensional (3D) fillers within the matrix represents a highly promising strategy for achieving excellent comprehensive performance. In this study, the possibility of implementing 3D network configuration in carbon fiber/copper (CF/Cu) composites is explored. A novel composite structure was developed through template-electrodeposition and hot-pressing sintering techniques, incorporating a 3D CF network within the Cu matrix. Additionally, tungsten carbide (WC) coating was applied to the CF surface using molten salt method. Research findings indicate that the 3D CF networks establish continuous heat flow channels within the Cu matrix, while the WC coating mitigates the interfacial thermal resistance by improving CF-Cu interface bonding. The 3D-CF(WC)/Cu composite obtained through the synergistic strengthening of configuration design and interface engineering exhibits excellent thermal and mechanical properties. The thermal conductivity (TC), coefficient of thermal expansion (CTE), and bending strength of the 3D-CF(WC)/Cu composite in the in-plane direction are 457.4 f 9.0 W m- 1 K-1, 6.9 f 0.4 x 10-6 K-1, and 281.9 f 5.2 MPa, respectively; and in the through-plane direction are 400.8 f 8.9 W m-1 K-1, 6.1 f 0.4 x 10-6 K-1, and 263.1 f 5.6 MPa, respectively. This research provides a novel approach to develop carbon reinforced metal matrix thermal management composites.