Wear resistance mechanism of graphene/copper composite foils with bimodal structure

Copper foils have a wide range of applications in modern industry. However, their wider utilization is restricted by the poor wear resistance of pure copper. Therefore, improving the abrasion resistance of copper foils is essential for their application in various scenarios. In this study, controlling the parameters of pulsed electro-deposition and incorporating graphene, pure copper foil, and graphene/copper (Gr/Cu) composite foil with distinct microstructures were successfully prepared. Gr/Cu composite foil with bimodal structures exhibits excellent wear resistance, with a coefficient of friction (COF) 0.2 lower than pure Cu foil and a wear rate of only 61.4% of pure Cu foil. We investigated the effects of bimodal structure and graphene on the wear resistance mechanism of Gr/Cu composite foil. The presence of ultrafine grains (UFG), fine grains (FG), and coarse grains (CG) in the bimodal structure enhances the wear resistance of the Gr/Cu composite foil, by resisting crack initiation and propagation. In addition, graphene provides lubrication, and stress dispersion and prevents abrasive particles from entering the foil surface, thus preventing delamination and spalling, which further im-proves wear resistance. This research demonstrates the potential synergistic effect of bimodal structures and graphene to improve the wear resistance of copper foils, which is promising to provide more durable solutions for a wide range of industries.