Enhanced Wear Resistance and Thermal Dissipation of Copper–Graphene Composite Coatings via Pulsed Electrodeposition for Circuit Breaker Applications

Copper, though highly conductive, requires improved wear resistance and thermal dissipation in applications that involve continuous movement and current-induced vibrations, such as power breakers. Conventional solutions, such as copper-tungsten alloys or lubricant use, face limitations in durability, friction, or environmental impact. This study explores the development of copper-graphene (Cu-GNPs) composite coatings using pulsed electrodeposition to enhance the tribological, thermal, and mechanical properties of circuit breaker components by adopting an industrially scalable technique. The influence of deposition bath temperature, duty cycle, and frequency on coating morphology, hardness, wear resistance, and heat dissipation was systematically evaluated using a 2