Mechanical and wear evolution of in situ synthesized Ti–Cu alloy matrix hybrid composite reinforced by low-cost activated carbon and silica fume waste ceramic for industrial applications

This study successfully used the powder metallurgy technique to produce hybrid Ti-7% Cu (vol%) matrix nanocomposites (TMNCs) reinforced with activated carbon and silica fume at reduced sintering temperatures, i.e., 1100 °C. The effect of different amounts of additives in the hybrid reinforcements on the bulk density, microstructure, mechanical properties, and wear of the nanocomposite samples thus prepared was investigated. X-ray diffraction (XRD) analysis revealed that the uniform distribution of hybrid ceramics in the nanocomposites and the formation of in situ Ti2Cu and TiC phases resulted from the interaction of Ti with both Cu and activated carbon during the milling and sintering processes, respectively. On the other hand, the values of the microhardness, ultimate strength, and longitudinal modulus of the non-reinforced sample (TS0) were 1.66 GPa, 401.20 MPa, and 172.40 GPa, respectively, which increased to 2.17 GPa, 591.25, and 256.24 GPa, respectively, for the sample containing 16 vol% of hybrid reinforcements (TS8). Finally, for the applied load of 40 N, the wear rate decreased from 0.0196 to 0.0089 mg/s with increases in the hybrid reinforcements from 0 to 16 vol%. Thus, the addition of activated carbon and silica fume can act as superb reinforcements in TMNCs.