Trade-Offs Among Arc Erosion Resistance, Wear Resistance, and Compressive Performance: Designing Cu-Nb-Gr Composites with a Semi-Continuous Gr-Rich Structure Coupled with an Nb-Rich Load-Bearing Structure

Abstract

Developing Cu-based composites with excellent electrical and mechanical properties under multiphysics-coupled service conditions remains challenging. Novel Cu-Nb-Gr composites were fabricated by high-energy ball milling and High-pressure Multi-field Assisted Rapid Sintering. Experiments combined with computational fluid dynamics (CFD) and finite element method (FEM) simulations were used to investigate how Gr regulates material performance. The incorporation of 3 vol.% Gr promoted the formation of a semi-continuous Gr-rich structure coupled with an Nb-rich load-bearing structure. Under arc erosion, the semi-continuous Gr-rich structure provided efficient heat-conduction pathways, reducing the peak temperature and metal-vapor recoil force, while the Nb-rich load-bearing structure suppressed liquid–metal spattering and stabilized the molten pool. Simultaneously, Gr dynamically spread to form a continuous solid-lubricating film during sliding friction, significantly reducing the coefficient of friction and interfacial shear stress. Furthermore, under compressive loading, the semi-continuous Gr-rich structure coupled with the Nb-rich load-bearing structure alleviated interfacial elastic–modulus mismatch and extreme stress concentration, limiting macroscopic plastic deformation of the matrix. Consequently, Cu-Nb-3Gr achieved a favorable balance of arc-erosion resistance, wear resistance, and compressive performance, providing a new strategy for improving conventional Cu-based composites.