Microstructure and Mechanical Performance of Novel Al2O3-Cu-Cr Composites Consolidated by Conventional Powder Metallurgy

Paulina Piotrkiewicz; Justyna Zygmuntowicz; Marcin Wachowski; Ireneusz Szachogłuchowicz; Waldemar Kaszuwara

doi:10.2478/adms-2026-0009

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Microstructure and Mechanical Performance of Novel Al2O3-Cu-Cr Composites Consolidated by Conventional Powder Metallurgy

Advances in Materials Science

Volume 26 (2026): Issue 2 (June 2026)

By: Paulina Piotrkiewicz, Justyna Zygmuntowicz, Marcin Wachowski, Ireneusz Szachogłuchowicz and Waldemar Kaszuwara

Open Access

|Jun 2026

Abstract

This study investigates the fabrication, microstructural evolution, and mechanical properties of Al₂O₃-Cu-Cr ceramic-metal composites containing 2.5 vol.% metallic phase produced by uniaxial pressing followed by free sintering in a reducing atmosphere. The composites were sintered at temperatures ranging from 1200°C to 1400°C in order to evaluate the influence of thermal processing on densification behaviour, phase stability, and mechanical performance. The results demonstrated a strong dependence of physical properties on sintering temperature. Increasing the temperature from 1200°C to 1400°C improved the relative density from 82.85% to 97.99%, while open porosity decreased from 16.57% to 0.09%. Simultaneously, water absorption was reduced from 4.66% to 0.2%, indicating near-complete densification at 1400°C. XRD analysis confirmed the presence of stable α-Al₂O₃, Cu, and Cr phases without formation of undesirable secondary reaction products. SEM/EDS observations revealed a homogeneous distribution of discrete Cu-Cr metallic regions within the alumina matrix and satisfactory ceramic-metal interfacial bonding. The composites sintered at 1400°C exhibited a hardness of 13.8 ± 1.6 GPa and fracture toughness of 4.41 ± 0.78 MPa·m^0.5. Digital image correlation analysis during compression testing demonstrated localized strain evolution preceding brittle fracture. The results indicate that Cr addition may contribute to improved microstructural stability and densification behaviour of Al₂O₃-Cu composites processed by conventional powder metallurgy routes.

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Articles in this issue

DOI: https://doi.org/10.2478/adms-2026-0009 | Journal eISSN: 2083-4799 | Journal ISSN: 1730-2439

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Language: English

Page range: 91 - 118

Submitted on: Mar 29, 2026

Accepted on: Jun 12, 2026

Published on: Jun 23, 2026

Published by: Gdansk University of Technology

In partnership with: Paradigm Publishing Services

Keywords:

Ceramic-metal composites,

pressure-less sintering,

Microstructure evolution,

mechanical properties

Related subjects:

Materials sciences,

Functional and smart materials

© 2026 Paulina Piotrkiewicz, Justyna Zygmuntowicz, Marcin Wachowski, Ireneusz Szachogłuchowicz, Waldemar Kaszuwara, published by Gdansk University of Technology
This work is licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 3.0 License.

Volume 26 (2026): Issue 2 (June 2026)