Powder Metallurgy technique has been used to prepare composite samples made of exfoliated graphite nano sheets (EGNS)and graphite flakes (GF) of 1, 3 and 5 weight % with copper chips. Effect of both graphite and its size on morphological, mechanical, and tribological behavior of copper matrix camposite has been investigated. Same unexpected characteristics have been identified due to the addition of graphite flakes and its exfoliated nano sizes with copper metal matrix. Nano-like grain boundary (NLGB) phenomenon has been reported. A decrease in hardness has been measured within the used weight fractions. Surprisingly, there was an increase in wear rates with an increase in wt % GF added to the copper matrix. In the case of EGNS, an increase in wear rate is reported for a weight fraction of 1%, which then decreases as more EGNS is added until it reaches approximately the same wear rate of pure Cu matrix at 5% EGNS. It is believed that the increase in wear at 1% EGNS is due to delamination domination theory. Measuring the counter part wear characteristics more deeply, evaluating the dispersion quantitatively, and explaining the delaminating theory of the EGNS/Cu metal matrix composites is recommended for future work.
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