In this study, Cu-based composites reinforced with boron carbide (B₄C) and hybrid B₄C-graphite additions were fabricated via the powder metallurgy (PM) route. The effects of reinforcement content and sintering parameters on the mechanical, electrical, wear, and microstructural properties were systematically investigated. The optimum composition for single phase reinforcement was obtained with 1 wt% B₄C, sintered at 850 °C for 1 h, showing significant improvements in hardness (~90.4 HV), compressive strength (768 MPa), and wear resistance, while maintaining good electrical conductivity with only a ~ 6.7 % increase in resistivity compared to pure copper. Increasing B₄C content to 3–5 wt% resulted in higher porosity, grain coarsening, and Cu₂O formation, which deteriorated both strength and conductivity. Hybrid composites produced with 1 wt% B₄C and varying graphite additions (3–15 wt%) revealed a balance between lubrication and mechanical properties. The Cu-1B₄C-3Gr sample exhibited the best performance, with compressive strength of ~600 MPa, hardness of ~99 HV, low wear rate (8.1 × 10 −5 mm 3/N·m), and relatively stable electrical resistivity. At higher graphite contents, excessive porosity and weak interfaces promoted strength degradation, despite improved lubricating behavior. XRD and SEM–EDX analyses confirmed phase stability of B₄C and graphite within the Cu matrix, while localized Cu₂O formation was more evident at higher graphite ratios. Overall, the results demonstrate that controlled hybrid reinforcement particularly Cu-1B₄C-3Gr offers a promising strategy for developing copper-based composites with an optimum balance of mechanical strength, wear resistance, and electrical performance for advanced engineering applications.
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