Characterization and Optimization of Cu-Al2O3 Nanocomposites Synthesized via High Energy Planetary Milling: A Morphological and Structural Study

Abstract

This study examines the synthesis and characterization of a copper–alumina nanocomposite powder. Mechanical milling is employed to synthesize the powder, and a holistic analysis is conducted to evaluate its morphological and structural properties. TEM analysis reveals the presence of alumina particles within the copper matrix, indicating the formation of both coarse and fine particles at different stages of synthesis. XRD analysis demonstrates a reduction in copper’s crystallite size with increasing milling time, attributed to defects generated within the crystal lattice during milling. Additionally, statistical analysis is utilized to determine the significance of different factors influencing the synthesis process. ANOVA analysis reveals that milling time has a significant impact on the particle size of the nanocomposite powder, while temperature and their interaction do not exhibit significant effects. Optimization techniques are utilized to identify solutions that meet the specified constraints for milling time, temperature, particle size, and differential thermal response, resulting in favorable solutions within the desired ranges. The study highlights the efficacy of mechanical milling for producing nanocomposite powders with enhanced mechanical properties, offering promising prospects for advanced materials in various industries. Additionally, the characterization results provide valuable insights into the microstructure and phase distribution of the nanocomposite powder. The application of the Williamson–Hall method proves to be effective in determining the crystallite size of the synthesized powder.