Fabrication, mechanical and thermal properties of copper coated graphite films reinforced copper matrix laminated composites via ultrasonic-assisted electroless plating and vacuum hot-pressing sintering.

In the trend of integration of structure and function, novel thermal management materials are urgent to be developed owning good mechanical properties as well as excellent thermal properties. In this work, a complete and dense copper (Cu) coating with a thickness of 400 nm was deposited on the surfaces of graphite films (GFs) by ultrasonic-assisted electroless plating, which can improve the surface roughness of GFs and interfacial bonding between GFs and Cu foils. Cu-coated and uncoated GFs reinforced copper matrix laminated composites (noted as GFs(Cu)/Cu and GFs/Cu) were fabricated by optimized vacuum hot-pressing sintering. Based on the scratch test and microstructures of GFs(Cu) and GFs(Cu)/Cu composites, addition of Cu coating can improve the interfacial adhesion and element diffusion behavior, and intuitively explains the mechanical interlocking effect at the C–Cu interface. On basis of the nanoindentation mechanical properties across GFs(Cu)/Cu and GFs/Cu interfaces, the interfacial transition region with Cu coating of ~3 μm is three times of that without Cu coating. Flexural strength of 27.6 vol% GFs(Cu)/Cu laminated composite is 45.9 MPa, which is 56% higher than that of the corresponding GFs/Cu laminated composite. In-plane thermal conductivity (TC) and out-of-plane coefficient of thermal expansion (CTE) of 69.4 vol % GFs(Cu)/Cu laminated composite are 1177.8 W/m·K and −2.5 ppm/K respectively, which could be explained on the theoretical calculations and interfacial structures. In conclusion, the Cu coating on surfaces of GFs can generally improve the interfacial bonding, mechanical properties and thermal properties of GFs(Cu)/Cu laminated composites. It provides an effective way to develop novel structural and functional materials for thermal management. [ABSTRACT FROM AUTHOR]