Advancing Copper Wire Technology: Graphene/Cu Composites for Superior Conductivity and Strength

Copper-based composites with enhanced strength and conductivity are critically important for improving efficiency and reducing energy consumption in the energy and power industries. However, scalable production of copper-based composites that simultaneously enhance both conductivity and strength through conventional methods remains a significant challenge. This work explores the synthesis of high-quality graphene/copper (Gr/Cu) composite powders using in situ chemical vapor deposition (CVD). These powders were further processed through powder metallurgy and annealing techniques to produce wires with both high conductivity and increased mechanical strength. The morphology, structure and properties of Gr/Cu composite powders with different morphologies and graphene content were systematically analyzed by means of advanced characterization technology and metallographic structure analysis. The integration of high-quality graphene not only facilitated rapid electron transfer pathways but also enhanced mechanical properties through mechanisms such as grain refinement and load transfer. The produced annealed Gr/Cu composite wires exhibited electrical conductivities exceeding 100% International Annealed Copper Standard (IACS) and tensile strengths above 238 MPa. These findings are vital for the development of a new generation of high-conductivity electrical copper materials and products, contributing to the restructuring of energy resources and advancing the electrical copper industry.