Processing and Characterization of Graphite–Nickel Composites Using Spark Plasma Sintering and Thermo-Mechanical Simulator
Authors :- MH Shah, A Patel, NI Jamnapara, P. Bhingole et al.
Publication :- Journal of Materials Engineering and Performance (Springer), 2025
This study explores the mechanical and tribological performance of graphite–nickel composites (GNCs) fabricated by spark plasma sintering (SPS) with varying nickel contents (0, 30, 40, and 50 wt.%). High-purity graphite and nickel powders were ball-milled for homogeneous mixing and consolidated at 1000 °C under 40 MPa uniaxial pressure with a 7 min dwell time. The influence of Ni addition on relative density, microstructural evolution, hardness, and dry sliding wear behavior was systematically investigated. XRD confirmed the absence of carbide formation, while SEM/EDS analysis revealed a continuous Ni network and clean Ni–graphite interfaces. The composites achieved relative densities above 97%, with Shore D hardness increasing by ~ 20% compared to pure graphite. Among the investigated compositions, the 40 wt.% Ni sample exhibited the highest hardness and superior wear resistance, attributed to the synergistic effects of Ni-induced load-bearing reinforcement, graphite-based tribolayer lubrication, and enhanced interfacial bonding. The results establish a clear link between composition, microstructure, and properties, demonstrating the potential of SPS-processed GNCs as lightweight, wear-resistant materials for structural and tribological applications.