Foamed-metal-reinforced composites: Tribological behavior of foamed copper filled with epoxy–matrix polymer

• Foamed copper was filled effectively with the liquid epoxy matrix for tribology.
• Foamed copper embedded was effective in transmitting heat and sharing load.
• The composites possess better thermal conductivity and wear resistance.

To improve the thermal performance and wear resistance of epoxy–matrix polymers, foamed copper materials filled with a curable epoxy matrix have been developed for tribological studies. Graphite flakes were incorporated as friction additive in the epoxy matrix. The tribological properties of foamed-copper-reinforced composites were investigated using a UMT-2 friction and wear tester. The temperature of the frictional area was measured using an infra-red thermal camera, and the effect of metallic skeletons on temperature was calculated by the finite element analysis (FEA). The results show the foamed-copper-reinforced composites are effective in transmitting heat and sharing load along the interconnected metallic skeletons, and therefore possess better thermal conductivity and wear resistance.