Structure and Properties of WC–Cu Layered Composites Obtained under Vibration Conditions

—WC–Co composite is one of the most popular and widely used. To improve some functional properties, thermal conductivity, corrosion resistance, etc., a search is underway for alternative metal binders with the possible replacement of Co with copper to reduce sintering temperatures and provide a higher thermal conductivity of the composite. Previously, it was shown that melt impregnation of freely poured refractory powders into a crucible-mold, activated by low-frequency vibration (LFV) of their compositions, differs from the methods used in industry in the simplicity of technology, short duration, and the possibility of obtaining composites with a high content of refractory phase with its frameless packaging. Two- to three-layer WC–Cu/Cu and Cu/WC–Cu/Cu composites with different arrangement of the working WC–Cu layer along the height of the ingot and different structural characteristics and properties of the layer have been obtained. The influence of thermal temporal conditions of LFV, pressure of cold prepressing of WC powder, dilution of carbide powder with copper powder, and geometry of stacking of alloy components on the formation of a given lamination of a composite alloy, a given composition, and a minimum porosity of the WC–Cu working layer was analyzed. The hardness and wear resistance of the WC–Cu layer were measured and their relationship to the layer structure and controlled parameters of the composite synthesis process control was established. Both the porosity of the structure and the presence of dense macroaccumulations of WC in the Cu matrix can be reduced to a minimum by preventive small prepressing of freely poured powders at room temperature before loading the alloy components into the furnace, followed by processing of the vibration. Composites with a homogeneous structure and low porosity of the working layer have been obtained.