Bradley Bialke
Pronouns: he/him
Research Mentor(s): Mark Hammig
Research Mentor School/College/Department: Nuclear Engineering and Radiological Sciences / Engineering
Program: UROPF
Session: Session 3 (11:00am – 11:50am)
Authors: Bradley Bialke, Mark Hammig
Abstract
Copper metal exhibits excellent electrical and mechanical properties that make it extremely useful across a variety of industries. However, its high density often limits applications in weight-sensitive fields such as aerospace or automotive manufacturing. Through recent advancements in nanotechnology, it has become possible to create lightweight yet mechanically strong copper sheets and wires, offering a promising way to reduce mass even further without compromising performance or structural integrity of a part. In this study, we developed a method to synthesize copper nanoparticles and form lightweight copper sheets, and evaluated their electrical characteristics and potential use in weight-sensitive applications. Synthesis of copper nanoparticles was achieved by reducing copper sulfate using thioglycolic acid. The pH was carefully monitored and adjusted with hydrazine hydrate and hydrochloric acid to control the size and aggregation of nanoparticles. The nanoparticles were then deposited within a thin layer of aramid Kevlar nanofibers during vacuum filtration. The resulting sheets had a thickness of between 20 and 35 micrometers and a density of no more than 1.228 g/cm3, which is approximately 7.3 times lighter than bulk copper. The best electrical resistance achieved by a sheet was 0.05 ohms, which is on the same order of magnitude as the resistance of commercially available copper (about 0.0168 ohms)—although the majority of samples had resistances within the still-outstanding 1 to 10 ohm range. Furthermore, the sheets exhibited excellent mechanical properties given their thinness. These results suggest that copper nanoparticles synthesized through our method can be used to effectively produce lightweight copper sheets that exhibit electrical and mechanical properties in line with those of bulk copper. This research presents a promising method to address challenges of weight reduction in applications of copper-based materials while maintaining their desirable characteristics.
