In electronic packaging, Sn-Zn lead-free solder has great application prospects. Sn-9Zn-xBi alloys were obtained by smelting. This paper details a systematic study of the effect of Bi on the microstructure, melting behavior, wettability, mechanical behavior, antioxidant properties, and electrical conductivity of Sn-9Zn-xBi alloy, as well as the interfacial reaction in Sn-9Zn-xBi/Cu joints. The coarse Zn-rich phase became larger with an increase in the addition of Bi, which is harmful to the oxidation resistance of the solders. The melting temperature, solidus temperature, and liquidus temperature decreased with the increase in the addition of Bi, but the melting range increased. Adding a proper amount of Bi could substantially improve the spreading rate of Sn-9Zn, but reduce its oxidation resistance. Because of the solid solution effect of Bi element, the tensile strength of the Sn-9Zn solders could be enhanced, but the plastic and electrical conductivity was decreased. The IMC layer of the Sn-9Zn and Cu joints consisted of the ε-CuZn₅ phase and the γ-Cu₅Zn₈ phase. With an increase in the Bi element, the thickness of the interfacial reaction layer was firstly increased. When the Bi element content exceeded 3 wt.%, the inhibitory effect of the aggregated Bi elements on the formation of IMC was greater than the positive effect of the longer reaction time, and the thickness of the IMC decreased.

The homogeneous distribution of carbon nanotubes (CNTs) in the Cu matrix and good interfacial bonding are the key factors to obtain excellent properties of carbon nanotube-reinforced Cu-based composites (CNT/Cu). In this work, silver-modified carbon nanotubes (Ag-CNTs) were prepared by a simple, efficient and reducer-free method (ultrasonic chemical synthesis), and Ag-CNTs-reinforced copper matrix composites (Ag-CNTs/Cu) were fabricated by powder metallurgy. The dispersion and interfacial bonding of CNTs were effectively improved by Ag modification. Compared to CNTs/Cu counterparts, the properties of Ag-CNTs/Cu samples were significantly improved, with the electrical conductivity of 94.9% IACS (International Annealed Copper Standard), thermal conductivity of 416 W/m·k and tensile strength (315 MPa). The strengthening mechanisms are also discussed.