This study reports the fabrication and characterization of copper–silicon carbide (Cu–SiC) metal matrix composites produced using powder metallurgy (PM) combined with thermo-compression processing (TCP), a dual route that remains limited in Cu–SiC research. Micro-sized SiC particles (1–25 wt.%) were incorporated into Cu, compacted, sintered, and subsequently subjected to sequential forging and annealing. Unlike conventional PM-only processing, TCP significantly reduced porosity, promoted more uniform reinforcement dispersion, and relieved residual stresses, creating a strong synergy between densification and microstructural refinement. SEM, EDS, XRD, and Raman analyses confirmed phase stability, homogeneous reinforcement distribution, and the absence of deleterious interfacial phases. The integrated PM + TCP route achieved an ultimate tensile strength of ~209 MPa, hardness of ~65 HRB, and toughness of ~35 MJ/m³ at approximately 3 wt.% SiC. The superior performance at this composition resulted not from the lowest porosity but from the combined effects of uniform particle dispersion, improved particle–matrix bonding, and deformation-driven refinement. These findings establish TCP as an effective post-sintering strategy that overcomes intrinsic porosity and interfacial limitations in Cu–SiC composites. Overall, powder metallurgy combined with the thermo-compression processing is identified as a promising processing pathway for developing high-strength, thermally stable Cu–SiC materials for structural and thermal management applications.

This study reports the fabrication of copper-based metal matrix composites reinforced with a combination of micro- and nano-sized titanium carbide (TiC) particles using the powder metallurgy route. The micro-TiC content was maintained at 5 wt.%, while the nano-TiC addition was systematically varied between 1 and 3 wt.% in increments of 1 wt.%. The consolidation of the blends was achieved by uniaxial compaction at 500 MPa, followed by sintering in a nitrogen atmosphere at 750–900 °C for 2 h. Tribological assessment under dry sliding conditions was performed using a pin-on-disk apparatus. Structural and microstructural examinations using X-ray diffraction (XRD), scanning electron microscopy (SEM), and energy-dispersive spectroscopy (EDS) confirmed a uniform incorporation of the reinforcements within the Cu matrix. The incorporation of nano-TiC up to 2 wt.% significantly enhanced density, hardness, and wear resistance, after which a marginal decline was observed. SEM analysis of worn surfaces revealed that adhesive wear, abrasion, and delamination were the primary wear mechanisms. To better understand the relationship between processing conditions and material responses, response surface methodology (RSM) was employed. The developed models for density, hardness, and wear loss showed good agreement with the experimental results, with confirmatory tests yielding errors of 1.59%, 2.06%, and 2%, respectively, thereby validating the approach’s reliability.