Methods of manufacturing composite materials, composite wires, and welding electrodes

A method of manufacturing a composite material, comprising:

• compacting a copper alloy powder into a plurality of substantially uniform compressed sub-assemblies such that the copper alloy powder of the plurality of compressed sub-assemblies has a packing density that is greater than 65%;
• providing a layer of un-compacted copper alloy powder within an aperture of a shell;
• layering the plurality of compressed sub-assemblies relative one another within the aperture of the shell, the plurality of compressed sub-assemblies forming a consecutive assembly of compacted copper alloy;
• sealing the consecutive assembly within the shell to form a billet;
• hot-extruding the billet at a temperature above 900° C. to form a rod;
• and
• drawing the extruded rod to form a composite wire having a desired diameter;
• wherein the shell is made of CuZr and the powder is dispersion strengthened copper;
• wherein the core and the shell have a metallurgical bond formed from co-extrusion;
• wherein the compressed sub-assemblies are compressed prior to layering the plurality of compressed sub-assemblies relative one another within the shell;
• and
• wherein the plurality of compressed sub-assemblies are layered on the layer of the copper alloy powder.