Development of Plasma-Sprayed Copper Alloy–Nickel-Clad Graphite Composite Coatings with Enhanced Tribological Properties
DOI:
https://doi.org/10.31891/2079-1372-2025-118-4-6-13Keywords:
nickel-clad graphite, copper alloy, composite coatings, thermal spray coatings, friction and wearAbstract
This study is focused on the development of composite plasma-sprayed coatings with a low coefficient of friction based on copper alloys with additions of nickel-clad graphite and on the investigation of their physicomechanical and tribological properties. Composite coatings were produced by atmospheric plasma spraying (APS) from agglomerated powders of copper alloys with the following compositions: BrONG-30 (70 wt.% BrOF10-1 + 30 wt.% nickel-clad graphite), BrOSNG-30 (70 wt.% BrOCTS5-5-5 + 30 wt.% nickel-clad graphite), and LNG-30 (70 wt.% L63 + 30 wt.% nickel-clad graphite). The application of graphite in a nickel shell improves its wettability by the metallic matrix and enhances adhesion. The obtained coatings exhibit high adhesion strength to the substrate (33–38 MPa) and density (94–97%). Tribological tests demonstrated that the LNG-30 – steel 45 friction pair showed the best performance. The inclusion of nickel-clad graphite reduced the friction coefficient by up to 1.5 times and increased wear resistance by up to 3.8 times. Using EDS and Auger spectroscopy, it was established that during friction in the LNG-30 – steel 45 pair, a film consisting of graphite (16–17 nm thick) and oxides of copper, zinc, nickel, and iron is formed on the counterbody wear track. The presence of such oxide films indicates a predominantly oxidative mechanism of friction, with minor adhesive interaction. The proposed coatings are promising for application in friction units, particularly under conditions where the use of liquid lubricants is limited or impossible
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