Tribological Performance of Spark Plasma Sintered Cu-Based Composites Reinforced with Sn, Pb, Fe, SiO2, and Graphite for Wet Sliding Conditions
摘要
Copper-based friction materials are widely used in bearings, braking systems, and torque transmission components; however, their limited wear resistance under high-load and wet sliding conditions restricts their application in advanced tribological systems. In this study, multi-additive Cu-based composites reinforced with Sn, Pb, Fe, SiO2, and graphite were fabricated via spark plasma sintering (SPS) and evaluated under wet sliding conditions. A Taguchi L27 orthogonal array was employed to investigate compositional effects while minimizing experimental trials. Wear rate, coefficient of friction (COF), hardness, and porosity were statistically analyzed using signal-to-noise (S/N) ratios and analysis of variance (ANOVA). The maximum hardness reached 194 HB, while the minimum wear rate was reduced to 0.30 × 10−4 mm3/m. The lowest, highest COF and porosity were 0.150, 0.197, and 3.4%, respectively. ANOVA revealed that Fe was the dominant factor governing hardness (F = 331.24, p < 0.001), whereas graphite exhibited the highest statistical contribution to wear rate (F = 29.97, p < 0.001) and friction behavior (F = 74.28, p < 0.001). SiO2 and graphite significantly influenced porosity evolution (p < 0.001). The results demonstrate that graphite effectively reduces friction through the formation of lubricating films, while SiO2 enhances wear resistance and mechanical stability due to its hardness and thermal stability. The combined addition of Fe, Sn, and Pb further contributes to strengthening and improved load-bearing capacity. Microstructural observations revealed uniform reinforcement distribution and reduced porosity in SPS-processed samples. The hybrid reinforcement system significantly improved wear resistance, friction stability, and hardness, highlighting the potential of SPS-fabricated Cu-MMCs for high-performance tribological applications.