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<p>Copper-based materials are extensively utilized in advanced high-power electric slip rings, yet the relatively poor wear resistance limits their service life. To address this issue, this study proposed cold-sprayed Cu/B<sub>4</sub>C composite coatings to enhance the wear resistance of copper-based materials. Three types of Cu/B<sub>4</sub>C spray powders with Cu:B<sub>4</sub>C volume ratios of 1:1 (0.5CBC), 2:1 (CBC), and 4:1 (2CBC), along with pure copper coatings, were fabricated via high pressure cold spray method (HPCS). The friction and wear behavior of coatings against 5mm Al<sub>2</sub>O<sub>3</sub> balls under a load of 5 N for 20000 cycles were systematically investigated. Surface morphologies and sheet resistance of different materials were characterized, and the wear evolution mechanisms were analyzed. Results revealed that B<sub>4</sub>C constitutes 2.66 ~ 4.58 vol.% in the composite coatings, and sheet resistance as low as 11.75-17.00 μΩ/□. The CBC coating exhibits significantly higher hardness compared to copper coating and copper bulk. Additionally, it demonstrates a friction coefficient of 0.26 (copper bulk: 0.37) and a wear rate of 1.51 × 10<sup>−5</sup> mm<sup>3</sup>&#xa0;N<sup>−1</sup>&#xa0;m<sup>−1</sup>, both of which are notably lower than those of copper coating and copper bulk. The incorporation of B<sub>4</sub>C particles effectively enhances the frictional and mechanical properties of the copper coating by distributing the applied load and mitigating direct wear, thereby significantly improving durability and extending service life.</p>

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Microstructure and Tribological Properties of Cold-Sprayed Cu/B4C Composite Coating

  • 期刊论文

  • 发表日期：

    2025年8月20日

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  • Chun Li,
  • Kangzhi Ma,
  • Zheng Zhang,
  • Liyong Ni,
  • Bo Wen,
  • Zhenxiao Yang,
  • Runhan Shao,
  • Dong Qu

摘要

Copper-based materials are extensively utilized in advanced high-power electric slip rings, yet the relatively poor wear resistance limits their service life. To address this issue, this study proposed cold-sprayed Cu/B4C composite coatings to enhance the wear resistance of copper-based materials. Three types of Cu/B4C spray powders with Cu:B4C volume ratios of 1:1 (0.5CBC), 2:1 (CBC), and 4:1 (2CBC), along with pure copper coatings, were fabricated via high pressure cold spray method (HPCS). The friction and wear behavior of coatings against 5mm Al2O3 balls under a load of 5 N for 20000 cycles were systematically investigated. Surface morphologies and sheet resistance of different materials were characterized, and the wear evolution mechanisms were analyzed. Results revealed that B4C constitutes 2.66 ~ 4.58 vol.% in the composite coatings, and sheet resistance as low as 11.75-17.00 μΩ/□. The CBC coating exhibits significantly higher hardness compared to copper coating and copper bulk. Additionally, it demonstrates a friction coefficient of 0.26 (copper bulk: 0.37) and a wear rate of 1.51 × 10−5 mm3 N−1 m−1, both of which are notably lower than those of copper coating and copper bulk. The incorporation of B4C particles effectively enhances the frictional and mechanical properties of the copper coating by distributing the applied load and mitigating direct wear, thereby significantly improving durability and extending service life.