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<p>Addressing the urgent demand for highly conductive, wear-resistant materials in current-carrying friction pairs. This study designed a composite of agglomerated nano-TiO<sub>2</sub> powder and micron-sized Cu powder. Using atmospheric plasma spraying technology, TiO<sub>2-x</sub>/Cu composite coatings with varying ceramic contents (10 wt.%, 30 wt.%, and 50 wt.%) are synthesized in a single-step reaction. The effects of the ceramic/metal ratio on the coating’s microstructure, mechanical properties, electrical properties, and tribological behavior are systematically investigated. The results indicate that the ceramic/metal ratio significantly regulates the coating properties. As the TiO<sub>2-x</sub> ceramic content increases, the composite coating’s microhardness markedly improves, but the electrical conductivity gradually decreases. Further dry friction and current-carrying friction tests on the composite coating revealed that under both conditions, the COF increased with higher ceramic content, yet the wear rate decreased significantly. Lower ceramic content resulted in a low COF due to the tendency to form an oxide glaze layer during friction. Higher ceramic content, while increasing the COF, significantly reduced the wear rate owing to the hard ceramic skeleton structure. It undergoes a transformation in its wear mechanism, shifting from predominantly adhesive wear to fatigue wear. Notably, the T30 coating demonstrates excellent adaptability to extreme environments due to the synergistic effect of its oxide glaze layer and hard support skeleton. This study offers a novel strategy for synergistically optimizing the performance of high ceramic content composite coatings and their application under current-carrying conditions.</p>

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Influence of nano ceramic content on the microstructure and current-carrying tribological behaviors of reaction synthesized TiO2-x/Cu composite coating

  • 期刊论文

  • 发表日期：

    2026年2月23日

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  • Peng Wang,
  • Zekun Li,
  • Wenchang Wang,
  • Da Zeng,
  • Guozheng Ma,
  • Junhong Jia,
  • Haidou Wang

摘要

Addressing the urgent demand for highly conductive, wear-resistant materials in current-carrying friction pairs. This study designed a composite of agglomerated nano-TiO2 powder and micron-sized Cu powder. Using atmospheric plasma spraying technology, TiO2-x/Cu composite coatings with varying ceramic contents (10 wt.%, 30 wt.%, and 50 wt.%) are synthesized in a single-step reaction. The effects of the ceramic/metal ratio on the coating’s microstructure, mechanical properties, electrical properties, and tribological behavior are systematically investigated. The results indicate that the ceramic/metal ratio significantly regulates the coating properties. As the TiO2-x ceramic content increases, the composite coating’s microhardness markedly improves, but the electrical conductivity gradually decreases. Further dry friction and current-carrying friction tests on the composite coating revealed that under both conditions, the COF increased with higher ceramic content, yet the wear rate decreased significantly. Lower ceramic content resulted in a low COF due to the tendency to form an oxide glaze layer during friction. Higher ceramic content, while increasing the COF, significantly reduced the wear rate owing to the hard ceramic skeleton structure. It undergoes a transformation in its wear mechanism, shifting from predominantly adhesive wear to fatigue wear. Notably, the T30 coating demonstrates excellent adaptability to extreme environments due to the synergistic effect of its oxide glaze layer and hard support skeleton. This study offers a novel strategy for synergistically optimizing the performance of high ceramic content composite coatings and their application under current-carrying conditions.