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<p>The lifespan of plunger pumps is often limited by wear at the distributor plate and copper-pad rotor interface. Molybdenum disulfide (MoS<sub>2</sub>) is renowned for its exceptional solid lubrication properties. This study employed a high-energy ball milling method to prepare micro-/nano-MoS<sub>2</sub> composite powder, which was then used to fabricate Cu/MoS<sub>2</sub> composite coatings (with an Al bond layer) via the cold spraying (CS) process. Results indicate that at 900&#xa0;°C spraying temperature, a vortex-dominated microstructure formed at the Cu-Al interface. The average friction coefficient decreased from 0.77 (unlubricated coating) to 0.09 (sprayed lubricated coating). The reduction in friction coefficient and wear rate was primarily attributed to the boundary lubrication effect of the MoS<sub>2</sub> surface layer in the composite coating. By lowering shear forces during friction, excellent anti-friction and wear-resistant properties were achieved. The optimized cold spraying processing window identified in this study provides valuable guidance for manufacturing wear-resistant coatings for critical pump friction components.</p>

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Study on Interface Modulation Mechanism of Cold-Sprayed Micro-/Nano-MoS2/Cu Self-lubricating Anti-Wear Composite Coating

  • 期刊论文

  • 发表日期：

    2025年12月2日

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  • Zishuo Hao,
  • Chunzhi Gong,
  • Jing Liu,
  • Yuan Liu,
  • Chaoqun Lin,
  • Jiaying Liu,
  • Taoding Liang,
  • Qiming Liu,
  • Xiubo Tian

摘要

The lifespan of plunger pumps is often limited by wear at the distributor plate and copper-pad rotor interface. Molybdenum disulfide (MoS2) is renowned for its exceptional solid lubrication properties. This study employed a high-energy ball milling method to prepare micro-/nano-MoS2 composite powder, which was then used to fabricate Cu/MoS2 composite coatings (with an Al bond layer) via the cold spraying (CS) process. Results indicate that at 900 °C spraying temperature, a vortex-dominated microstructure formed at the Cu-Al interface. The average friction coefficient decreased from 0.77 (unlubricated coating) to 0.09 (sprayed lubricated coating). The reduction in friction coefficient and wear rate was primarily attributed to the boundary lubrication effect of the MoS2 surface layer in the composite coating. By lowering shear forces during friction, excellent anti-friction and wear-resistant properties were achieved. The optimized cold spraying processing window identified in this study provides valuable guidance for manufacturing wear-resistant coatings for critical pump friction components.