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<p>To address the thermal decomposition of WS<sub>2</sub> during thermal spraying and enhance the solid lubrication performance of WS<sub>2</sub>-containing coatings, this study prepared WS<sub>2</sub>@(Cu<sub>2</sub>O/Cu) core–shell powders via a facile chemical replacement method. These powders were then blended with Cu powder to fabricate Cu/WS<sub>2</sub>/Cu<sub>2</sub>O composite coatings using atmospheric plasma spraying. Quantitative XRD analysis showed that compared with the directly mixed Cu/WS<sub>2</sub> powder, the core–shell powder effectively reduced both the loss and decomposition rates of WS<sub>2</sub> during plasma spraying. At 15&#xa0;wt.% WS<sub>2</sub> in raw powders, the WS<sub>2</sub> loss rate decreased from 87.1 to 71.2%, and the WS<sub>2</sub> decomposition rate dropped from 42.3 to 28.1%. Reciprocating ball-on-disk wear tests demonstrated significantly improved tribological properties of this coating. Under a 20&#xa0;N load, its coefficient of friction (COF = 0.09) was 39% and the wear rate was 17% of the coating prepared with mixed Cu/WS<sub>2</sub> powders, respectively. XPS and EDS analyses revealed that a Cu<sub>2</sub>O tribofilm formed on the surface of the copper-based coating during friction. The Cu<sub>2</sub>O nanoparticles and WS<sub>2</sub> in the core–shell powder promoted the formation of a more continuous and homogeneous lubricating film—mainly composed of Cu<sub>2</sub>O and WS<sub>x</sub>O<sub>y</sub>—which accounted for the coating’s superior tribological performance.</p>

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Fabrication of Low-Friction Cu-Based Composite Coatings Using WS2@(Cu2O/Cu) Core–Shell Powders and Their Tribofilm Formation Mechanism

  • 期刊论文

  • 发表日期：

    2026年8月4日

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  • Bolong Han,
  • Yuxin Liang,
  • Yiying Li,
  • Yuhang Shi,
  • Hongtao Liu,
  • Xiaowei Li,
  • Jianghao Qiao

摘要

To address the thermal decomposition of WS2 during thermal spraying and enhance the solid lubrication performance of WS2-containing coatings, this study prepared WS2@(Cu2O/Cu) core–shell powders via a facile chemical replacement method. These powders were then blended with Cu powder to fabricate Cu/WS2/Cu2O composite coatings using atmospheric plasma spraying. Quantitative XRD analysis showed that compared with the directly mixed Cu/WS2 powder, the core–shell powder effectively reduced both the loss and decomposition rates of WS2 during plasma spraying. At 15 wt.% WS2 in raw powders, the WS2 loss rate decreased from 87.1 to 71.2%, and the WS2 decomposition rate dropped from 42.3 to 28.1%. Reciprocating ball-on-disk wear tests demonstrated significantly improved tribological properties of this coating. Under a 20 N load, its coefficient of friction (COF = 0.09) was 39% and the wear rate was 17% of the coating prepared with mixed Cu/WS2 powders, respectively. XPS and EDS analyses revealed that a Cu2O tribofilm formed on the surface of the copper-based coating during friction. The Cu2O nanoparticles and WS2 in the core–shell powder promoted the formation of a more continuous and homogeneous lubricating film—mainly composed of Cu2O and WSxOy—which accounted for the coating’s superior tribological performance.