The study investigates the influence of nickel-clad graphite additives on the structure and tribological properties of plasma-sprayed brass coatings. Using atmospheric plasma spraying technology, brass-based coatings with 0%, 10%, 30%, and 50 wt.% nickel-clad graphite additives were deposited on the steel substrates. The structure of the composite coatings contains a brass-based matrix and graphite additives. Wear tests of the coatings were conducted in a pin-on-ring configuration under dry sliding conditions, using a steel ring as the counterpart. The brass-based coating with 10 wt.% graphite exhibited a 5-6 times lower wear rate and a 1.6 times lower friction coefficient compared to the pure brass coating. Using micro-x-ray spectral analysis and Auger spectroscopy, it was found that a graphite layer and copper oxide film form on the worn surfaces of the coating and its steel counterpart. These tribolayers act as a lubricating film, preventing adhesive interaction between the coating and the steel counterpart. However, both the friction coefficient and wear rate increase with the 30-50 wt.% of graphite content in the plasma-sprayed coatings due to the deterioration of the coatings under friction conditions.
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