Metal-based ceramic composite laser cladding offers substantial compensations in enhancing brake disc surface characteristics. Laser cladding was utilized to combine B4C powder (10–40%) with Ni 63 powder to make Boron Carbide (B4C)/Nickel 63 composite coatings. For the subsequent experiments, the specimens were ground and polished. Bonding strength, fracture toughness, and residual stress were examined with the B4C content. The fracture morphologies were checked using a scanning electron microscope (SEM). It was observed that the bonding strength of various coatings might approach 175 MPa. Best bonding was observed when the B4C level was between 15% and 30%. The porousness of the coating continuously raised as B4C content increased. The coating’s maximum permeability was 5.6% after the B4C level reached 30%. As the B4C level in the coating grew, the coating’s compression resistance decreased. The bonding strength was within desirable limits, and compression resistance was consistently strong. The material bending strength increased when the B4C materials were reduced below 35%; at this level, the bending strength was highest. The bending strength was covered by the optimal range of bonding strength. Good bonding strength and mechanical characteristics were achieved when B4C content was 20% to 30%. The 20% B4C coating had the smoothest fracture morphologies and the strongest bonding strength, making it the most stable. For the estimation of total matrix deformation and corresponding coating stress on coated brake discs, Ansys software was utilized to create a static structural model.
This paper presents an experimental study of Cu-Mo alloys prepared by powder metallurgy (PM) method. Also, improving the dispersion and wettability of Mo in the Cu matrix was aimed. Mo particles were added by 0.24, 0.48, 0.73 and 0.97% volume fraction to Cu powder. The mixture was mechanically milled by planetary ball mill at a rotational speed of 140 rpm for 24 h under hydrogen atmosphere, with milling ball size of ∼25 times the size of the metal powders. Liquid acetone was utilized as a process control agent (PCA). Paraffin wax (0.5 wt%) was used to decrease the friction with die during the compaction process. The mixture of the blended powder was compacted at ambient temperature under three different pressures (400, 600 and 800 MPa) and then sintered in a vacuum furnace at 1000 °C for 1 h by a heating rate of 5 °C min−1. The microstructure examination showed a homogeneous dispersion of Mo particles within the Cu matrix with no evidence of new phases formation during the sintering process. Also, the relative density of samples has been increased by increasing both of Mo content and the compaction pressure. The results revealed that the compaction pressure of 600 MPa was the most suitable pressure as it gave the highest densification. Cu—0.97% volume fraction Mo alloy samples exhibited finer Mo particles with a homogenous distribution in the Cu matrix and well bonding with the Cu particles. The microhardness was increased gradually by increasing Mo wt%, while the compressive strength was decreased by increasing the Mo contents. Both the electrical and thermal conductivities were decreased gradually by the addition of Mo. While the coefficient of thermal expansion (CTE) was decreased by Mo addition.
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