The tribological properties of cold sprayed Ni-WC metal matrix composite (MMC) coatings were investigated under dry sliding conditions from room temperature (RT) up to 400°C, and during thermal cycling to explore their temperature adaptive friction and wear behavior. Characterization of worn surfaces was conducted using scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), and Raman spectroscopy to determine the chemical and microstructural evolution during friction testing. Data provided insights into tribo-oxide formation mechanisms controlling friction and wear. It was determined that the steady-state coefficient of friction (CoF) decreased from 0.41 at RT to 0.32 at 400˚C, while the wear rate increased from 0.5×10-4 mm3/N·m at RT to 3.7×10-4 mm3/N·m at 400˚C. The friction reduction is attributed primarily to the tribochemical formation of lubricious NiO on both the wear track and transfer film adhered to the counterface. The increase in wear is attributed to a combination of thermal softening of the coating and a change in the wear mechanism from adhesive to more abrasive. In addition, the coating exhibited low friction behavior during thermal cycling by restoring the lubricious NiO phase inside the wear track at high temperature intervals. Therefore, cold sprayed Ni-WC coatings are potential candidates for elevated temperature and thermally self-adaptive sliding wear applications.

Silicon nitride on steel sliding contacts may provide advantageous tribological properties over traditional self-mated pairs, however the friction and wear behavior at high sliding speeds (>1 m/s) is not well understood. Previous studies at low sliding speeds (< 1 m/s) have found that the wear mechanisms change as a function of the operating parameters, e.g. atmosphere, sliding speed, load, and temperature, due to the formation of transition metal oxides such as Fe2O3 and Fe3O4. This study detected transient effects of the dry silicon nitride on steel contact over a range of sliding speeds to understand their relation to tribochemical reactions and the resulting tribological behavior. Two sets of dry silicon nitride on steel experiments were conducted at 1.45 GPa maximum Hertzian pressure. The first set were low sliding speed reciprocating experiments, conducted at an average of 0.06 m/s, conducted at variable operating temperature, ranging from 23 °C to 1000 °C. In the low sliding speed experiments, transitions of the wear mechanism from adhesive wear, to abrasive wear, then to oxidative wear was observed when the operating temperature increased. The second set were high sliding speed experiments, conducted at variable sliding speeds, ranging from 1 m/s to 16 m/s. In the high sliding speed experiments, a transition from adhesive wear to oxidative wear was observed when the sliding speed surpassed 4.5 m/s. The high sliding speed experiments were accompanied by in-situ instrumentation which detected the presence of a tribofilm which correlated to a reduction in friction, and its formation was linked to tribochemical reactions induced by high flash temperatures. Both sets of experiments had a maximum estimated contact temperature of 1000 °C where oxidative wear was prevalent. Although, the low sliding speed experiments underwent severe bulk oxidation and thermal softening effects, while the high sliding speed experiments experienced localized flash heating events with temperatures sufficient to form a semi-coherent tribofilm that was lubricious and significantly improved wear resistance. Therefore, the effects of transition metal oxides in sliding contacts are determined to be significantly influenced on their mechanisms of formation and interrelated to the operating parameters as found for dry sliding silicon nitride on steel contacts.