Tribotechnical Characteristics of CuAl7–W–WC Composites Fabricated by Electron Beam Additive Manufacturing

This work presents a study on the development and evaluation of the tribological characteristics of metal matrix composites (MMCs) based on aluminum bronze CuAl7, reinforced with tungsten (W) and tungsten carbide (WC) particles, produced using electron beam additive manufacturing (EBAM).
The aim of the study is to obtain wear-resistant materials based on aluminum bronze with a surfaceengineered composite layer of CuAl7–W–WC and to investigate their tribological performance under dry sliding conditions at room and elevated temperatures in air.
The authors employed a combined wire–powder feed method, which enabled the fabrication of composite coatings with a uniform distribution of the reinforcing phase. Samples were produced from pure bronze (CuAl7), as well as composites containing 10 vol. % (CuAl7–W5–WC5) and 20 vol. % (CuAl7–W10–WC10) of reinforcing particles. It was established that the addition of W and WC significantly reduces the wear rate compared to pure bronze, while the friction coefficients of the composites remain comparable to those of the base material.
The wear mechanisms of the obtained MMCs were identified as predominantly oxidative, with the formation of a multilayered tribofilm containing copper and iron oxides, acting as a solid lubricant. The presence of reinforcing particles limits direct contact with the counterbody and suppresses plastic deformation of the matrix, thereby enhancing wear resistance. This study demonstrates the potential of EBAM technology for precise surface modification and provides new insights into the wear mechanisms of MMCs under hightemperature sliding conditions. The developed materials can be used in the manufacturing of components with enhanced wear resistance, such as those used in mechanical engineering and aerospace applications.

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