Copper-titanium diboride coatings obtained by plasma spraying reactive micropellets

Electrotribological applications require materials with both high electrical conductivity and wear resisance. For this purpose, a copper- base plasma sprayed coating containing titanium diboride particles was developed. The process for fabricating this CU- TiB₂ coating consists of plasma spraying reactive powders that contain a Cu- Ti alloy and boron. The reaction between the copper alloy and boron proceeds in different steps going from solid- state diffusion of titanium and copper to the synthesis of TiB₂ in a liquid below 1083 ‡C. Plasma sprayed copper coatings contain finer TiB₂ crystals than Cu- TiB₂ materials synthesized in a furnace at 1200 ‡C. Coatings with 25 vol% TiB2 have hardnesses that are comparable to Cu- Co- Be and Cu- Ni- Be alloys and to Cu- W and Cu- Mo alloys used in spot welding. Their low electrical resistivity of 52 ΜΩ cm could be increased by lowering the oxygen content with coatings and controlling the formation of TiB₂ clusters, the titanium content in solution in copper remaining low after the synthesis reaction.