Abstract This review systematically evaluates recent progress in high-temperature tribology of metal matrix composites, with a specific focus on Ni-based composite coatings. It comprehensively analyzes the tribological performance of various metallic composites under extreme thermal-mechanical conditions, emphasizing the synergistic effects of the incorporation of solid lubricants and ceramic hard phases in alloy systems. The discussion covers critical aspects: particle reinforcement mechanisms, thermal spraying fabrication techniques, and post-treatment methodologies for microstructural optimization. Special attention is devoted to the unique advantages of Ni-based coatings in aerospace propulsion systems and automotive powertrain applications, where exceptional wear resistance and thermal stability are paramount. Through critical assessment of phase evolution mechanisms and tribo-oxidation behavior across wide temperature ranges (room temperature (RT)–800 °C), the work elucidates the structure-property relationships in these coating systems. Building upon extensive literature analysis over the past five years, innovative design strategies are proposed to enhance the adaptive tribological performance of Ni-based composites through multi-scale architecture engineering and self-lubricating phase regulation. Notably, through synergistic strengthening and tribochemically activated mechanisms, the strategy of integrating solid lubricants, hard phases, and in-situ grown intermetallic compounds, demonstrates promising potential for addressing the severe wear challenges in Ni-based composite coatings at ≈400 °C, which predominantly arise from creep-induced deformation. This synthesis provides both theoretical guidance for metal matrix system optimization and practical insights for next-generation high-temperature tribological applications.
Sun et al. (Thu,) studied this question.
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