Enhanced mechanical and tribological properties of nickel foam-reinforced copper-based self-lubricating composites for high-temperature applications

Purpose This study aims to design a copper-based self-lubricating composite reinforced with a three-dimensional (3D) nickel foam structure to enhance its mechanical and tribological properties. Design/methodology/approach The copper-based composites were synthesized by infiltrating a nickel foam skeleton with a slurry containing copper, graphite, molybdenum and chromium, followed by solvent evaporation and hot-press sintering. The impact of sintering temperature on the composite’s mechanical properties was systematically investigated, and its load-bearing capacity was evaluated at room temperature, along with an assessment of its tribological behavior at both room temperature and 300 °C. Findings The composite sintered at 800 °C exhibited a homogeneous phase distribution, fully preserving the integrity of the nickel foam architecture. Compared to the matrix sample, the composite showed a significant enhancement in compressive strength (65%) and flexural strength (167%). At room temperature, the nickel foam skeleton reduced the average friction coefficient to 0.26 and the volume of wear to 1.1 × 10−4 mm³/(N·m), while wear depth was reduced from 33.95 to 23.13 µm. Under high temperature (300 °C), wear depth decreased even further from 10.75 to 4.55 µm, indicating improved thermal stability and enhanced wear resistance. Originality/value This work presents an innovative fabrication strategy for copper-based self-lubricating composites by integrating a 3D nickel foam framework, thereby enhancing both mechanical robustness and tribological performance. The systematic optimization of sintering parameters and the comprehensive evaluation of high-temperature behavior provide new insights into advanced self-lubricating samples for high-temperature applications. In addition, this research can be specifically applied in industrial scenarios such as high-temperature guide rails, aerospace brake pads, joint bearings for large machinery and joint bushings. Peer review The peer review history for this article is available at: Link to the cited article