In order to improve the wear resistance and service life of the copper, the composite coating consisting of a Ni-base self-fluxing alloy (NiCrWB+50%Al2O3) and WC (WC-12%Co) alloy were sprayed on a copper substrate using High Velocity Air Fuel(HVAF). The coating could meet the operating requirements including high hardness, good wear resistance and low cost. The Ni-base composite coating was analyzed by means of optical microscopy, scanning electron microscopy (SEM), electron probe microanalysis (EPMA) and X-ray diffraction (XRD). The results indicated that the structure of coating was composed of melted particles and partly unmelted round particles of Ni-base alloy, and WC particle. Only a small proportion of the Al2O3 particles were retained in the coating. The phases in the coating consisted of γ-Ni, WC and a little Ni3B. Amorphous structures appeared and some Al2O3 phase existed. The adhesion strength between coating and copper substrate was more than 50MPa. Wear results showed that the Ni-base composite coating exhibited better wear resistance than the coating with no WC particles.

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