Molybdenum disulfide (MoS2) films are widely used to improve friction performance, but they are difficult to fabricate using conventional thermal spray processes due to thermal decomposition of the feedstock powder. In this study, Cu-MoS2 composite coatings are fabricated by cold spraying using mechanically milled powders containing different concentrations of MoS2. Investigators found that increasing the concentration of MoS2 in the powder improved some coating properties while degrading others. Through testing it was determined that the ideal concentration of MoS2 is 5wt%. Increasing the milling time of the powder mixture also provided benefits in terms of hardness and wear resistance.

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