The electromagnetic railgun, a novel kinetic energy weapon, has found utility in military operations due to its enhanced safety features and superior precision. This study investigates the enhancement of wear resistance in CuCrZr rails through the plasma cladding of CuCrZr-CeO 2 coatings with a varying Cerium dioxide (CeO 2) content. To enhance the wear resistance of the CuCrZr track, plasma cladding of CuCrZr-CeO 2 coatings with varying CeO 2 content was investigated. The impact of CeO 2 content (0%, 0.1%, 0.15%, 0.2%, 0.25%, 0.3%) on the microstructure, phase composition, and mechanical properties of the CuCrZr coating was assessed using scanning electron microscopy (SEM), X-ray diffraction (XRD), EDS(Energy Dispersive Spectrometer) surface scanning, friction and wear tests, and hardness analysis. The findings indicate that a CeO 2 content of 0.15% leads to a transition in the coating’s microstructure from columnar to equiaxed crystals, with the densest grain structure. Beyond 0.15% CeO 2, pore defects in the coating increase, compromising mechanical properties. The coating containing 0.15% CeO 2 exhibits optimal performance, with a hardness of 75.3, representing a 5.31% increase compared to CeO 2-free CuCrZr coatings. Under a 10 N load, the friction coefficient decreases by approximately 17.9% to about 0.64. Moreover, the minimum wear mass is reduced by 44.7% to 3.87 mg. The aforementioned research findings hold immense importance in extending the lifespan of the electromagnetic railgun and improving its operational efficiency.
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