A new technique combining wire and powder in the form of a ‘hybrid’ feedstock during arc spraying has been explored in this study. The primary goal of this research was to investigate the feasibility of incorporating a second phase in a Babbitt matrix by spraying wire and powder simultaneously. While Tin-based Babbitt alloys have excellent tribological properties, such as a low friction coefficient and frictional resistance, making them popular materials for sliding bearings, dual-phase/composite coatings have been of interest due to their potential to perform better than corresponding single constituent coatings. A further objective was to assess the effect of copper (Cu), molybdenum (Mo), and tungsten carbide (WC) contents as second-phase reinforcements on composite Babbitt coatings' microstructure and tribological properties. These effects were systematically investigated through scanning electron microscopy (SEM), microhardness tests, and dry sliding, as well as lubricated wear tests. The study demonstrated that a hybrid arc spray process effectively incorporated Cu, Mo, and WC particles into the coating. The wear test results indicated that adding the second phase enhanced the wear resistance of the coating.
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