The development of high-performance Cu-matrix composite coatings is a key research focus in materials science and surface engineering. This study presents an innovative hybrid method that combines cold-sprayed Cu-Ti-B 4C deposition with in-situ high-frequency induction remelting to fabricate a (TiB 2+TiC)/Cu composite coating on a pure Cu substrate. Comprehensive characterization revealed that the coating exhibited excellent surface integrity, with a dense, pore- and crack-free microstructure, and strong metallurgical bonding to the substrate. It has a smooth, planar surface, substantially minimizing post-processing machining requirements. The in-situ TiB 2 and TiC reinforcements were uniformly distributed throughout the coating, exhibiting clean interfaces and strong cohesion with the Cu matrix. The coating achieved microhardness values of 195–250 HV 0.2, which are comparable to those of medium- to high-strength copper alloys. The induction cladding process initiates solid-state reactions between Ti and B 4C in the cold-sprayed deposition. The subsequent dissolution-reprecipitation process during solidification yielded three distinct reinforcement morphologies: (i) needle-like TiC microfibers, (ii) fibrous-like TiB 2, and (iii) TiB 2-TiC eutectic structures. The formation of these morphologies is governed by the solidification dynamics and intrinsic crystallographic growth tendencies. The superior mechanical properties and exceptional chemical stability of these reinforcements endow the (TiB 2 + TiC)/Cu composite coating with remarkable hardness, excellent corrosion resistance, and outstanding tribological performance, thereby demonstrating its strong potential for engineering applications.
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