In this paper, Al-20Si-5Fe-2Ni composites reinforced with varying contents of Mo 2BC and Cu-coated Mo 2BC were fabricated via vacuum hot-press sintering. The influence of Cu-coated Mo 2BC content on the mechanical and tribological properties of the composites was systematically examined. Results revealed that the Cu coating on Mo 2BC ceramic particles reacted with the aluminum alloy matrix during sintering, leading to the formation of Al 2Cu interfacial bridges. The incorporation of Cu-coated Mo 2BC significantly enhanced the overall mechanical properties of the composites, which was attributed to the synergistic effects of interfacial bridging strengthening and the pinning effect provided by the Mo 2BC ceramic particles. Moreover, the tribological performance of the Al-20Si-5Fe-2Ni composites was markedly improved. When sliding against GCr15 bearing steel, the primary wear mechanisms of the unreinforced alloy included adhesive, fatigue, and abrasive wear. With the addition of up to 20 wt.% Cu-coated Mo 2BC, a smooth and continuous oxide film formed on the worn surface, which exerted a lubricating effect and reduced wear. However, as the content of Cu-coated Mo 2BC further increased to 30 wt.%, agglomeration of Mo 2BC particles became evident. Under applied shear stresses during sliding, these agglomerated particles were prone to fracture and disperse within the wear track, ultimately resulting in an increased friction coefficient and higher wear rate.
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