Study on the Effects of CeO2 on the Micro-Structure and Wear Resistance of CuCrZr Plasma Cladding Coatings

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-CeO2 coatings with a varying Cerium dioxide (CeO2) content. To enhance the wear resistance of the CuCrZr track, plasma cladding of CuCrZr-CeO2 coatings with varying CeO2 content was investigated. The impact of CeO2 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 CeO2 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% CeO2, pore defects in the coating increase, compromising mechanical properties. The coating containing 0.15% CeO2 exhibits optimal performance, with a hardness of 75.3, representing a 5.31% increase compared to CeO2-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.