Synthesis and Tribological Characteristics of High-Performance Self-Lubricating CoCrFeNiMox-Ni/MoS2-Ag-Cr2O3 Composites

High-temperature self-lubricating materials with stable tribological performance across a wide temperature range are essential for advanced mechanical systems under extreme conditions. However, balancing mechanical strength and lubrication efficiency remains a key challenge. This study fabricated CoCrFeNiMox-Ni/MoS₂-Ag-Cr₂O₃ composites (<i>x</i> = 0.2, 0.5, 1) via spark plasma sintering, aiming to investigate the effect of Mo content on their microstructure, mechanical properties, and tribological behavior. Microstructural analysis showed that the as-sintered composites mainly consist of FCC phase, Cr₂O₃, Ag, and Ni/MoS₂. Increasing Mo content from 0.2 to 1 wt.% significantly promoted the formation of hard σ-phase intermetallics, leading to increased hardness (up to 546 HV) and yield strength (peaking at 502 MPa). Tribological tests at 25-800 °C indicated continuous lubrication behavior in all composites. The minimum friction coefficient was 0.23, and wear rates remained below 10^-6 mm³/N·m. In the low-to-medium temperature range, lubrication was dominated by the synergistic effect of Ni/MoS₂ and Ag: Ni/MoS₂ formed low-shear-strength films, while Ag reduced surface adhesion. Meanwhile, the Mo solid solution strengthened and the σ-phase enhanced wear resistance by improving hardness and inhibiting plastic deformation. At high temperatures, tribochemical reactions generated lubricating films composed of oxides and molybdates, which maintained tribological performance by reducing direct contact between friction pairs. This study demonstrates that Mo-doped high-entropy alloy composites can serve as high-performance wide-temperature self-lubricating materials, providing a basis for designing "matrix-lubricant" systems for extreme-temperature applications.