Effect of Cu content in Cu-coated diamond/Ni-based composite coatings on microstructure and properties

Copper-coated diamonds were synthesized using a high-energy ball milling method with binder assistance method, and diamond-Ni alloy composite coatings were fabricated through induction heating. The effects of Cu coatings on the microstructure and wear resistance of the composite coatings were comprehensively analyzed. Results indicate that the Cu coating prepared via the high-energy ball milling method with binder assistance method effectively mitigates diamond's thermal degradation, significantly reducing carbide formation in the coatings as the Cu content increases. The addition of Cu-coated diamond notably improves the tribological properties of the coatings, with a 6 wt% Cu content reducing the friction coefficient by 14.2 %. Moreover, the diamond particles remained intact during wear tests, demonstrating the coating's superior durability and robustness. © 2025 Elsevier B.V.