The 3wt.% MoS2-Ni3Al-based friction material has attracted widespread attention due to its excellent high-temperature stability and the remarkable effect of the gradient self-lubricating film formed by the synergy of 1.5wt.% GNS and MoS2. The primary objective of this study is to optimize the mechanical and tribological properties of the 3wt.% MoS2-Ni3Al-based friction material. Specifically, it aims to explore the effects of graphene with varying contents on the microstructure of the 3wt.% MoS2-Ni3Al-based friction material and systematically investigate the friction properties and underlying friction mechanisms of the friction material when different amounts of graphene are incorporated. Composites containing 0wt.%-2wt.% nano-graphene sheets (GNS) are fabricated via the powder metallurgy route, which combined cold pressing forming and subsequent sintering processes. To comprehensively evaluate the effect of the graphene content on the material properties, a series of characterization and testing methods are employed. The phase composition, microstructure, and surface chemical states of the material are analyzed by X-ray diffraction, scanning electron microscopy, and X-ray photoelectron spectroscopy. Combined with mechanical property tests and ring block wear experiments, the effects of the GNS content on the mechanical properties and friction performance at room temperature and 500 ℃ are investigated. Additionally, the wear mechanisms under different conditions are revealed through analysis of wear scar morphology and wear debris composition. The experimental results indicate that the incorporation of graphene exerts a significant impact on the properties of the 3wt.% MoS2-Ni3Al-based friction material. With the increase of the graphene content, the density of the material shows a continuous downward trend. In contrast, the compressive strength and hardness first increases and then decreases. At room temperature and 500 ℃, the friction coefficient and wear rate of the material both show a trend of first decreasing and then increasing with the increase of the GNS content. At 500 ℃, the friction coefficient of each sample formulation is 20%-25% higher than at room temperature, and the wear rate increases by 25%-30%, with a more pronounced dependence on rotational speed. When the GNS content is 1.5wt.%, the material achieves the optimal comprehensive performance: the Brinell hardness reaches 168HBS, and the compressive strength attains 392 MPa. Under the working condition of 1 400 r/min, the friction coefficient is reduced to 0.284, and the wear rate is 54% lower than that of the matrix material without graphene addition. At 500 ℃, this proportioned sample remains the best at all rotational speeds, with a wear rate maintains between 4.0×10‒7 and 6.5×10‒7 mg/m. The wear mechanism at room temperature and 1 400 r/min is a combination of oxidative wear and adhesive wear. When the GNS content is insufficient, the material has poor lubrication performance. If the content exceeds 2wt.%, agglomeration occurs, leading to reduced material density and deterioration of mechanical and tribological properties, and the negative effects of agglomeration at 500 ℃ are further amplified. However, when the GNS content exceeds 1.5wt.%, the grains of the composite become coarse, the splitting effect of the non-metallic graphene phase becomes prominent, and thus the material properties start to deteriorate. Further investigation on the wear mechanism under different rotational speeds with 1.5wt.% GNS content reveals that abrasive wear is the dominant mechanism at 600 r/min; at 1 400 r/min, the wear mechanism is dominated by both abrasive wear and oxidation wear; and at 2 300 r/min, fatigue wear and abrasive wear are the main wear mechanisms. In conclusion, graphene plays a significant regulatory role in modifying the microstructure and properties of the 3wt.% MoS2-Ni3Al-based friction material, and the friction material achieves the optimal comprehensive performance when the graphene content is 1.5wt.%. GNS exerts a dual strengthening mechanism on the 3wt.% MoS2-Ni3Al-based friction material. On one hand, it optimizes the material microstructure and enhances the mechanical properties through the synergistic effect of solid solution strengthening and grain refinement strengthening. Specifically, C atoms in GNS dissolve into the Ni3Al lattice, causing lattice distortion (solid solution strengthening), and GNS can hinder the growth of grains during the sintering process (grain refinement strengthening). On the other hand, GNS and MoS2 form a gradient lubricating structure on the friction surface: GNS contributes to the formation of a continuous and high-strength lubricating film, while MoS2 fills the defects in the lubricating film. The synergistic effect of these two components effectively reduces the friction resistance. Meanwhile, the high toughness of GNS can effectively inhibit the initiation and propagation of cracks on the friction surface under high-speed working conditions, thereby significantly improving the wear resistance of the material.
Key words
3wt.% MoS2-Ni3Al based friction material /
graphene /
powder metallurgy /
synergistic lubrication mechanisms /
mechanical properties /
tribological properties
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Funding
Basic Research Project of the Liaoning Provincial Department of Education (LJ222511258013); Liaoning Provincial Science and Technology Plan Joint Program (2024-BSLH-009); 2025 Special Discipline Construction Project of Dalian University (Interdisciplinary Youth Project) (DLUXK-2025-QNLG-012)
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