Self-propagating High-temperature Synthesis Reaction Research Articles

The effect of low-energy high-current pulsed electron beam irradiation on the structure, phase composition and mechanical properties of Ni3Al and Ni3Al-TiC composites

Using scanning and transmission electron microscopy, X-ray diffraction, indentation and bending tests we studied the evolution of microstructure, phase composition and mechanical properties of TiC-free Ni3Al and Ni3Al-TiC composites (TiC content was 10 and 30 vol%) fabricated by self-propagating high-temperature synthesis (SHS) under pressure induced by low-energy high-current pulsed electron beam (LEHCEB) irradiation with the surface energy density of 8, 12 and 18 J/cm2. It was found that the irradiation results in the improvement of phase composition of the near-surface layer by way of the increase of yield of SHS reaction. LEHCEB irradiation enables formation of nanocomposite structure in the near-surface layer of Ni3Al-TiC composites with decreased grain size of Ni3Al matrix, refined TiC particles and increased volume fraction of TiC. This structure leads to the increase of microhardness but decrease of strength under bending. Two mechanisms of TiC particles refining are suggested. The effect of surface energy density on the manifestation degree of the found phenomena is discussed. The contribution of different hardening mechanisms to the overall hardening is considered.

On the complex synthesis reaction mechanisms of the MAB phases: High-speed in-situ neutron diffraction and ex-situ X-ray diffraction studies of MoAlB

High-intensity in-situ neutron diffraction was used in this work to characterise the reaction mechanisms of the MAB phase ceramic, MoAlB, synthesised using both standard pressureless sintering in a vacuum furnace and induction-assisted self-propagating high-temperature synthesis (SHS). The high-speed diffractogram capture rate of 0.1–20 Hz (0.05–10 s) allowed the identification of intermediate phases with lifespans of 1–30 s. It was found that MoAlB formed during pressureless sintering through a multi-stage reaction beginning at ∼510 °C with the formation of MoAl12. An SHS reaction occurred at ∼578 °C, producing metastable β-MoB as an intermediate phase, followed by MoAlB and Mo3Al8. MoAlB was also found to be present during two separate temperature windows, initially following the SHS reaction at ∼578 °C, decomposing almost completely by ⁓1020 °C, then re-forming at ⁓1200 °C. For the induction-assisted SHS process, a reaction between the elemental powders at ∼660 °C lead to the primary formation of β-MoB as an intermediate phase, followed by a transition to α-MoB and intercalation with Al, forming MoAlB in ∼3 s from the beginning of the SHS reaction. Neutron diffraction (ND), X-ray diffraction (XRD), scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDS) were used post-reaction to confirm the compositions and analyse the microstructure of samples produced using both methods.

Study on electrothermal ignition model of self-propagation high-temperature synthesis system for samarium vaporization

The quality of short-wave radio communication in the ionosphere depends largely on the state of the ionosphere, but it is uncontrollable and unreliable. The release of gaseous samarium into the ionospheric space can form high-density plasma clouds, which is of great significance for improving the quality of shortwave radio communication. The high temperature and high heat released by the self-propagation high-temperature synthesis reaction can effectively heat and vaporize the samarium. At the same time, this method can effectively avoid the adverse impact of the reaction of individual components of the reaction material on the ionization efficiency of samarium, and greatly improve the ionization efficiency of the samarium. Therefore, self-propagation high-temperature synthesis is an important method for heating and vaporizing samarium. To study the ignition model of self-propagation high-temperature synthesis system for heating and vaporizing samarium, and to design and control the ignition process is the premise for heating and vaporizing samarium. Based on the theory of chemical reaction and heat conduction, the electrothermal ignition process is studied in detail. By analyzing the change of energy distribution in the ignition process, a theoretical model of ignition under the electric energy heating mode is proposed, and a theoretical equation for calculating the ignition time is derived. The model can be used to design and control the ignition system and explain many phenomena in the ignition process. In addition, the electrothermal ignition test was carried out for heating and vaporizing samarium in the self-propagation high-temperature synthesis system to obtain the ignition power and ignition time of different reaction systems under different samarium content and porosity, and further analyze the universality of the calculation model. The results show that the test results are in good agreement with the theoretical calculation results, and the validity of the model is verified, which provides an important support for the design of self-propagation high-temperature synthesis reaction heating and vaporizing samarium ignition system.

Reactive Bimetallic Nanostructures Based on Triply Periodic Minimal Surfaces: A Molecular Dynamics Study toward the Limits of Performance.

A variety of intermetallic compounds possesses high enthalpies of formation. These compounds may be formed from reactive compacts or nanostructures comprised of unreacted precursor metals. These precursor structures support self-propagating high temperature synthesis (SHS) reactions which afford very high specific energy densities and rates, with excellent spatial control and a variety of useful applications. The present work compares the reactivity of notional bimetallic nanostructures based on well-known triply periodic minimal surfaces (TPMSes) with the popular reactive nanolaminate (RNL) modality for the Ni/Al system, using a molecular dynamics approach. TPMS-derived nanostructures were found to have lower ignition energies and faster reaction rates than RNLs of comparable periodicity, while the maximum achievable temperature of ignitions was found to be modulated by a complex interplay of factors including reaction rate and specific metal/metal interface density. Nanostructure reactivity and thermochemistry is also affected by effective diffusion dimensionality and recalescent precipitation of intermetallic crystallites. The TPMS-derived reactive nanostructures presented herein anticipate plausible advances in nanofabrication technology.

Fabrication of (Ti-Al-Si)/(Ti-C)/Ti – layered alloy by SHS pressing

A metal-carbide-intermetallic material based on combustion products of the layer system (Ti-Al-Si)/(Ti-C)/Ti was for the first time obtained with the help of self-propagating high-temperature synthesis (SHS) combined with pressing. Exothermic synthesis from elementary powders was carried out at a pressure of 10 MPa, and pressing of the hot synthesis product was carried out at a pressure of 100 MPa. It has been shown that SHS pressing contributes to the formation of permanent joints of «metal/carbide/intermetallic» layers. The main features of microstructure formation, phase composition, and strength properties of transition zones at the boundary between reacting SHS compositions, Ti-C and Ti-Al-Si and Ti-metal substrate are investigated. It is shown that during SHS reaction, a homogeneous microstructure of Ti-C and Ti-Al-Si layers with an insignificant content of cracks and pores is formed. The thickness of the transition zone between the layers was at least 15 µm. The main phase formed in the combustion product of Ti-Al-Si layer is, according to the results of X-ray phase analysis, triple phase Ti20Al3Si9, the content of which, calculated by the Rietveld method, was at least 87 wt. %. In addition, the combustion product contains a secondary phase of Ti3Al in the amount of 13 wt. %. The energy dispersion analysis revealed that diffusion of aluminium through the titanium carbide layer into the titanium substrate to a depth of approx. 30 µm is observed. Microhardness value of the combustion product of Ti-Al-Si layer was about 10 GPa. The rectilinear nature of crack propagation in the synthesized combustion product of Ti-Al-Si layer, as well as the Palmquist crack resistance coefficient varying within 5.1-5.7 MPa·m1/2, indicate the fragility of the material.

Mechanical activation time of 6B2O3–13Al powder mixture vs. structure and phase composition of SHS products

The paper discusses the time of mechanical activation of the 6B2O3–13Al powder mixture affecting the self-propagating high-temperature synthesis (SHS), exothermic reaction temperature, structure, and phase composition of synthesis products. It is found that the time increase of the mechanical activation up to 180 min leads to a reduction in the average size of aluminum and boron trioxide particles down to 4.8 and 3.5 μm, respectively. Aluminum particles with boron trioxide inclusions are observed on the particle surface and inside their structure. Changes in the particle size and structure in the initial mixture components modify the SHS reaction front from chaotic to by layers. The structure of SHS products consists of the alumina layer (63–68 wt%) with aluminum dodecaboride (AlB12) particles (32–37 wt%) distributed under this layer. After 10 and 60 min of mechanical activation, acicular and elongated AlB12 particles appear in products synthesized from the 6B2O3–13Al powder mixture. Based on the data obtained, the SHS with subsequent mechanical activation is proposed for the fabrication of the Al2O3/AlB12 nanocomposite from the 6B2O3–13Al powder mixture. It is shown that after washing grinded SHS products with hydrochloric acid solution, the synthesized powder contains 100 wt% AlB12.

Ultra-fast synthesis and thermodynamic analysis of MoAlB by self-propagating high-temperature combustion synthesis

MoAlB as a typical member of MAB phases has attracted much-growing attention due to its unique properties. However, the low production of MoAlB powders limits its further development and potential applications. In the present work, the ultra-fast preparation of high-purity MoAlB powders in a few seconds is achieved by self-propagating high-temperature synthesis (SHS) using a raw powder mixture at an atomic ratio of Mo : Al : B = 1 : 1.3 : 1. SHS reaction mechanism is obtained by analyzing the corresponding composition changes of starting materials. Furthermore, the thermodynamic prediction for the SHS reaction is consistent with the present experiments, where the preparation of MoAlB also conforms to two common self-propagating conditions of the SHS. The enthalpy vs. temperature curve shows that the adiabatic temperature of the reaction decreases with the amount of excuse Al increasing but increases when pre-heating the reactants. Also, this thermodynamic calculation provides a new idea for the preparation of other MAB phases by the SHS.

Research on the underwater cutting mechanism of flux-cored arc cutting for aluminum alloy process

With the fast-growing demand of aluminum alloys in ships and deep-sea pressure structures, an accurate and efficient underwater cutting operation for aluminum alloy is significant. However, its underwater arc cutting mechanism is still not clear enough, which limits its further application. The challenges lie in poor underwater visibility and complex underwater environment. In this study, process experiments, underwater sensor, and numerical simulations were conducted during cutting process to investigate the cutting mechanism of 5,052 aluminum. Firstly, the effect of parameters were investigated on cutting current, voltage, and water depth on the underwater kerf formation. In addition, three typical kerf formations, including “V” type, “II” type and “∧” type, were found; Secondly, visual sensing system was setup to monitor the cutting arc trajectory and the combustion process during the cutting process. Specially, the underwater burning phenomenon was observed. Finally, Finite Element Analysis was performed to further analyze the underwater arc cutting kerf formation of aluminum alloy. A semi-ellipsoidal composite heat source was applied to simulate the underwater arc, and the aluminum thermal reaction-generated heat was introduced. A dynamic method named “birth and death elements” was utilized to simulate the removal of molten metal. The temperature test results show that the simulation process is feasible. All results showed that different cutting parameters led to different cutting mode and affected the kerf forming. 5,052 aluminum alloy in the deep water environment (≥50 m) kerf significantly narrowed. The kerf cross-section produces an inward concavity and the kerf surface is as wide as the cutting wire. The aluminum kerf forming process is greatly impacted by the process parameters and self-propagating high-temperature synthesis reaction during aluminum alloy cutting. The periodicity of the cutting process was computed by the numerical simulation with the arc motion trajectory monitored by the high-speed camera. The numerical results of temperature distribution and kerf shape were consistent with the experimental data, which revealed the cutting mechanism.

Reaction Behavior and Formation Mechanism of ZrB2 and ZrC from the Ni-Zr-B4C System during Self-Propagating High-Temperature Synthesis

Self-propagating high-temperature synthesis (SHS) is a good way to prepare ZrB2-ZrC/metal cermet composites. In this work, ZrB2-ZrC/Ni cermet composites with various Ni contents were successfully fabricated by SHS using the Ni-Zr-B4C system. The effects of Ni content and particle size of the B4C powder on the SHS reaction were investigated. The results indicated that with an increase in Ni content, the adiabatic temperature, maximum combustion temperature, ignition delay time, and ceramic particle size in the product all showed a gradually decreasing trend. The SHS products and the ignition of the SHS reactions were significantly dependent on the B4C particle size. The formation mechanism of ZrB2 and ZrC during SHS from the Ni-Zr-B4C system was proposed based on the combustion wave quenching experiment.

The method for efficiently releasing samarium vapor to generate artificial plasma clouds in the ionosphere

Vaporized samarium (Sm) has been released in the ionosphere for artificially creating plasma clouds, which can tailor radio propagation of information systems. The titanium-boron (Ti-B) self-propagating high-temperature synthesis (SHS) reaction can be used to vaporize Sm for releasing in the ionosphere. In this paper, a one-dimensional Fourier combustion model of Sm vaporizing by Ti-B reaction is established, based on the principle of chemical reaction and heat conduction. The Gauss-Seidel iterative algorithm is used to numerically simulate the SHS process of titanium-boron-samarium (Ti-B-Sm) system. This study first investigates the impact of different green compact porosity and content of Sm on the temperature field distribution, stable temperature and wave rate of the combustion process. The calculation shows that the porosity has little effect on the stable combustion temperature. With the increase of porosity, the stable combustion temperature remains basically unchanged, while the combustion wave rate shows a downward trend. The amount of Sm has a significant negative effect on the stable combustion temperature and the combustion wave rate. The higher the amount of Sm is, the more quickly the stable combustion temperature and the combustion wave rate decrease. The theoretical result indicates that, Sm could not exceed 35 % for being heated and vaporized. And the porosity could not exceed 52 % for efficient vaporization of Sm and stability of combustion wave. Finally, taking the Ti-B-Sm system with 30 % Sm contents as an example, several experiments were carried out using green compacts with different porosity. The experiments show that the maximum temperature of the compact during the combustion process is very close when the porosity varies from 30 % to 45 %, about 2075 K, which is in agreement with the simulation. The combustion wave rate is distributed from 5 mm/s to 8 mm/s within the range of 30 % and 50 % of porosity. Finally, the combustion products are detected by diffraction of X-rays (XRD), scanning electron microscope (SEM) and energy dispersive spectrometer (EDS). It shows that the Ti-B-Sm compact with 30 % Sm content and porosity not exceeding 52 % can effectively vaporize Sm, and the vaporization efficiency of Sm is about 75 %. The results of this study provide guidance for payloads of future experimental campaigns in the ionosphere.

Fe-Si Intermetallics/Al2O3 Composites Formed between Fe-20% Si and Fe-70.5% Si by SHS Metallurgy Method

Fe–Si intermetallics–Al2O3 composites were fabricated by thermite-assisted combustion synthesis. Combustion reactions were conducted with powder compacts composed of Fe2O3, Al, Fe, and Si. The starting stoichiometry of powder mixtures had an atomic Fe/Si proportion ranging from Fe-20% to Fe-70.5% Si to explore the variation of silicide phases formed with Si percentage. Combustion in the mode of self-propagating high-temperature synthesis (SHS) was achieved and the activation energy of the SHS reaction was deduced. It was found that the increase of Si content decreased the combustion temperature and combustion wave velocity. Three silicide compounds, Fe3Si, FeSi, and α-FeSi2, along with Al2O3 were identified by XRD in the final products. Fe3Si was formed as the single-phase silicide from the reactions with Si percentage from Fe-20% to Fe-30% Si. FeSi dominated the silicide compounds in the reactions with atomic Si content between Fe-45% and Fe-55% Si. As the Si percentage increased to Fe-66.7% Si and Fe-70.5% Si, α-FeSi2 became the major phase. The microstructure of the composite product showed that dispersed granular or nearly spherical iron silicides were embedded in Al2O3, which was dense and continuous. Most of the silicide grains were around 3–5 μm and the atomic ratio of silicide particles from the EDS analysis confirmed the presence of Fe3Si, FeSi, and FeSi2.

Fabrication of NiAl and TiC intermetallic matrix composite coatings

ABSTRACT In this work, the intermetallic matrix composite coatings of the TiC-Ti2Ni-Ti3Al system were investigated. Induction heating was used to initiate the self-propagation high-temperature synthesis (SHS) reaction of the multilayer systems of Ti/C-Ni/Al-Ti on the steel substrate. The role of Ni/Al reaction on the SHS process of Ti/C-Ni/Al-Ti was compared to that of Ni/Al-Ti. The results showed that the TiC composite system was composed of TiC dispersed in the intermetallic Ti-Al and Ti-Al systems. This indicates that high exothermic reaction of the SHS process of Ni/Al initiated the subsequent reactions in the Ti-Al, Ti-Ni, and Ti-C systems. The Ti3Al-Ti2Ni multiphase system was formed due to the interaction between the liquid product of NiAl and Ti. Surprisingly, NiAl was disappeared in the Ti/C-Ni/Al-Ti system. This work improves the understanding of the formation mechanism of the NiAl reaction as the agent for the formation of TiC-Ti2Ni-Ti3Al intermetallic matrix composite.

Synthesis of FeSi-Al2O3 Composites by Autowave Combustion with Metallothermic Reduction

Fabrication of FeSi-Al2O3 composites with a molar ratio of FeSi/Al2O3 ranging from 1.2 to 4.5 was conducted by the self-propagating high-temperature synthesis (SHS) method. The synthesis reaction involved metallothermic reduction of Fe2O3 and SiO2 by Al and the chemical interaction of Fe and Si. Two combustion systems were examined: one contained thermite reagents of 0.6Fe2O3 + 0.6SiO2 + 2Al, and the other had Fe2O3 + 2Al to mix with different amounts of Fe and Si powders. A thermodynamic analysis indicated that metallothermic reduction of oxide precursors was sufficiently exothermic to sustain the combustion reaction in a self-propagating mode. The SHS reaction carrying out co-reduction of Fe2O3 and SiO2 was less exothermic, and was applied to synthesize products with FeSi/Al2O3 = 1.2–2.5, while the reaction reducing only Fe2O3 was more energetic and was adopted for the composites with FeSi/Al2O3 = 2.5–4.5. Moreover, the former had a larger activation energy, i.e., Ea = 215.3 kJ/mol, than the latter, i.e., Ea = 180.4 kJ/mol. For both reaction systems, the combustion wave velocity and temperature decreased with increasing FeSi content. Formation of FeSi-Al2O3 in situ composites with different amounts of FeSi was achieved. Additionally, a trivial amount of aluminum silicate was detected in the products of high FeSi contents due to dissolution of Si into Al2O3 during the SHS process.

Composite Metal-Matrix Alloys Based on Ni-Al for Obtaining Wear-Resistant Coatings by Electric Spark Deposition

The paper presents the research results on produsing by the method of liquid-phase self-propagating high-temperature synthesis (SHS) the composite metal-matrix alloys intended for the obtaining of wear-resistant coatings by electric spark deposition (ESD). Oxides NiO, Cr2O3 and mineral concentrate ZrO2 were used as a melting charge. Alloys based on the Ni-Al system with aluminides of complex composition containing Cr and Zr were obtained by means of the alumothermic SHS reaction. Wear-resistant coatings were formed on steel 45 by the ESD method by means of the newly obtained alloys,. The maximum wear resistance of the coatings was obtained using the alloys containing Cr (wt% 18) and Zr (wt% 1.9).

Study of long-term post-SHS phase kinetics in Ni/Al reactive multilayer nanofoils

We present the results of the recent experiments with two species of Ni/Al reactive multilayer nanofoils (RNMFs) supporting the self-propagating high-temperature synthesis (SHS) reaction. SEM method was used to evaluate their general structure and quantitative chemical composition before and after reaction. Phase composition was determined from XRD spectra. Special attention was paid to the stability of phase composition over relatively long time intervals after SHS reaction – order of the hours and days. In some cases, XRD spectra showed notable evolution of crystalline structure, which can have significant impact on practical application of SHS, for instance, in soldering technologies. To our knowledge, similar effect has been previously observed only for SHS-reactive powder mixtures.

Combustion synthesis of FeAl−Al2O3 composites with TiB2 and TiC additions via metallothermic reduction of Fe2O3 and TiO2

Abstract Combustion synthesis involving metallothermic reduction of Fe2O3 and TiO2 was conducted in the mode of self-propagating high-temperature synthesis (SHS) to fabricate FeAl-based composites with dual ceramic phases, TiB2/Al2O3 and TiC/Al2O3. The reactant mixture included thermite reagents of 0.6Fe2O3+0.6TiO2+2Al, and elemental Fe, Al, boron, and carbon powders. The formation of xFeAl−0.6TiB2−Al2O3 composites with x=2.0−3.6 and yFeAl−0.6TiC−Al2O3 composites with y=1.8−2.75 was studied. The increase of FeAl causes a decrease in the reaction exothermicity, thus resulting in the existence of flammability limits of x=3.6 and y=2.75 for the SHS reactions. Based on combustion wave kinetics, the activation energies of Ea=97.1 and 101.1 kJ/mol are deduced for the metallothermic SHS reactions. XRD analyses confirm in situ formation of FeAl/TiB2/Al2O3 and FeAl/TiC/Al2O3 composites. SEM micrographs exhibit that FeAl is formed with a dense polycrystalline structure, and the ceramic phases, TiB2, TiC, and Al2O3, are micro-sized discrete particles. The synthesized FeAl−TiB2−Al2O3 and FeAl−TiC−Al2O3 composites exhibit the hardness ranging from 12.8 to 16.6 GPa and fracture toughness from 7.93 to 9.84 MPa·m1/2.

Self-propagating reaction mechanism of Mg–TiO2 system in preparation process of titanium powder by multi-stage reduction

The novel method for the preparation of titanium powder by multi-stage reduction was proposed. The primary reduction adopted self-propagating high-temperature synthesis (SHS) mode. This paper focuses on the primary reduction process of Mg–TiO2 system under the condition of off-balance reaction. The effects of different material ratios, material arrangement methods and reaction initiation modes on the SHS reaction process of Mg–TiO2 system and its reaction mechanism were systematically studied. SHS mode was used to Mg–TiO2 system, and non-stoichiometric low-valent titanium oxide intermediate including α-Ti (Ti2O type) and TiO was directly obtained (with oxygen content of 13.93 wt%). SHS reaction initiated by local ignition is more sufficient than by overall heating method. Compared with the loose setting materials, the compacts can increase the effective contact interface of the reactants, and SHS reaction proceeds more sufficiently, which is favorable for obtaining lower oxygen content product. The adiabatic temperatures of the Mg–TiO2 system at different initial conditions were calculated according to the improved calculation method. When the initial temperature is 298 K, the adiabatic temperature of Mg–TiO2 system is between 1363 and 2067 K at different material ratios. Therefore, unreacted or partially excess Mg at the reaction front will diffuse into the unreacted region in gas or liquid form, thereby preheating the material and initiating further SHS reaction.

Intermetallic/Ceramic Composites Synthesized from Al–Ni–Ti Combustion with B4C Addition

The fabrication of intermetallic/ceramic composites by combustion synthesis in the mode of self-propagating high-temperature synthesis (SHS) was investigated in the Al–Ni–Ti system with the addition of B4C. Two reaction systems were employed: one was used to produce the composites of xNiAl–2TiB2–TiC with x = 2–7, and the other was used to synthesize yNi3Al–2TiB2–TiC with y = 2–7. The reaction mechanism of the Al–Ni–Ti system was strongly influenced by the presence of B4C. The reaction of B4C with Ti was highly exothermic, so the reaction temperature and combustion velocity decreased due to increasing levels of Ni and Al in the reactant mixture. The activation energies of Ea = 110.6 and 172.1 kJ/mol were obtained for the fabrication of NiAl- and Ni3Al-based composites, respectively, by the SHS reaction. The XRD (X-ray diffraction) analysis showed an in situ formation of intermetallic (NiAl and Ni3Al) and ceramic phases (TiB2 and TiC) and confirmed no reactions taking place between Ti and Al or Ni. The microstructure of the product revealed large NiAl and Ni3Al grains and small TiB2 and TiC particles. With the addition of TiB2 and TiC, the hardness of NiAl and Ni3Al was considerably increased and the toughness was also improved.

An Evaluation of Combustion Kinetics for the Synthesis Reaction of the Reinforcing Phase During Casting Phase During Casting

The computer modeling of the solidification process in castings with local composite reinforcement (LCR) obtained as a result of in situ reactions of self-propagating high temperature synthesis (SHS) is difficult due to limited data on the thermo-physical parameters of exothermic effects and the kinetics of the synthesis reaction. In the present study, Hadfield cast steel casting was manufactured with LCR containing titanium carbide particles obtained in situ by the SHS method. Reaction kinetics of titanium carbide synthesis in the composite casting were determined on the basis of temperature measurements in the area of LCR during the process. For the estimation of the reaction, the Fourier Thermal Analysis method was used. The paper presents the results of temperature measurement and the results of the calculation of SHS reaction kinetics. It was found that the reaction time under the conditions of the analyzed casting is below 3 s.

Microstructure and properties of the laser cladded in-situ ZrB2-ZrC/Cu composite coatings on copper substrate

The ZrB2-ZrC reinforced Cu matrix composite coating was prepared on a copper substrate by laser cladding and a self-propagating high-temperature synthesis (SHS) reaction. The zirconium ceramics were in-situ synthesized according to the designed SHS reaction within the coatings. The macromorphology, microstructure, phase composition, the interface of the zirconium ceramic phase/metal matrix, microhardness and wear resistance of the composite coating were analyzed and discussed. The results indicated that the in-situ ZrB2 ceramic had a needle-like morphology, the preferred growth direction was [1¯1¯20], and the ZrB2 were coated with the Ni dendritic crystals. Ni formed an intermediate transition layer between the ceramic and the metal matrix. The submicron particle phases (ZrC) had a rectangular morphology in the copper matrix, and the side length was 500 nm. The hard ceramic fibers and particles were in-situ synthesized that were dispersed homogeneously in the metal matrix, which improved the mechanical properties of the coating. The mean value of the microhardness of the composite coatings was 410 HV0.2, which was nearly 6 times higher than that of the copper. The microhardness gradually decreased from the composite coating surface to the transition zone and then sharply dropped in the transition zone to the substrate. This trend agrees with the distribution of the ceramic reinforcements. The wear mechanism of the composite coating was a combination of abrasive wear and adhesive wear, and the wear volume loss was approximately 85% lower than that of the uncoated substrate.