In Situ Synthesis and Tribological Characterization of TiC–Diamond Composites: Effect of the Counterface Material on Wear Rate and Mechanism

TiC bonded diamond composites were prepared from a mixture of Ti, graphite, and diamond powders as raw materials, with Si as sintering additives, through high-temperature and high-pressure (HTHP) technology. The reaction between Ti and graphite under 4.5–5 GPa pressure and 1.7–2.3 kW output power can produce TiC as the main phase. The diamond particles are surrounded by TiC, and the interface is firmly bonded. The coefficient of friction (COF) of TiC–diamond composites with POM and PP balls decreases with increasing load for a specific friction velocity. However, the COF of TiC–diamond composites with agate, Cu and Al balls increases with the rising load because of the enhanced adhesive wear effect. The COF of PP, Cu and Al balls slightly increases with the increase in friction velocity at a certain load. SEM results show that the surface of agate balls has rough, pear-shaped grooves and shallow scratches. The scratches on the surface of POM balls are wrinkled. The PP balls have pear-shaped groove scratches on their wear surfaces. The wear mechanism of TiC–diamond composites with Cu ball pairs is primarily adhesive wear. The abrasion of TiC–diamond composites with Cu ball pairs remains almost unchanged as the load increases. However, the depth and width of the pear-shaped grooves on the wear surface of TiC–diamond composites are significantly increased. This phenomenon may be attributed to the high rotational speed, which helps to remove the residual abrasive debris from the friction grooves. As a result, there is a decrease in both the depth and width of the pear-shaped grooves, leading to a smoother overall surface. The wear mechanism of TiC–diamond composites with Al ball pairs is abrasive wear, which increases with an increasing load. When the load is constant, as the speed increases, the wear morphology of TiC–diamond composites with Al ball pairs transitions from rough to smooth and then back to rough again. This phenomenon may be attributed to the wear mechanism at low speeds being groove wear and adhesive wear. As the speed increases, the wear particles are more easily removed from the wear track, leading to a reduction in abrasiveness. As the speed increases, the wear surface becomes roughened by a combination of grooves and dispersed wear debris. This can be attributed to the increased dynamic interaction between surfaces caused by higher speed, resulting in a combination of abrasive and adhesive wear. In addition, Cu and Al ball wear debris appeared as irregular particles that permeated and adhered to the surface of the TiC phase among the diamond particles. The results suggest that TiC–diamond composites are a very promising friction material.