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Abstract The wear resistance and tribological characteristics of spark plasma sintered ZrB 2 + B 4 C, ZrB 2 + SiC and ZrB 2 + ZrC composites were investigated under dry sliding conditions at applied loads of 5 N and 50 N in air. The microstructure, deformation and damage characteristics were studied using scanning electron microscopy, confocal electron microscopy, a focused ion beam and atomic force microscopy. The friction coefficient values were very similar for all composites with values ranging from 0.63 to 0.72 and with the lowest value recorded for the ZrB 2 + SiC composite at a 5 N applied load. The ZrB 2 + ZrC composite was the most wear resistant, with wear rates at a 5 N load of 6.15 × 10−6 mm3/(N·m) and at a 50 N of 7.3 × 10−6 mm3/(N·m). None, or a very limited number of grain pull-outs and/or lateral fractures of grains were found during the wear tests. At the 5 N load, abrasive grooves connected with deformations and Hertzian crack formations were the main wear mechanisms in all systems, with limited crack formations in the ZrB 2 + ZrC composite. Tribofilm formations connected with debris origin, oxidation and tribochemical reactions were dominant in all composites, with similar chemical compositions but different sizes and thicknesses at the 50 N load. Highlights • To enhance the oxidation resistance, COF, WR and KIC different additives (SiC, B 4 C and ZrC) have been introduced to ZrB 2. • Detailed understanding of the tribological characteristics of Zirconium Diboride composites. • Description and understanding of tribochemical reactions. [ABSTRACT FROM AUTHOR]

The research concerns the optimisation of sintering zirconium by spark plasma sintering (SPS) and modification of microstructures by introducing the manganese component. The problems of preparing mixtures for sintering were investigated. An additive of 2.5 wt% and 5 wt% manganese micropowders and 1 wt% and 2.5 wt% manganese nanopowders were utilized. An increase in the oxygen content in sintered mixtures made of zirconium and manganese along with an increase in their milling time in water was found. 100 rpm was determined as a safe mixing speed. The introduction of manganese nanopowders into zirconium did not significantly improved the homogeneity of the material. Manganese in larger quantities accumulates at the grain boundaries. The material is very difficult to machining, which is indicated by difficulties in sample preparation. • The conditions of high-speed mixing and sintering by the SPS method did not cause the entire manganese content to react to form ZrMn 2. • Due to the explosiveness of the mixture, 200 rpm was adopted as the optimal speed of homogenization of mixtures. • Mechanical milled Zr–Mn mixtures tend to oxidize. [ABSTRACT FROM AUTHOR]