Analysis of the Wear and Corrosion Resistance on Cu-Ni-Al Composites Reinforced with CeO₂ Nanoparticles

This study evaluates the wear and corrosion resistance of the Cu-50Ni-5Al alloy reinforced with CeO₂ nanoparticles for potential use as anodes in molten carbonate fuel cells (MCFCs). Cu-50Ni-5Al alloys were synthesized, with and without the incorporation of 1% CeO₂ nanoparticles, by the mechanical alloying method and spark plasma sintering (SPS). The samples were evaluated using a single scratch test with a cone-spherical diamond indenter under progressive normal loading conditions. A non-contact 3D surface profiler characterized the scratched surfaces to support the analysis. Progressive loading tests indicated a reduction of up to 50% in COF with 1% NPs, with specific values drop-ping from 0.48 in the unreinforced alloy to 0.25 in the CeO₂-doped composite at 15 N of applied load. Furthermore, the introduction of CeO₂ decreased scratch depths by 25%, indicating enhanced wear resistance. The electrochemical behavior of the samples was evaluated by electrochemical impedance spectroscopy (EIS) in a molten carbonate medium under a H₂/N₂ atmosphere at 550 °C for 120 h. Subsequently, the corrosion products were characterized using X-ray diffraction (XRD), scanning electron microscopy coupled with energy dispersive spectroscopy (SEM-EDS), and X-ray photoelectron spectroscopy (XPS). The results demonstrated that the CeO₂-reinforced alloy exhibits superior electro-chemical stability in molten carbonate environments (Li₂CO₃-K₂CO₃) under an H₂/N₂ atmosphere at 550 °C for 120 h. A marked reduction in polarization resistance and a pronounced re-passivation effect were observed, suggesting enhanced anodic protection. This effect is attributed to the formation of aluminum and copper oxides in both compositions, together with the appearance of NiO as the predominant phase in the materials reinforced with nanoparticles in a hydrogen-reducing atmosphere. The addition of CeO₂ nanoparticles significantly improves wear resistance and corrosion performance. Recognizing this effect is vital for creating strategies to enhance the material's durability in challenging environments like MCFC.