Abstract
Anodizing a simple and effective method to improve the wear resistance of 6061 aluminum alloy. In this study, the microstructure of 6061 aluminum alloy oxide films (AAO) was adjusted by changing the electrolyte temperature (5, 15, and 25 °C) using 160 g/L sulfuric acid as the electrolyte. The phase composition, microstructure, and morphological characteristics of the specimens were detected using X-ray diffractometer and field emission scanning electron microscopy (SEM). The hardness, elastic modulus, and tribological properties of the films were examined using hardness testers and a rotary friction tester. The results showed that as the temperature of the electrolyte increases, the surface of the oxide films changes from uniformly distributed small-sized pores to a coral-like loose porous structure, and the thickness of the films increases. The electrolyte temperature has a significant effect on the friction performance of the AAO films. When the solution temperature decreases from 25 to 5 °C, the steady-state friction coefficient decreases from 0.46 to 0.39. According to the morphology of the wear tracks, it can be determined that the main wear mechanism of AAO films gradually changes from delamination wear to abrasive and adhesive wear, and the wear rate drops by ~69%.
Highlights
Aluminum is the most abundant metallic element in the earth’s crust
The results indicated that the larger the pore size, the higher the friction coefficient of the films, and under wear conditions from 1 to 10 mN, only slight plastic deformation occurred on the surface, while under conditions from 10 mN to 1 N, a thicker smooth film formed by a combination of friction-induced chemical reactions and debris formed by the compaction of the aluminum alloy oxide films (AAO) appeared at the contact interface
Temperature reached 25 ◦C, coral-like loose porous structures appeared on the surface of the AAO, which had a negative impact on the hardness and elastic modulus of the films
Summary
The low density, high specific strength, excellent thermal conductivity, and corrosion resistance of aluminum and its alloys (Al-Cu, Al-Mg, Al-Mg-Si and Al-Zn) are promoting the development of aerospace, construction, automobile, shipbuilding, controllable fusion technology and chemical industries [1–4]. The Mg and Si elements in 6061 aluminum alloy (Al-Mg-Si) improve the plasticity, weldability, and processability of the material, making the 6061 aluminum alloy widely used in electrical fixtures and electronic precision instruments, aerospace, and automotive structural parts [5–7]. Micro-arc oxidation, anodizing, plasma electrolytic oxidation, enameling, painting, and electroplating are often used in industry to improve the surface performance and service life of aluminum alloys [12,13]. Anodizing has become the most promising preparation technology of aluminum alloy films because of its low cost, excellent film performance, functionality, and colorability. In the process of anodizing, electrochemical reactions occur on the surface of aluminum alloy
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