THE ABRASION OF AL-SI COATINGS WITH DIFFERENT SILICON CRYSTAL MORPHOLOGY, APPLIED IN AUTOMOTIVE SILENCERS

Abstract

This paper compares the abrasibility of aluminium-silicon coatings with silicon crystals of various forms. The tests were performed on Al-Si coatings with the chemical comp67890-osition corresponding to that of hypoeutectic and peritectic silumins (6-10wt% Si), manufactured by hot-dipping on type X2CrTi12 steel and by cold cladding with 60% cold reduction on AlMn1Cu alloy. The hot-dip coatings deposited on X2CrTi12 steel were investigated as made and after a two-stage heat treatment: 420oC/2h/water and 120oC/2h/air. The morphology, shape, and size of silicon crystals in the coatings were studied under a microscope and with the image analysis technique (determining the shape factor among other parameters). Image analysis was also applied to the evaluation of abrasive wear resistance of the coatings using a ball wear test. Their adhesion strength was tested with the scratch test method. The test results indicated that the change in Al-Si coating silicon crystal morphology (from large sharp edged and needle-like to smaller rounded particles) was heat induced, which, compared to the pre-treatment condition, lowered abrasion resistance values and produced a more uniform abrasion loss. This condition was regarded as more desirable in terms of maintaining the coating continuity during drawing, with no risk of spalling. It was also demonstrated that clad Al-Si coatings could provide an alternative solution for the widely used hot dip coatings on steel sheet.