Abstract

An Al–Cr composite alloyed layer composed of an Al enriched layer, a Cr enriched layer and a transition layer from the surface to the bulk along the cross-section was deposited on a 45# steel substrate by composite technology, where Cr was deposited using double glow plasma surface metallurgy (DGPSM), and Al was then implanted by ion implantation (IIP) to achieve higher micro-hardness and excellent abrasive resistance. The composite alloyed layer is approximately 5[Formula: see text][Formula: see text]m, and as metallurgical adherence to the substrate. The phases are Al8Cr5, Fe2AlCr, Cr[Formula: see text]C6, Cr (Al) and Fe (Cr, Al) solid solution. The wear resistance tests were performed under various rotational speed (i.e. 280, 560 and 840[Formula: see text]r/min) with silicon nitride balls as the counterface material at ambient temperature. The Al–Cr composite alloyed layer exhibits excellent wear resistance when the speed is 280[Formula: see text]r/min with a friction coefficient as low as 0.3, which is attributed to Al8Cr5 in the Al implanted layer that withstands abrasive wear. Better wear resistance (friction coefficient: 0.254) at 560[Formula: see text]r/min is resulted from the formation of a high micro-hardness zone, and an oxidation layer with lubrication capacity. In addition, the composite alloyed layer suffers severe oxidative wear and adhesive wear at 840[Formula: see text]r/min due to the increment of the frictional heating. When compared to the 45# steel substrate, the enhanced wear resistance of the Al–Cr composite alloyed layer demonstrates the viable method developed in this work.

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