Poor Wear Resistance Research Articles

First Principles Calculation of the Influence of Alloying on the Phase Stability, Elasticity, and Thermodynamic Properties of the MoNbTiVX (X = Al/Cr) Refractory High-Entropy Alloy

In response to the poor wear resistance and high-temperature oxidation resistance of titanium alloys during service, a series of lightweight refractory high-entropy alloys (RHEAs) can be designed for the laser cladding coating of titanium alloy surfaces, with due consideration of the compositional and structural characteristics of titanium alloys. Firstly, the structural stability, mechanical and thermal properties of four lightweight RHEAs (MoNbTiV, AlMoNbTiW, CrMoNbTiV, and AlCrMoNbTiV) with equal atomic ratios were designed and calculated using first principles combined with quasi-harmonic approximation (QHA). The results indicate that all four RHEAs are stable BCC, exhibiting elastic anisotropy and ductility. The lightest density is 6.409 g/cm3. Adding Al/Cr can cause structural distortion and affect its mechanical properties. Their Young’s moduli are in the following order: AlCrMoNbTiV > MoNbTiV > CrMoNbTiV > AlMoNbTiV. The thermal expansion coefficients of the four RHEAs and titanium alloys are very close, with a difference in linear expansion coefficient of less than 1.16 × 10−5/K. Meanwhile, the metallurgical bonding of four types of RHEA coatings was successfully achieved on a Ti-6Al-4V(TC4) substrate through laser cladding technology, and all coatings exhibited a unique BCC solid solution phase.

Electrophoretic deposition of polyetheretherketone/polytetrafluoroethylene on 316L SS with improved tribological and corrosion properties for biomedical applications

Introduction316L stainless steel (316L SS) has poor wear and corrosion resistance compared to that of the Cp-Ti and Ti-6Al-4V implants [when studied under a physiological environment using phosphate-buffered saline (PBS)]. However, 316L SS implants are cost-effective. Their wear and corrosion properties can be improved by depositing biocompatible coatings.MethodIn this research work, a polymer coating of polyetheretherketone (PEEK) and polytetrafluoroethylene (PTFE) was deposited at optimized parameters (20 V for 3 min) on 316L SS via electrophoretic deposition (EPD). We compared the performance between of the PEEK coating and hybrid PEEK/PTFE coatings for biomedical applications. The PEEK/PTFE coating was sintered at 350°C for 30 min.Results and DiscussionScanning electron microscopy (SEM) analysis revealed that the PEEK/PTFE coating showed a uniform coating with a uniform thickness of ∼80 µm. Fourier transform infrared (FTIR) spectroscopy analysis confirmed the presence of bonds attributed to the PEEK and PTFE coatings. The PEEK/PTFE coating exhibited adequate average surface roughness (Ra) of 2.1 ± 0.2 µm with a high value of contact angle of 132.71 ± 3, indicating the hydrophobic nature of the PEEK/PTFE coating. Scratch tests evaluated that the PEEK/PTFE coating demonstrated a 7 N load, which indicated the good adhesion between the coating and 316L SS. Furthermore, the PEEK/PTFE coating demonstrated good wear resistance, capable of withstanding a 7 N load under dry conditions, and showed a specific wear rate of ∼0.0114 mm3/Nm. Electrochemical analysis conducted using the phosphate-buffered saline (PBS) solution demonstrated that the corrosion rate of 316L SS was reduced from 0.9431 mpy to 0.0147 mpy by depositing the PEEK/PTFE coating. Thus, the developed coatings present suitable wear and corrosion resistance and are thus considered for potential orthopedic applications.

A Comprehensive Review on the Tribological Evaluation of Polyether Ether Ketone Pristine and Composite Coatings.

Polymer coatings have gained a lot of attention in the recent past because of their ability to be easily coated on complex shapes, their low cost, and their ability to reduce friction as compared to other materials. Polyether ether ketone (PEEK) is one such high-performance polymer that has gained significant attention in recent years due to its exceptional mechanical properties, chemical resistance, and thermal stability making it a prominent candidate for applications in industries. However, PEEK in its pristine form exhibits poor wear resistance with a moderate coefficient of friction (0.30-0.38). Many attempts have been made by several researchers to improve its wear resistance and lower the COF by developing composite coatings. Hence, in this review, we aim to summarize and present in detail the tribological evaluation of pristine PEEK and PEEK composite coatings by discussing the various methods adopted by the researchers to improve the properties of PEEK, the different types of reinforcements and various dispersion techniques used to develop PEEK composite coatings. By consolidating and analyzing the existing body of knowledge, we also aim to offer valuable insights into the development of more durable, high-performance PEEK nanocomposite coatings for a broad range of tribological applications.

Synergetic effect of in-situ TiB2 reinforcement and nano precipitation on wear behavior of ZE41 magnesium matrix composite

The rise in carbon dioxide pollution and energy consumption has increased the demand for lightweight materials such as magnesium in automotive and aerospace industries. However, magnesium alloys face challenges like poor wear resistance and mechanical strength. To overcome these limitations, a promising approach involves developing heterogeneous hybrid microstructures through reinforcement addition and microstructural engineering. This study focuses on the tribological performance of a newly developed in-situ sub-micron sized TiB2/ZE41 composite under various microstructural conditions, comparing it to the unreinforced ZE41 Mg alloy. Wear experiments were conducted using a pin-on-disc tribometer under normal loads of 10, 20, 40, and 60 N at a sliding velocity of 1 m/s. Scanning electron microscopy (SEM) coupled with energy dispersive spectroscopy (EDS) was used to analyze the worn surfaces in order to identify damage types and surface distortions. By correlating worn surface microstructures with test parameters, predominant wear mechanisms for each material condition under specific loads were determined. Results consistently showed that the presence of in-situ TiB2 reinforcements, β-phase, and rare-earth precipitates enhanced wear resistance regardless of the load conditions. Additionally, the study established a scientific understanding of the wear behavior of ZE41 Mg alloy, with and without in-situ TiB2 particles and precipitates, through analysis of dominant wear mechanisms, wear-induced subsurface deformation mechanisms, kernel average misorientation, grain orientation spread, and microhardness evaluation.

Microstructure and wear resistance of the CuSn19Ti10/diamond composite coatings on copper substrate by laser cladding

Copper and its alloys are well-known for their excellent electrical and thermal conductivity but are limited by poor mechanical strength and wear resistance. In this study, CuSn19Ti10/diamond composite coatings with strong metallurgical bonding and free from defects such as cracks and porosity were successfully fabricated on pure copper substrates using laser cladding. The process parameters included a laser power of 3000 W, a scanning rate of 15 mm/s, a spot diameter of 2.5 mm, and a lapping rate of 30 %. A comprehensive analysis of the microstructure and wear resistance was performed on coatings with 0, 2.5 %, 5 %, and 10 % (wt%) diamond content using SEM, EDS, XRD, and white light interferometry. The results indicate that the coatings consist of α-(Cu), Cu2SnTi, (Cu, Sn)Ti2, TiC, and diamond phases. The addition of diamond significantly improved both the hardness and wear resistance, with the 5 wt% diamond composite demonstrating the most notable wear resistance. This optimal composition balances diamond content, ensuring effective retention within the CuSn19Ti10 matrix, thereby reducing plastic deformation and minimizing diamond pull-out during wear.

Wear and friction behavior of wrinkled-Ti3C2Tx /epoxy composites

Herein, the tribological behavior of the epoxy/wrinkled-Ti3C2Tx MXene composites against 440C stainless steel under dry sliding conditions was investigated. Due to the inherent brittleness and poor wear resistance of epoxy resin, wrinkled-Ti3C2Tx MXenes (delaminated using MTHPA: methyl tetrahydrophthalic anhydride) were incorporated in various concentrations (0.1-1 Wt.%). The sliding experiments showed little impact of MXenes’ addition on the friction coefficient values. Meanwhile, the wear resistance of epoxy was significantly improved, particularly with 0.2 wt% MXene, showing a 91.82% improvement. This improvement of the epoxy’s wear properties at a low MXene concentration is attributed to the homogenous MXene distribution and strong interfacial adhesion. The present study opens up new horizons for the application of epoxy/wrinkled-Ti3C2Tx MXene nanocomposites as dry sliding wear components.

Investigation of Friction and Erosion Wear Properties of Titanium and Titanium Alloy Pipes.

Titanium alloys are applied in oil and gas development and transportation to improve conditions because of their high specific strength and corrosion resistance. However, the disadvantage of poor wear resistance has become an obstacle to developing titanium alloys. The friction and wear properties of pure titanium TA3 and titanium alloy TA10 were tested under different loads and different friction forms using a reciprocating friction and wear tester. Moreover, the erosion resistance of pure titanium TA3 and titanium alloy TA10 was studied using a gas-solid erosion tester. The results show that the wear rate of TA3 and titanium alloy TA10 increases with increasing friction load. Under a load of 50 N, the mass losses of TA3 under dry friction and wet friction were 0.0013 g and 0.0045 g, respectively, while the mass losses of TA10 were 0.0033 g and 0.0046 g, respectively. While the load increased to 70 N, the mass loss of TA3 was even greater, reaching 0.0065 g, and the mass loss of TA10 was 0.0058 g. The wear forms of TA3 and TA10 include abrasive wear, adhesive wear and oxidation wear. The joint action of various friction forms leads to the loss of materials. Under the simulated working conditions, the erosion rates of TA3 and TA10 were 1.01 × 10-3 g/s and 0.94 × 10-3 g/s. The erosion mechanism is the same, including plowing, indentation and cracking.

Precipitation Refinement via Aging Time Modification for Enhancing Wear Resistance in Ti–V–Nb Microalloyed High‐Manganese Steels

It is imperative to ensure an even distribution of refined precipitates to enhance wear resistance. Herein, different heat treatments are to control the size and distribution of precipitates. The treatments include water quenching at 1100 °C followed by aging at 400 °C for 24, 60, and 84 h, designated as AT24, AT60, and AT84, respectively. The microstructure, mechanical properties, and impact wear properties of high‐manganese steel are investigated under solution and aging conditions using scanning electron microscopy, field‐emission scanning electron microscopy, tensile testing, and impact abrasive wear testing. Notably, the absence of nanoscale precipitates largely accounts for the poor wear resistance of as‐casting steel, whereas the strengthening effect of larger micrometer‐sized precipitates is insufficient. After the solution and aging treatment, nanosized precipitates continuously form within the matrix, conducive to the formation of the deeper work‐hardening layer, thereby improving the wear resistance. The fine micrometer‐sized precipitates and evenly distributed nanoscale precipitates in AT60 actively contribute to toughness. Additionally, these precipitates interact with slip dislocations, providing stronger strengthening via the Orowan looping mechanism. The wear mechanisms of steel can be transformed from wide, deep pits to shallow grooves and microcutting by extending the aging time.

Oil-Resistant Underoil Superhydrophilic Metallic Foams for Lampblack Prefiltration.

Superwetting/repelling coatings have been utilized to address the issue of oil contamination on lampblack prefiltration metallic foam by both academia and industry. Nevertheless, the widely adopted superamphiphobic coatings are currently costly and suffer from poor wear resistance. In this study, we propose an oil-resistant underoil superhydrophilic (LSH) coating by a dip-coating method. The subsequent heating process at 200 °C for 5 min strengthens the designed coating based on lithium polysilicate cross-linking reinforcement. The LSH coating with a minimal water contact angle up to 3.4° under soybean oil can spontaneously achieve oil desorption within 7 s under water. Moreover, the coating retains its superhydrophilicity after enduring 900 friction cycles under a 500 g load or being immersed in 50 °C soapy water for 48 h. Hence, the LSH coating with great durability on metallic foam for lampblack prefiltration resulted in a 9.3% decrease in the oil absorption weight ratio after a 17-day cooking test. This work underscores the potential application of the LSH coating in lampblack prefiltration components, presenting promising technological advancements in self-cleaning for the catering industry.

Enhanced wear resistance of in-situ nanoscale TiC reinforced Ti composites fabricated by additive manufacturing

The poor wear resistance of Ti alloys limits its application in the orthopedic and dental surgery field. TiC as an ideal reinforcement phase can improve wear resistance due to its high hardness, low coefficient of friction, and good bio-compatibility. However, the wettability of the interface between the TiC and Ti matrix is poor, which leads to low mechanical properties and wear resistance. In situ TiC formed through the addition of a C source can enhance interfacial bonding. In this work, the Ti-graphite composites are prepared by Laser powder bed fusion (LPBF). On the one hand, the LPBF can prepare various complex porous shapes according to the personalized customized demand. On the other hand, the LPBF can provide a high cooling rate, suppressing grain growth and refining grains, and also can obtain equally distributed nanoscale TiC particles. The results show that the composites are mainly composed of Ti, TiC, and residual graphite. With the increase of graphite content, the amount of TiC increases and the grain becomes smaller, and the microhardness increases from 317 HV0.2 to 408 HV0.2. Meanwhile, the Ti-1.5 wt%Gr composite has a low friction coefficient, volume of wear, and wear rate, which is attributed to the high hardness of TiC particles and lubrication of graphite. The oxide on the surface of the wear mark is mainly composed of TiO2 and TiO. The main wear mechanisms of the composites are oxidation wear and adhesive wear.

Influences of Ti3AlC2 content on tribological behavior of cold-sprayed Ni-Ti3AlC2 composite coatings

As a type of lightweight and high-strength materials, aluminum alloys have been widely applied in such fields as aerospace and automobile manufacturing, which, however, easily wear out in harsh and complex environments due to their defects like poor wear resistance, low hardness, and easy deformation. For this reason, it is necessary to prepare a coating on the surface of aluminum alloys to enhance their wear resistance. In this work, Ni-Ti3AlC2 composite coatings were prepared on the aluminum alloy surface through cold spraying technology, and the influences of Ti3AlC2 content on the microstructure, mechanical properties, and tribological behavior of the Ni-Ti3AlC2 composite coatings were explored. It turned out that the mechanical properties and tribological behavior of the composite coatings were significantly improved with the increase of Ti3AlC2 content. Therein, the Ni-50%Ti3AlC2 composite coating exhibited a porosity of 0.384 %, a hardness of 310 HV0.2, and a bonding strength of 51.6 MPa, while its wear rate significantly declined to 1.87 × 10−5 mm3/N∙m. Because of the increase of Ti3AlC2 ceramic content, the compaction effect and shot peening effect of the ceramic hard phase were gradually enhanced, which further aggravated the deformation degree of Ni metal, thus improving the density, hardness, bonding strength, and wear resistance of composite coatings.

Impact of precursor content on microstructure and properties of in-situ synthesized Ni60A-xTiC ceramic composite coating

To improve the surface properties of copper components, Ni60A-xTiC composite coatings with different precursor (TiFe and Cr3C2) contents were fabricated on copper surface by plasma cladding in this paper. The surface of all composite coatings forms a ceramic film composed of a dense layer (TiO2 and Ti2O3) and a loose layer (Fe2O3 and FeO). As the precursor content increases, the number and size of TiC particles in the composite coating have a tendency to increase, resulting in a gradual increase in microhardness. The wear resistance of the composite coating increases first and then decreases. Too high precursor content (20 wt. %) can lead to poor interface connection and wear resistance deterioration of the coating. Furthermore, the melting loss resistance of the composite coating is significantly better than that of the Ni60A coating due to the barrier effect of the ceramic film, and it becomes better with the increase of precursor content. To sum up, the composite coating with 15 wt. % precursor content is more suitable because of its smooth appearance, good interface connection and excellent comprehensive performance.

Elevated Temperature Tribological Behavior of Duplex Layer CrN/DLC and Nano Multilayer DLC-W Coatings Deposited on Carburized and Hardened 16MnCr5 Steel

This study investigates the impact of temperature on the tribological performance of duplex layer CrN/DLC and nano-multilayers DLC-W coatings deposited using hybrid PVD-PECVD techniques on carburized and hardened 16MnCr5 discs cut from internal combustion engines valve tappets. Reciprocating dry sliding experiments were conducted at 25 °C, 150 °C, 200 °C, and 250 °C to analyze the high-temperature tribological behavior of the coatings. The wear mechanisms were characterized using SEM, EDS mapping, Raman spectroscopy, and nanoindentation. The lowest coefficient of friction was obtained for CrN/DLC at 25 °C. The CrN/DLC coefficients of friction (COF) increase with temperatures due to increasing adhesive wear. Similarly, DLC-W exhibited a comparable trend with increasing temperature from 25 °C to 250 °C. Both coatings’ wear resistance decreased with higher temperatures due to the transformation of sp3 C bonds to sp2 C bonds, facilitating the plastic deformation of the coatings and afterward of the substrate. The CrN/DLC displayed superior wear resistance to the DLC-W coating across all temperatures. The DLC-W multilayer coating showed poor wear resistance above 150 °C, being completely removed during the testing. Compared to both coatings, the uncoated 16MnCr5 discs exhibited higher coefficients of friction and wear rates at all temperatures. Predominant wear mechanisms observed in the coated discs were adhesive and abrasive. The study revealed a decrease in the coatings’ structural and mechanical properties with rising temperatures. Hard abrasive WC particles were identified as contributing to increased wear rates in the multilayer DLC-W coatings.

Investigation of Microstructure and Interfacial Reactions of Diffusion Bonding of Ni-Ti6Al4V Materials Joined by Using Ag Interlayer.

Due to its super plasticity, low weight, and high mechanical resistance properties, generally, Ti6Al4V is used for aeronautical applications. However, it has low resistance to plastic shearing. In addition, it has poor wear resistance. For these reasons, a lot of techniques have been developed to improve its wear resistance. Investigations of microstructure and interfacial reactions of diffusion bonding of Ni and Ti6Al4V materials have been performed experimentally. Ni samples were prepared with 50 ± 5 µm Ni powders in cylindrical shape. For diffusion bonding, Ag foil was used for improving the interlayer and connection quality. Nickel and its alloys can be joined by using some different processes, and the use of an interlayer can further facilitate the joining process and improve the joint quality. The experiments were carried out under the protected atmosphere. Argon gas was used for protection. The experiments were performed under 5 MPa pressure for 60 min duration at 850 °C, 900 °C, and 950 °C thermal conditions. Investigations of metallurgical structure occurring in the interface areas were examined by optic analysis of EDS, SEM, and X-ray. The strength of the joints was tested by lap-shear tests. From observations, the best quality of the coalescence at interfaces was indicated at elevated temperatures.

Significantly lowering friction and wear of CoCrNi medium-entropy alloy film via massive interstitial carbon-induced amorphization

CoCrNi medium-entropy alloy (MEA) exhibits exceptional damage-tolerance, particularly at cryogenic temperatures, but demonstrates poor wear resistance. In this study, we propose a strategy to significantly reduce friction and wear of CoCrNi MEA film through the introduction of massive interstitial carbon-induced amorphization. The microstructure of as-sputtered CoCrNi film reveals an anisotropic columnar nanograin structure, featuring a primary face-centered-cubic (fcc) phase and a minor hexagonal-close-packed (hcp) phase. Upon the introduction of 16 at.% interstitial carbon (CoCrNi-C), a remarkable phase transformation occurs, resulting in an isotropic amorphous structure. Under low-load and low-sliding-velocity conditions, the CoCrNi-C film exhibits a 21% reduction in coefficient of friction (CoF) and 17% reduction in wear rate. More notably, when subjected to higher loads and sliding velocities, the CoCrNi film experiences rapid failure within the initial 100 cycles, manifesting as microcracks, breakage, and peeling. In contrast, the amorphous CoCrNi-C film demonstrates remarkable durability, sustaining over 5000 cycles without failure. The wear rate exhibits a negative correlation with load but a positive correlation with sliding velocity. This enhanced wear resistance can be attributed to the amorphous nature of the CoCrNi-C film, which inhibits local strain accumulation, preventing strain localization that typically leads to crack initiation and propagation in the CoCrNi film. Additionally, the formation of a protective oxide layer contributes to the improved wear resistance of CoCrNi-C film under higher loads and lower sliding velocities. This study provides valuable insights into the design of wear-resistant CoCrNi-based MEA coatings through massive interstitial carbon-induced amorphization.

Carbon nanotube functionalization supports mechanical, tribological, and biological response of freeze‐dried ultra‐high molecular weight polyethylene‐based bio‐composites

AbstractAcetabular cup liners made of ultra‐high molecular weight polyethylene (UHMWPE), in hip implants fail mostly due to wear debris generation and poor wear resistance. Consequently, strengthening UHMWPE becomes essential. The current work exhibits how the addition of 5 vol% carbon nanotubes (CNT) and functionalized carbon nanotubes (fCNT) in UHMWPE (denoted as U) affects the mechanical properties (hardness, elastic modulus) and tribological properties (wear resistance) of biocomposites. To form a composite, powders were mixed using a planetary centrifugal mixer followed by freeze‐drying to disperse‐CNTs, followed by its compression molding at 220°C for 1 h at 10 MPa. With the addition of CNT and fCNT, ≥95% densification was obtained for all samples resulting an increase in hardness and elastic modulus from 74.96 MPa to 168.11 MPa (124%) and 1.65 GPa to 2.96 GPa (79%), respectively, which led to the reduction in wear rate from 12.5 × 10−5 mm3/Nm (U) to 2.5 × 10−5 mm3/Nm (UfCNT). The amount of apatite formation enhanced from U (58.2%) to UfCNT (65.1%) is confirmed via X‐ray diffraction and X‐ray photoelectron spectroscopy. Cell proliferation studies have validated the cytocompatible efficacy of U‐CNT composites with osteoblast‐like MG‐63 cells, making UfCNT as potential material for acetabular cup liners.

Enhancing corrosion and wear resistance of a 7075 aluminum alloy via depositing TC4 coating

Aluminum alloys have been widely used in engineering due to their high strength and low density. However, their poor corrosion and wear resistance have largely limited their application in marine equipment. This study successfully improved the corrosion and wear resistance of a typical 7075 Al alloy by depositing a high-performance TC4 titanium alloy coating using in-house annular laser cladding equipment. Microstructural investigations revealed that the defect-free TC4 coating is metallurgically bonded to the 7075 Al alloy substrate along with excellent bond strength. Electrochemical test results showed that compared to the hot-forged 7075 Al alloy and hot-forged double-phase TC4 bulk alloy, the TC4 coating exhibits superior corrosion resistance due to its net-basket α-single-phase microstructure. Further, wear testing results showed that the coefficient of friction and wear volume of the TC4 coating are far lower than that of 7075 Al alloy. The enhanced wear resistance is closely related to the high hardness of the TC4 coating and its excellent fatigue-wear resistance. Therefore, this work can serve as a reference to improve Aluminum alloys' corrosion and wear resistance by depositing Titanium alloy coatings using the annular laser cladding process, which shall widen the potential applications of Aluminum alloys in marine equipment.

Microstructure and properties of novel nano-lamellar Al27Nb18(CrZr0.5)xTi55−1.5x eutectic high-entropy alloy coatings on Ti-6Al-4V alloy

The serious wear damage caused by low surface hardness and poor wear resistance of titanium alloy severely limits its further application in engineering field. In this work, novel eutectic high entropy alloys (EHEAs) were designed by means of infinite solution strategy combined with mechanical assistance to explore the application of EHEAs in the field of surface protection coating. Three types of EHEA coatings were achieved through the adjustment of the Cr and Zr element proportions on Ti-6Al-4V alloy by laser cladding. The microstructure was eutectic structure composed of Laves and BCC/B2 phases with superlattice structure. A significant presence of stacking faults, Lomer-Cottrell locks and other defects is observed within the BCC/B2 phase, which contributes to the enhancement of both microhardness and nano-hardness. Al27Cr25Ti18Nb18Zr12 coating showed excellent wear resistance and minimal volume loss, which are 0.340 (65.38 % of the substrate) and 6.71 × 10−5 mm3/N·m (16.89 % of the substrate). Notably, the three alloys exhibit interesting selective corrosion behavior, which is mitigated by the presence of a nano-lamellar eutectic structure that limits pitting propagation.

The Influence of Adding B4C and CeO2 on the Mechanical Properties of Laser Cladding Nickel-Based Coatings on the Surface of TC4 Titanium Alloy.

The development of titanium alloys is limited by issues such as low hardness, poor wear resistance, and sensitivity to adhesive wear. Using laser cladding technology to create high-hardness wear-resistant coatings on the surface of titanium alloys is an economical and efficient method that can enhance their surface hardness and wear resistance. This paper presents the preparation of two types of nickel-based composite coatings, Ni60-Ti-Cu-xB4C and Ni60-Ti-Cu-B4C-xCeO2, on the surface of TC4 titanium alloy using laser cladding. When the B4C addition was 8 wt.%, the hardness of the cladding layer was the highest, with an average microhardness of 1078 HV, which was 3.37 times that of the TC4 substrate. The friction coefficient was reduced by 24.7% compared to the TC4 substrate, and the wear volume was only 2.7% of that of the substrate material. When the CeO2 content was 3 wt.%, the hardness of the cladding layer was the highest, with an average microhardness of 1105 HV, which was 3.45 times that of the TC4 substrate. The friction coefficient was reduced by 33.7% compared to the substrate material, and the wear volume was only 1.8% of that of the substrate material.

Effect of SiC content on the microstructure and wear behavior of cold-sprayed Al-SiC coatings deposited on AZ31 alloy substrate

As a promising and recently developed deposition technique, cold spray deposition method is among the most recently implemented approaches to enhance the poor hardness and wear resistance of AZ31B magnesium alloy. This study investigated the effect of SiC content on the microstructural characteristics, microhardness, and wear behavior of cold-sprayed Al-(16, 28, and 38 wt%) SiC composite coatings. The incorporation of SiC particles into the Al-matrix coating led to the development of a mechanical interlocking mechanism and improved coating-substrate interfacial bonding. The microhardness of the Al-38 wt% SiC coating was approximately 80 % higher than that of the bare substrate due to reduced porosity and a uniform distribution of SiC particles. For coatings with higher SiC content, the dominant wear mechanism transitioned from adhesive to abrasive wear, as evidenced by the friction coefficient (COF) values and wear track micromorphology. The Al-16 wt% SiC coating exhibited the lowest COF and wear rate values, indicating superior wear resistance among the specimens.