Wear Rate Research Articles

Improving surface finish of laser additively manufactured curvilinear surfaces via electropolishing and electroless coating

Abstract Laser directed energy deposition (LDED) is a very useful additive manufacturing (AM) technique for repairing and manufacturing complex shaped parts compared to traditional manufacturing techniques. However, the inadequate surface quality of the LDED fabricated components limits their direct utilization in different sectors. In addition, improving the surface finish of the curvilinear surfaces (useful for cooling channels and fuel nozzles) is also challenging. Hence, the current study focuses on surface modification of LDED fabricated SS 316L hollow cylindrical samples by combining electropolishing and electroless coating. We have performed electropolishing (two different currents, 8A and 15A) on the as-deposited (AD) sample with and without the application of the grinding process. The electropolishing reduced the roughness of the AD sample from 3.2 µm to 0.85 µm and 0.74 µm for 8A and 15A, respectively. The reduction in roughness was more at a higher current value due to the rapid anodic dissolution of the surface peaks. A further reduction in roughness was observed when grinding was performed before electropolishing. However, grinding resulted in higher material removal from the deposited surfaces and reduction in roughness was also minimal. Hence, only the electropolishing sample was selected for the next step, in which Ni-P electroless coating was performed on the surface to form a protective layer. After electroless coating, the COF and wear rate were reduced by 9.5 % and 25.6 % compared to the AD sample. Delamination and severe plastic deformation were the major wear mechanisms for the AD sample, whereas abrasion was dominant for the coated sample. The current work proposes a combined surface modification approach of electropolishing and electroless coating for the LDED processed components with curvilinear surfaces.

Multi-objective optimization in EDM of functionally graded Fe-Al using grey relational analysis

Abstract Functionally Graded Materials (FGMs) are multipurpose materials with a specific goal of managing changes in structural, thermal, or functional qualities. They feature a spatial variation in microstructure and/or composition. The current work prepared three layers of sample with different chemical compositions of Fe-Al FGM (50 Al-50 Fe, 45 Al-55 Fe, and 40 Al-60 Fe) at. % produced by powder metallurgy, then studied the machining behavior of these samples. The literature on the machining behavior of FGM was reviewed, and the influence of electrical discharge machine (EDM) process parameters such as voltage (V), current (I), pulse-on time, and pulse-off time on performance characteristics (material removal rate (MRR), tool wear rate (TWR), and surface roughness (Ra)) was investigated. The optimal machining settings for Fe-Al FGM samples will be ascertained by use of Grey Relational Analysis (GRA), which is based on the Taguchi approach, after an experimental investigation of the L18 orthogonal array design of trials. The GRA findings verify that V 140 volts, Ip10 A, Ton 100 μs, and Toff 75 μs is the optimal combination of process parameters. It has been found that the voltage is more significantly affected than the rest of the input parameters to obtain greater material removal rate (MRR) and lower tool wear rate (EWR) and surface roughness (Ra) through the response table. According to the study, choosing the right process parameters can improve the multi-performance feature.

Enhancement of friction and wear performance of polytetrafluoroethylene composites through the synergistic effect of hard fillers

AbstractThe Stirling engine is a high‐efficiency externally heating piston engine. The self‐lubricating properties of polytetrafluoroethylene (PTFE) are crucial for the operation of Stirling engines. Three PTFE composites filled with different contents of carbon fiber (CF), polyimide (PI) and nano‐zirconia (nano‐ZrO2) were prepared and their mechanical, friction and wear properties were investigated. The results showed that the density of CF‐containing PTFE composites was significantly reduced by 1.46% to 6.9% compared to neat PTFE. Meanwhile, the incorporation of fillers greatly enhanced the hardness by more than 21.4% over the hardness of neat PTFE. In addition, the friction coefficients of three PTFE composites were lower than those of neat PTFE, and the wear rate of these composites was three orders of magnitude lower than that of neat PTFE. In particular, the wear rate of PTFE filled with CF and PI at high pressure (2 MPa) and high velocity (4 m/s) was only 1.24 × 10–6 mm3/Nm. The wear morphology was also analyzed by scanning electron microscopy and energy‐dispersive x‐ray spectroscopy. It was found that the addition of CF and PI in PTFE has the most pronounced improvement on tribological performances. The synergistic effect of CF's mechanical reinforcement and PI's adhesive properties reduces the wear of the matrix, resulting in excellent wear resistance of PTFE composites.Highlights The compressive strength of PTFE was reinforced by CF and nano‐ZrO2. CF can lower the density and significantly enhance hardness of PTFE. Synergistic CF and PI enhance PTFE composites' friction & wear performance. Adhesive fillers & debris size key to forming uniform continuous transfer films.

Study on the Properties and Mechanism of m‐FACs/f‐Fe3O4/Epoxy Wear‐Resistant Magnetic Coating

ABSTRACTIn view of the wear problem of key parts of magnetic fluid seal device, epoxy resin (EP) composite coatings reinforced with Fe3O4 and fly ash cenospheres (FACs) were fabricated successfully. The structural and morphological features of the fillers and the composite coatings were characterized by Fourier transform infrared and scanning electron microscopy. CFT‐I material surface performance comprehensive tester was used to investigate the tribological behaviors of the as‐prepared composite coatings. Vibrating sample magnetometer was used to investigate the coatings' magnetic property. The formation mechanism of the composite coating was analyzed by the infrared spectrum results combined with molecular dynamics simulations. The results demonstrated that adding a certain amount of double fillers will have a synergistic effect, and its mechanical properties are better than those of single fillers. The tribological property of the m‐FACs/f‐Fe3O4/EP composite coatings was optimal under magnetic fluid friction, which is about an order of magnitude lower than the wear rate under dry friction. The saturation magnetization of the m‐FACs/f‐Fe3O4/EP composite coating is 2.77 emu/g, and the magnetic susceptibility reaches 4.64 × 10−4 m3/kg. Therefore, the m‐FACs/f‐Fe3O4/EP composite coating will be expected to solve the wear problem of equipment components in complex environments of magnetic field and friction.

In Vitro Wear of Human Enamel Against Monolithic Zirconia After Staining, Glazing and Polishing Treatments.

To evaluate the effect of staining, glazing, and polishing of stabilized zirconia with 5 mol% of yttrium oxide (5Y-TZP) on the wear behavior of opposing tooth enamel. The plane specimens of 5Y-TZP were divided into 6 groups (n = 10), according to surface treatment: as sintered, staining, glazing, polishing, staining followed by glazing, and staining followed by polishing, and positioned against tooth enamel during the two-body wear test (20 N, 2 Hz, until completing 300,000 cycles). The wear rates of tooth enamel were evaluated using a profile projector and a digital pachymeter as a measure of vertical height loss. The data were analyzed by one-way ANOVA and a Tukey post hoc test (α = 0.05). Polishing reduced the vertical height loss (p < 0.001) while there was no difference among other groups. Polishing is recommended as a finishing procedure to reduce the wear rates of tooth enamel, and finishing procedures (glazing or polishing) performed after staining did not affect the vertical height loss of tooth enamel. Polishing is the recommended finishing procedure for preshaded 5Y-TZP to reduce the wear rates of opposing tooth enamel. Staining is applied to the occlusal surface to reproduce the pigmented groove appearance, and glazing or polishing performed after staining did not affect the wear rates of opposing tooth enamel.

An Investigation on the High-Temperature Stability and Tribological Properties of Impregnated Graphite

Impregnated graphite is a common material for friction pairs in aeroengine seals, especially at high temperatures. For the convenience of the application of graphite materials in aeroengines, an SRV-4 tribometer and a synchronous thermal analyzer are employed to study the tribological properties and thermal stability of pure, resin-impregnated, metal-impregnated, and phosphate-impregnated graphite against stainless steel from room temperature to 500 °C. The results indicate that impregnations can improve the wear resistance and thermal stability of graphite at high temperatures. Compared with other impregnated graphite materials, the resin-impregnated graphite shows a good friction coefficient and poor wear rate and thermal stability over 300 °C, due to the degradation and oxidation of the resin-and-graphite matrix. The metal- and phosphate-impregnated graphite materials exhibit excellent wear resistance and thermal stability under 500 °C as a result of the protection of the impregnations, while the average friction coefficient of the metal-impregnated graphite is much greater than the phosphate-impregnated graphite, and even reaches 2.14-fold at 300 °C. The wear rates for the graphite impregnated with resin, metal, and phosphate are 235 × 10−7, 7 × 10−7, and 16 × 10−7 mm3N−1m−1 at 500 °C, respectively. Considering all aspects, the phosphate-impregnated graphite exhibits excellent tribological properties and thermal stability.

On the Influence of Microstructure and Properties of Direct Laser Deposited 50Cr6Ni2Y Coatings with Different TiC Contents

Three 50Cr6Ni2Y + x wt.% TiC (x = 1.5, 3.0, 4.5) alloy steel coatings were prepared using direct laser deposition (DLD) technology. The microstructure, microhardness, and wear resistance of DLD samples were studied. The results indicate that DLD coatings were composed of α-Fe (Fe-Cr-Ti), γ-Fe (Fe-Ni), and TiC. When the added TiC content was 3.0 wt.%, the DLD coating without cracks was fabricated, and TiC particles were well embedded in the sample. In addition, the coating demonstrated the best performance, with a microhardness of 758 ± 23.3 HV0.2, an average friction coefficient of 0.58, and a wear rate of 0.37 %. The addition of an appropriate amount of TiC as a reinforcing phase, on the one hand, had played a role in the second phase strengthening. On the other hand, the diffusion interfaces formed between TiC particles and the matrix allowed some Ti elements to melt into the matrix and formed a solid solution, playing a role in solid solution strengthening. The results could provide a reference for the preparation and repair of laser additive manufacturing high-performance wear-resistant parts.

Hematological Response to Particle Debris Generated During Wear–Corrosion Processes of CoCr Surfaces Modified with Graphene Oxide and Hyaluronic Acid for Joint Prostheses

Various surface modifications to increase the lifespan of cobalt–chromium (CoCr) joint prostheses are being studied to reduce the wear rate in bone joint applications. One recently proposed modification involves depositing graphene oxide functionalized with hyaluronic acid (a compound present in joints) on CoCr surfaces, which can act as a solid lubricant. This paper analyzes the biological alterations caused by wear–corrosion phenomena that occur in joints, both from the perspective of the worn surface (in vitro model) and the particles generated during the wear processes (in vivo model). The analysis of the inflammatory response of macrophage was performed on CoCr surfaces modified with graphene oxide and functionalized with hyaluronic acid (CoCr-GO-HA), before and after wear–corrosion processes. The wear particles released during the wear–corrosion tests of the CoCr-GO-HA/CoCr ball pair immersed in 3 g/L hyaluronic acid were intra-articularly injected into the experimental animals. The hematological analysis in vivo was made considering a murine model of intra-articular injection into the left knee in male adult Wistar rats, at increasing concentrations of the collected wear particles dispersed in 0.9% NaCl. Non-significant differences in the inflammatory response to unworn CoCr-GO-HA surfaces and control (polystyrene) were obtained. The wear–corrosion of the CoCr-GO-HA disk increased the inflammatory response at both 72 and 96 h of material exposure compared to the unworn CoCr-GO-HA surfaces, although the differences were not statistically significant. The pro-inflammatory response of the macrophages was reduced on the worn surfaces of the CoCr modified and functionalized with graphene oxide (GO) and hyaluronic acid (HA), compared to the worn surfaces of the unmodified CoCr. The hematological analysis and tissue reactions after intra-articular injection did not reveal pathological damage, with average hematological values recorded, although slight reductions in creatinine and protein within non-pathological ranges were found. Some traces of biomaterial particles in the knee at the highest concentration of injected particles were only found but without inflammatory signs. The results show the potential benefits of using graphene in intra-articular prostheses, which could improve the quality of life for numerous patients.

Frictional Abrasion of Rubber: Transition from Sliding to Rolling

ABSTRACT To develop applicable friction and wear models on tire scale, reliable test data are required. Consequently, friction tests on block level are requested because the distribution of contact pressure as well as slip velocity is nearly homogeneous at the contact surface of the sliding rubber block. However, wear mechanism and energy intensity levels of sliding rubber blocks and rolling rubber wheels or tires differ significantly. Consequently, linking both sliding and rolling frictional abrasion is required; thus, a wear model for rubber material is introduced to consider both deformation slip and sliding. The model input for sliding friction and resulting wear rate is derived from linear friction test experiments using sliding rubber blocks at different loading. A unique and sophisticated re-mesh algorithm ensures proper mesh modification due to abrasion of the structure. A wear energy evolution approach is developed to consider low abrasion with small sliding distances to predict wear at rolling rubber wheels. The simulation framework of abrasion modeling is successfully validated using laboratory abrasion tests.

Wear and Corrosion Resistance of ZrN Coatings Deposited on Ti6Al4V Alloy for Biomedical Applications

Zirconium nitrides films were synthesized on Ti6Al4V substrates at a bias voltage of −50 V, −80 V, −110 V and −150 V by the direct current (DC) reactive magnetron sputtering technique. The as-deposited coatings were characterized by X-ray diffraction (XRD), Fourier-transform infrared (FTIR) spectroscopy, scanning electron microscopy (SEM) and atomic force microscopy (AFM). The wear and corrosion resistance of the obtained ZrN coatings were evaluated to determine the possibility for their implementation in modern biomedical applications. It was found that the intensity of the diffraction peak of the Zr-N phase corresponding to the (1 1 1) crystallographic plane rose as the bias voltage increased, while the ZrN coatings’ thickness reduced from 1.21 µm to 250 nm. The ZrN films’ surface roughness rose up to 75 nm at −150 V. Wear tests showed an increase in the wear rate and wear intensity as the bias voltage increased. Corrosion studies of the ZrN coatings were carried out by three electrochemical methods: open circuit potential (OCP), cyclic voltammetry (polarization measurements) and electrochemical impedance spectroscopy (EIS). All electrochemical measurements confirmed that the highest protection to corrosion is the ZrN coating, which was deposited on the Ti6Al4V substrate at a bias voltage of −150 V.

Performance Evaluation of Polygonal and Cylindrical Ball Mills Using Discrete Element Method

ABSTRACTBall mills are frequently utilized in the chemical and mineral processing industries to reduce the size of particles. In mineral processing, cylindrical rotating mills with wear‐resistant materials are used at various operation scales. Polygon‐shaped rotating mills are used in artisanal and small‐scale mining due to technological and economic reasons. It is imperative to thoroughly evaluate polygon‐shaped mills to inform decisions regarding their improvement or replacement based on technological data. Even a minor enhancement in grinding efficiency and mill durability can yield substantial economic and environmental advantages. In this study, the performance of polygonal‐shaped mills was evaluated and compared with cylindrical profiles, taking into account power draw, collision energy dissipation, relative wear, and operational stability. The effect of installing lifters in the mills was also assessed. Simulations using the discrete element method (DEM) were carried out to describe the mechanical behavior of grinding media and its interaction with the mill walls. Notably, polygonal‐shaped mills without lifters facilitated interparticle interaction with limited centrifuging of particles compared to cylindrical mills without lifters. The installation of lifters in polygonal mills increased interparticle collisions and reduced power draw and wear rate. Cylindrical mills with lifters had high interparticle collisions similar to polygonal profiles but with much lower wear rate and high operational stability.

Preparation of Diisooctyl Phosphate‐Modified Ultra‐Small Zinc Oxide Nanoparticle and Investigation of Its Tribological Properties as Additive in Alkylnaphthalene

ABSTRACTZnO nanoparticle surface‐modified by diisooctyl phosphate (P204) was prepared by liquid‐phase in situ surface modification technique with zinc acetate as the raw material, P204 as the modifier and anhydrous ethanol as the solvent. The morphology and microstructure of the P204‐ZnO nanoparticle were characterised by transmission electron microscopy, X‐ray diffraction and Fourier transform infrared spectrometry. Its thermal stability was evaluated by thermogravimetric analysis; and its tribological properties as the additive in alkylnaphthalene were evaluated with an SRV‐5 friction and wear tester in reciprocal sliding mode. The results show that the as‐prepared P204‐ZnO nanoparticle has an average particle size of about 4 nm and a P204 content of about 42% (mass fraction); and the surface modifier is grafted onto the surface of ZnO nanoparticle by physical adsorption. With a mass fraction of 0.5% in alkylnaphthalene base oil, P204‐ZnO nano‐additive can mildly reduce the friction coefficient and drastically reduce the wear rate of the steel–steel sliding pair. This is due to the formation of the composite tribofilm via the adsorption and deposition of the nano‐additive on rubbed steel surfaces as well as the tribochemical reactions of the modifier P204 yielding phosphate and of steel substrate yielding iron oxides. The as‐formed composite tribofilm with a thickness of about 20 nm, consisting of phosphate and iron oxides as the binder as well as deposited ZnO nanoparticle as the filling phase, is responsible for the excellent friction‐reducing and antiwear abilities of P204‐ZnO nano‐additive for the steel sliding contact.

Pilot evaluation on an adapted tele-behavioral activation to increase physical activity in persons with depression: a single-arm pilot study

BackgroundPhysical activity has the potential to improve physical and mental health outcomes of persons with depression. However, feasible and acceptable strategies to integrate physical activity interventions into real-world settings are needed.ObjectiveTo assess the feasibility and acceptability of a manualized Behavioral Activation intervention aimed to increase physical activity in persons with depression (defined as a PHQ-9 score ≥ 10).MethodsA single-arm pilot study was conducted. The intervention consisted of 8 tele-therapy sessions delivered over a 10-week period. Measures of feasibility included screening, enrollment, intervention adherence, outcome data availability, and intervention fidelity. Acceptability was assessed with a post-intervention survey and qualitatively through focus groups and interviews. Preliminary efficacy of the intervention was assessed by evaluating pre-to-post changes in physical activity and depressive symptoms.ResultsAll feasibility metrics exceeded predetermined feasibility goal metrics with the exception of Fitbit wear and screening rate, which was due to a greater than anticipated enrollment rate. Participants (n = 15) reported perceived benefits from the intervention and convenience in attending tele-therapy sessions. Depressive symptoms, as measured by the PHQ-9 improved (16.8 at enrollment to 10.1 post intervention, Cohen’s d = 1.13). Self-reported moderate-to-vigorous physical activity (MVPA) increased from 22.0 min/week at baseline to 36.67 min/week post-intervention (d = 0.58). Physical activity as measured by the Fitbit showed little change (daily step 5543.29 during Week 1 to 6177.48 during Week 10, (d = 0.14); MVPA 21.23 min/week during Week 1 to 19.22 at Week 10 (d = 0.0.06).ConclusionsResults of the pilot study suggest the intervention is feasible to deliver and acceptable to participants. Preliminary results suggest the intervention may be effective in improving depressive symptoms and increasing self-reported physical activity.Trial registrationClinicalTrials.gov NCT04990401, Registered July 21, 2021.

Influence of Cu and Co addition on metallurgical and wear characteristics of AlCrFeNi high entropy alloy

The creation of new alloys with improved qualities has become essential in modern industries for high-performance materials. This work’s main objective is to use vacuum arc melting (VAM) to synthesize two different high-entropy alloys (HEAs): AlCrFeNiCu and AlCrFeNiCo. The mechanical properties, phase composition, grain boundaries, and alloy composition of the HEAs were studied. The predominant crystal structure, the Body-Centred Cubic (BCC) phase was obtained for both alloys. Significantly, the Co-containing HEA showed a smaller particle size than the Cu-containing HEA, which led to a 14.21% increase in microhardness. It indicates that the Co-based HEA will likely perform better than the Cu-based HEA in applications prone to abrasion, and indentation, and requiring high hardness levels based on the observed microstructure and hardness parameters. According to wear surface morphology studies, main effects analysis and ANOVA show that increasing loads and sliding distances increase wear rate, whereas sliding velocity has less effect. The best wear rate-reducing parameters are 10 N, 0.5 m/s, and 500 m for Cu-containing HEAs, and the same can be predicted using regression analysis. The study categorizes the intricate worn surface structure by describing different surface properties and wear mechanisms, such as grooves, delamination, adhesive wear, and pitting.

Trade-Off Between Wear/Corrosion Performance and Mechanical Properties in D-AlNiCo Poly-Quasicrystals Through CNT Addition to the Microstructure

An ultrafine-grained Al71Ni14.5Co14.5/CNT poly-quasicrystal (QC/CNT) composite was synthesized using spark plasma sintering of powder components developed through electroless Ni-P/CNT plating of Co particles and mechanical alloying. The performance of the synthesized samples was studied using various testing methods, such as room temperature/hot compression, wear, and corrosion tests. The results were compared to the properties of alloy samples fabricated from raw and coated powders (without CNTs). The wear rate and friction coefficient of the quasicrystalline samples improved significantly due to the contribution of the CNTs. The wear rate of the CNT-containing specimens was 0.992 × 10−4 mm3/N/m, which is 47.1% lower than that of the QC sample. The positive impact of the CNTs on the corrosion potential and current density was further validated by the potentiodynamic polarization tests in a saline solution. However, these improvements in surface properties came at the cost of a 21.5% reduction in compressive strength, although the compressive strength still remained above 1.1 GPa at 600 °C. The results highlight an interesting trade-off between surface properties and mechanical strength, pointing toward the development of materials suitable for extreme conditions.

Effect of chemical treatments of fibre surface on mechanical properties and wear rate of Beerakaya (Luffa acutangula) reinforced epoxy polymer composites

Effect of chemical treatments of fibre surface on mechanical properties and wear rate of Beerakaya (Luffa acutangula) reinforced epoxy polymer composites

Effect of addition on microstructures and mechanical properties of cBN/Cu-Zn-Ti composites via the pulse electric current sintering

In order to improve the performance of metal-bonded grinding wheels, the cBN/Cu-Zn-Ti composites were fabricated by pulse current sintering with several different Co contents (i.e., 5, 10, and 15 wt%) were added. The specimen microstructure, interfacial analysis and fracture morphology of pulse current sintering cBN grain were characterized by scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), and X-ray diffraction (XRD). The mechanical properties of hardness, wear resistance, and three-point bending strength of the fabricated specimens were tested. The electrochemical properties was also tested. The specimen shape fabricated by pulse current sintering using the composite Cu-Zn-Ti alloy doped by Co was better than pure Cu-Zn-Ti alloy. The microscopic analysis revealed that TiB2 and TiN were maintained between the Cu-Zn-Ti composites and cBN. With the addition of Co, the hardness, flexural strength and wear resistance of the specimens are improved. The new phase CoTi3 enhancing strength of the metal composite via the Orowan mechanism. The S5 specimen containing 15 wt% Co particles has the highest flexural strength, which is 485.83 MPa and satisfies the requirements of high speed grinding. Meanwhile, when the Co content reaches 10 %, the lowest friction coefficient (0.217) and lowest wear rate (0.81 mg) are achieved for the sample. With the addition of Co, the corrosion resistance of the material is significantly improved.

Microstructural, mechanical and wear behaviour of AA7075/ZrSiO4 surface composite developed via multi pass friction stir processing

ABSTRACT The microstructural, mechanical, and wear behaviour of the ZrSiO4-reinforced AA7075 surface composites fabricated through friction stir processing was analysed. The microstructure of the friction stir processed surface composite shows refined grain 52 μm, 20 μm and 5 μm after 1, 2 and 3 FSP pass which also leads to the uniform dispersion of reinforced ZrSiO4 particles in the A7075 surface as revealed by SEM, EDS, and XRD. The microhardness and tensile strength of the FSP surface composite were significantly improved by 35% and 54%, respectively, with the effect of ZrSiO4 particles, after six passes as compared to the substrate material. The slurry abrasive wear resistance of the surface composite after six FSP passes increased to 95% as compared to the A7075 substrate material. Similarly, the slurry erosive wear resistance was improved with increasing slurry rotating speed, but as slurry concentration increased at six passes, the wear rate decreased further due to self-colloids occurring between the slurry particles. Hence, slurry erosive wear resistance was increased by up to 220% as compared to substrate material. Hence, the novel fabrication of friction stir processed surface composite will be very beneficial for aerospace and marine structural components and the fabrication process is very robust and cost-efficient.

Improving the morphology of terrace-like transfer film to reduce wear rate of graphite/PTFE composites via filling low content silica

Purpose The purpose of this paper is to fill low content of silica to improve the wear resistance of graphite/polytetrafluoroethylene (PTFE) composites, and to discuss the effect of low content of silica on the morphology of terrace-like transfer film. Design/methodology/approach The tribological properties of silica/graphite/PTFE composites were tested by rotating pin-on-disk friction and wear tester, and the morphology of terrace-like transfer film was observed by 3D laser scanning microscope and quantitatively analyzed through the multi-Gaussian function linear combination model. Findings The results showed that adding 3 wt.% silica in graphite/PTFE composites can reduce the wear rate by 87%. More importantly, the morphology of terrace-like transfer film changed significantly after filling a small amount of silica, including the increase of the number of layers and the coverage rate of transfer film. Originality/value This work is of great significance for further understanding the transfer film and achieving its morphology control to optimize the wear of high performance PTFE composites.

Tribological Properties of 7A04 Aluminum Alloy Enhanced by Ceramic Coating

The 7A04 Al alloy is a commonly used lightweight metal material; however, its low wear resistance limits its application. In this study, the wear resistance of this alloy was improved by preparing micro-arc oxidation (MAO) coatings, MAO/MoS2 composite coatings, and hard-anodized (HA) coatings on its surface. The friction and wear behaviors of these three coatings with diamond-like coated (DLC) rings under oil lubrication conditions were investigated using a ring–block friction tester. The wear rates of the coatings on the block surfaces were determined using laser confocal microscopy, and the wear trajectories of the coatings were examined using scanning electron microscopy. The results indicated that, among the three coatings, the MAO/MoS2 coating had the lowest coefficient of friction of 0.059, whereas the HA coating had the lowest wear rate of 1.47 × 10−6 mm/Nm. The MAO/MoS2 coatings exhibited excellent antifriction properties compared to the other coatings, whereas the HA coatings exhibited excellent anti-wear properties. The porous structure of the MAO coatings stored lubricant and replenished the lubrication film under oil lubrication. Meanwhile, the introduced MoS2 enhanced the densification of the coating and functioned as a solid lubricant. The HA coating exhibited good wear resistance owing to the dense structure of the amorphous-phase aluminum oxide. The mechanisms of abrasive and adhesive wear of the coatings under oil lubrication conditions and the optimization of the tribological properties by the solid–liquid synergistic lubrication effect were investigated. This study provides an effective method for the surface modification of Al alloys with potential applications in the aerospace and automotive industries.