Wear Resistance Of Aluminium Alloy Research Articles

Combining Ultrafast Laser Texturing and Laser Hardening to Enhance Surface Durability by Improving Hardness and Wear Performance

Aluminum alloy 7075 is utilized widely across marine, aerospace, and automotive sectors. However, its surface wear resistance has hindered its application in certain tribological environments. Addressing this challenge, the current study examines a hybrid laser method to increase surface wear resistance by combining two techniques: ultrafast laser texturing and laser‐based surface hardening. Ultrafast laser processing is conducted using 3 W laser power, 100 kHz pulse repetition rate, 4 mm s−1 scanning speed, and three different scan patterns. After the texturing operation, laser‐based surface hardening is then performed on these textures using a continuous wave laser. The laser heat treatment is conducted using laser powers of 400 and 500 W with three different scan speeds of 1, 2, and 3 mm s−1. Microhardness evaluations show a notable increase in hardness, with the hardest sample exhibiting a 17.8% increase compared to the pristine sample. The laser‐textured and laser heat‐treated samples exhibit a significant reduction in the average coefficient of friction and wear volumes compared to samples that were laser‐textured but not laser heat‐treated. The investigated laser processing strategy offers a promising approach for surface modification, enhancing both mechanical properties and wear resistance of aluminum alloy 7075 surfaces.

Enhancing Tribological Performance of Micro-Arc Oxidation Coatings on 6061 Aluminum Alloy with h-BN Incorporation

Micro-arc oxidation (MAO) coatings of aluminum alloy have great potential applications due to their high hardness and wear resistance. However, the micro-pores and defects formed in the discharge channels during the MAO process limit its application in the corrosion field. This study delves into the impact of h-BN nanoparticles into MAO coatings on their structure, corrosion resistance, phase composition, and tribological properties. The results show that the incorporation of h-BN particles reduces the porosity and surface roughness of the coating while enhancing its hardness and wear resistance. The best corrosion resistance is obtained at a concentration of 2 g/L h-BN. An analysis of worn surface morphology, corrosion resistance, and friction coefficient change was conducted to evaluate the performance of this coating. This method provides a new approach to enhance the surface hardness and wear resistance of aluminum alloys, which is significant for expanding the application of aluminum alloys in corrosion environments.

Microstructure and wear-resistant behaviors of Al2O3-TiO2 reinforced Ni-based composite coating plasma-sprayed on 6061 aluminum alloy

Aluminium alloy is a widely used lightweight alloy in automobile and rail vehicle components, especially in parts such as brake pads and wheels, which require high wear resistance. Herein, to improve the wear resistance of aluminium alloys, Al2O3–13%TiO2 (AT13) reinforced Ni-based composite coatings were prepared by plasma spraying on 6061 aluminium alloy. The impact of AT13 content and heat treatment on the microstructure and wear resistance of Ni-based alloy coatings was systematically investigated. From our analysis, it was demonstrated that, in comparison to the substrate, the average micro-hardness of the composite coating with 10 %AT13 increased by more than 11 times, with a high value of 1250.81 HV0.2. Moreover, the average friction coefficient and wear rate reduced by 66 % and four orders of magnitude, with low values of 0.17 and 8.99 × 10−7 mm3(N−1∙m−1), respectively, which indicated a significant enhancement in wear resistance. In addition, after heat treatment at 450 °C for 2 h, the micro-hardness of the composite coatings was improved, and the wear rate further decreased. This effect could be attributed to the encapsulation of the hard ceramic particles in the nickel-based alloy, which may suppress the dislocation motion in the composite coating. This study provides valuable insights into enhancing the wear resistance of metal-based alloy coatings with ceramic composite coatings.

Study of tribological performance and corrosion resistance of aluminum alloy 6063 composites enhanced with a combination of silicon carbide and tungsten disulfide particles

This research explores the effects of wear on a 6063 aluminum alloy matrix combined with silicon carbide (SiC) and tungsten disulfide (WS2) particulates. Dry friction wear tests were conducted on three materials: pure 6063 aluminum alloy, a composite with 4 wt% SiC and 4 wt% WS2 reinforcement, and another composite with 6 wt% SiC and 4 wt% WS2 reinforcement. These materials were tested against AISI410 stainless steel discs under varying loads (10N, 20N, and 30N) and sliding rates (0.5, 1.0, and 1.5 ms−1) following a Taguchi L27 orthogonal experimental plan. Main effect graphs (S/N ratios) and ANOVA analysis were utilized to determine optimal parameter combinations, and confirmation tests were carried out to validate the Taguchi results. Scanning electron microscope (SEM) images of wear areas showed that incorporating SiC and WS2 significantly enhanced the wear resistance of the aluminum alloy. This indicates that incorporating SiC and WS2 reinforcement has the potential to enhance the wear resistance of aluminum alloys, making them suitable for applications such as piston rings in internal combustion engines, which is in line with the requirements of engine performance. Furthermore, potentiodynamic polarization studies evaluated the corrosion resistance of the Metal Matrix Composites AA6063 in 3.5% NaCl. Results indicated that the AA6063 + 6 wt% SiC + 4 wt% WS2 composite exhibited superior corrosion resistance compared to AA6063 alone.

WITHDRAWN: Enhancing the Wear Resistance of Aluminium Alloys: Superior Effect of rGO-modification on Ni-W-P Coatings

The electroless coating of Ni-W-P, one of the well-known ternary alloy systems, has been successfully applied to aluminium. Moreover, adding rGO produced by the modified Hummers method to the bath content significantly improves the wear resistance. To optimize the rGO concentration, rGO is added to the bath with different concentrations and wear resistances at different sliding speeds (100, 200, and 300mm/sec) are tested. Furthermore, at the 300mm/sec sliding speed, rGO has reduced the friction coefficient of the coating by 42% and increased the wear resistances by approximately five times (from 8.43×10−7 to 1.87×10−7 mm3/Nm). As a result, developed Ni-W-P/rGO composite coatings are promising for both novel high-tech applications that need, are cost-effective, and have a long service life.

Effect of microtexture morphology on the tribological properties of PI/EP-PTFE-WS2 coating under starved oil and dry sliding wear

The limited wear resistance of aluminum alloys constrained their applications and longevity. Surface microtexture combined with polymer coating technology can prolong the service life of aluminum alloy materials under extreme conditions of aerospace. A370 aluminum specimens were textured with three types of microtexture surfaces including circular pits, rectangular grooves and cross grids. A PI/EP-PTFE/WS2 coating was designed and prepared on the surfaces of these textures by liquid spraying to improve the tribological properties of A370 aluminum under starved oil and dry sliding wear. The influences of different micro-texture morphology on the tribological performances of these coatings were experimented. The results indicated that the surface qualities of the micro-textures are improved by coating deposition on their surfaces. The friction coefficients of the coated surfaces on all micro-texture are effectively reduced under the relatively stable wear stage compared to the sample without micro-texture coating. The coating on the pitted texture exhibits superior performance in friction tests, reducing average coefficients and wear rate by 13.58% and 35.34% in dry sliding wear, and by 16.18% and 83.98% under the starved oil lubrication compared to the non-textured substrate, respectively. This is followed by the coating on cross-mesh texture and the rectangular groove texture. The reason is that the pitted texture facilitates the local stress release of coating during the process of coating deposition due to its smaller spacing between pits and higher density of pits per unit area. The bearing capacity of the pitted texture is highest and its deformation is the lowest. The wear debris created in the friction process is more easily accumulated in the pit units, which results in a reduction in wear.

Enhancing wear resistance of aluminum alloy by fabricating a Ti-Al modified layer via surface mechanical attrition treatment

The limited wear resistance of aluminum alloys hinders their application in lightweight equipment. Herein, we present the successful fabrication of a Ti-Al modified layer on the surface of aluminum alloy 2024 via surface mechanical attrition treatment (SMAT-Ti). Tribological assessments indicate an improvement in tribological performance. Specifically, the average friction coefficient and wear rate of the SMAT-Ti treated sample decreased by 49.1% and 81.9%, respectively, compared to untreated sample. Analysis of wear surfaces and molecular dynamics simulations demonstrate that the improvements observed can be attributed to the wear-resistant tribofilm formation. Furthermore, the integration of Ti particles beneath the subsurface facilitates the formation of HCP bands and dislocation locks. These microstructural changes obstruct frictional shear deformation and crack propagation, effectively reducing wear.

A Review of the Laser Cladding of Metal-Based Alloys, Ceramic-Reinforced Composites, Amorphous Alloys, and High-Entropy Alloys on Aluminum Alloys

As one of the lightest structural metals, the application breadth of aluminum alloys is, to some extent, constrained by their relatively low wear resistance and hardness. However, laser cladding technology, with its low dilution rate, compact structure, excellent coating-to-substrate bonding, and environmental advantages, can significantly enhance the surface hardness and wear resistance of aluminum alloys, thus proving to be an effective surface modification strategy. This review focuses on the topic of surface laser cladding materials for aluminum alloys, detailing the application background, process, microstructure, hardness, wear resistance, and corrosion resistance of six types of coatings, namely Al-based, Ni-based, Fe-based, ceramic-based, amorphous glass, and high-entropy alloys. Each coating type’s characteristics are summarized, providing theoretical references for designing and selecting laser cladding coatings for aluminum alloy surfaces. Furthermore, a prediction and outlook for the future development of laser cladding on the surface of aluminum alloys is also presented.

Study of wear and corrosion resistance of ATO nanoparticle–doped micro‐arc oxide film layers

AbstractIn order to enhance the corrosion and wear resistance of aluminum alloys in complex and variable environments, an Al2O3 ceramic film was prepared on the surface of 7A04 aluminum alloy in a silicate electrolyte system using a micro‐arc oxidation technique. Subsequently, antimony tin oxide (ATO) nanoparticles were used to dope the micro‐arc oxidation film to enhance the protective properties of the 7A04 aluminum alloy. The structural characteristics of the film were investigated by examining the surface and cross‐sectional morphology and the composition of the physical phases. The results show that ATO nanoparticles can promote the micro‐arc oxidation reaction, improve the surface morphology of the film layer, increase the thickness of the film layer and the denseness after sintering, and enter the film layer in the form of melt wrapping, which plays a role in refining the grain. In the study of the wear resistance and corrosion resistance of ATO‐doped ceramic film layers, it was found that the introduction of ATO nanoparticles did not significantly improve the wear resistance of the micro‐arc oxide ceramic film layers but significantly improved the corrosion resistance of the film layers.

Investigation of Dry Tribo-Behavior of Aluminum Alloy AA6061/Al2O3/Graphite Composites Synthesized by Stir Casting Technique

In order to meet the requirements of lightweight, high strength, and wear resistance, metal matrix composites are being manufactured with increasing interest, according to recent advancements in material science. Alumina (Al2O3) and Graphite (Gr) were added to the aluminum alloy matrix (AA6061) to increase the dry sliding wear resistance and to explore the impact of normal applied load and sliding speed on the coefficient of friction as well as its wear behavior. The composites were made by the stir casting technique. Hardness and tensile strength were two examples of mechanical qualities that have been assessed. Compared to the unreinforced aluminum alloy, the tensile strength of the metal matrix composites was improved by 17.7%, and the hardness increased by 44.1% at a loading of AA6061 (90wt%)/ Al2O3 (5wt%)/Gr (5wt%). A pin-on-disc tribometer was utilized to analyze the dry sliding tribo-behaviors of AA 6061 alloy reinforced with Al2O3 and Gr by varying the applied load and the sliding distance. The wear resistance of aluminum alloy reinforced with Gr (5wt%)/Al2O3(5wt%) increased by 85.0% when the load was applied at 25N compared to unreinforced aluminum alloy, and the frictional coefficient decreased by 58.0%. Additionally, an optical microscope and scanning electronic microscope were used to assess the worn surfaces.

The Effect of Incorporating Ceramic Particles with Different Morphologies on the Microstructure, Mechanical and Tribological Behavior of Hybrid TaC_ BN/AA2024 Nanocomposites

Improving the mechanical durability and wear resistance of aluminum alloys is a research challenge that can be solved by their reinforcement with ceramics. This article is concerned with the improvement of the mechanical properties and wear resistance of the AA2024 aluminum alloy surface. Surface composites were prepared by incorporating a hybrid of heavy particles (tantalum carbide (TaC), light nanoparticles, and boron nitride (BN)) into the AA2024 alloy using the friction stir process (FSP) approach. Three pattern holes were milled in the base metal to produce the composites with different volume fractions of the reinforcements. The effects of the FSP and the reinforcements on the microstructure, mechanical properties, and wear resistance are investigated. In addition to the FSP, the reinforced particles contributed to greater grain refinement. The rolled elongated grains became equiaxed ultrafine grains reaching 6 ± 1 µm. The refinement and acceptable distribution in the reinforcements significantly improved the hardness and wear resistance of the produced composites. Overall, the hardness was increased by 60% and the wear resistance increased by 40 times compared to the base alloy.

Influence of Continuity of Electric Spark Coatings on Wear Resistance of Aluminum Alloy

Influence of Continuity of Electric Spark Coatings on Wear Resistance of Aluminum Alloy

Al 5251-based hybrid nanocomposite by FSP reinforced with graphene nanoplates and boron nitride nanoparticles: Microstructure, wear, and mechanical characterization

Abstract The strength and wear resistance of aluminium alloys must be improved to enhance their usage in lightweight constructions. Thus, in this study, graphene nanoplates (GNPs) and boron nitride (BN) nanoparticles were reinforced into the Al 5251 aluminium alloy by friction stir processing (FSP). The Al 5251 aluminum alloy sheets were patterned with holes and filled by mono GNPs, mono BN nanoparticles and a hybrid of BN nanoparticles and GNPs. The microstructure, wear, and mechanical properties of the as-received, after FSP, and the manufactured surface nanocomposites were analysed. Wear tests were performed using two methods: weight loss and volume loss methods. FSP led to four times grain refinement. Due to the Zener pinning effect, the reinforcement nanoparticles improved the grain refinement effect by seven times decrease in the mean grain size. The wear rate by volume and weight loss with reinforcing BN nanoparticles decreased by 160 and 1,340%, respectively. Note that the GNP reinforcement insignificantly improved the wear resistance and hardness compared with the BN nanoparticles. The hardness was increased by 50, 120, and 80% by reinforcing the Al 5251 alloy with GNPs, BN, and a hybrid of BN nanoparticles and GNPs, respectively. The nanocomposite reinforced with GNPs exhibited superior mechanical properties compared to the other nanocomposites.

Effects of the Rolling Directions on Wear of the Aluminum Alloys

Due to the booming development of the automation industry and the transportation industry, the mechanical components are prone to wear under long-term operating conditions. To improve the wear resistance, effects of the rolling directions on wear of the aluminum alloys are studied. An optical microscope is used to analyze the crystal phase, and the correlation between the crystal grains and the rolling direction is studied. This study can therefore establish a key technology for improving the wear resistance of aluminum alloys.

Process optimization using grey relational analysis in dry sliding wear behavior on SiC/B4C/Talc reinforced Al 6061 hybrid metal matrix composite

In this research, investigations were carried out on Al6061 base alloy with the changing weight percentage of silicon carbide (SiC) and boron carbide (B4C) with keeping the amount of talc constant. The main objective of this present study was to improve the wear resistance of aluminum alloy using SiC/B4C/talc ceramic particles using stir-casting technique and how the eco-friendly talc content influencing the solid lubricity during the abrasion process. The experiments were conducted via orthogonal array of L27 using Taguchi’s method. The optimum value along with the coefficient of friction was obtained on the basis of grey relational equations and ANOVA, which helped in analysis of most influential input parameters such as applied load, sliding speed, sliding distance and percentage of reinforcement. Conformation tests were performed for the purpose of validation of the experimental results. The specimens were analyzed using scanning electron microscope (SEM) with EDX for micro structural studies. The SiC, B4C and talc presence in the composite helped to improve the mechanical properties, according to the results. The presence of solid lubricant talc as reinforcement to the aluminum hybrid composite reduced the wear properties and decreased the co-efficient friction. These wear resistance improved aluminum metal matrix composites could be used in automobile, defense and domestic applications where high strength and wear resistance required with lesser specific weight.

The Roles of Alloy Elements on Self-Lubrication of Anodic Al2O3/MoS2 Composite Films on Al Alloys

Aluminum alloys have good specific strength, corrosion resistance, and recyclability, so they are attracting attention from the automobile industry as a structural material to replace steel materials. Since aluminum alloys are prone to adhesive wear, resulting in poor tribological performance, it is necessary to improve the wear resistance by appropriate surface modification. It is known that filling some solid lubricants, such as MoS2 or PTFE, inside the anodic porous films is an effective method to improve the wear resistance of aluminum alloys in industry. However, few studies have been conducted on the alloy elements in aluminum alloys containing Si and Cu, especially casting alloys. The intermetallic compounds such as Si and CuAl2 contained in aluminum alloys usually cause defects inside the anodic films, which may affect the wear resistance of the anodic films. In this study, our purpose is to fabricate self-lubricating anodic Al2O3/MoS2 composite films on various aluminum materials by successive anodization and electrodeposition, to investigate the effects of alloy elements in aluminum alloys on the filling of MoS2 and wear resistance.Three kinds of commercial aluminum alloy sheets (A1100: 99.0% Al, A2017: Al-3.85% Cu, A4045: Al-9.85% Si) and an Al-12Si-5Cu casting alloy for automotive engine parts. Anodizing was performed using a sulfuric acid-based solution in constant current mode. After anodizing, anodic electrodeposition was performed in an ammonium tetrathiomolybdate solution, to incorporate molybdenum disulphide (MoS2) into the anodic films. The surface and cross section of the prepared sample were observed by FE-SEM to investigate the influence of intermetallic compounds in aluminum alloy on MoS2 anodic electrodeposition. GD-OES was used to examine the composition depth profiles inside the anodic Al2O3/MoS2 films. XPS was used to investigate the composition and chemical bond state of the formed MoS2. Furthermore, in order to evaluate the influence of the substrate on the wear resistance, the friction coefficient of various samples was measured using a reciprocating wear tester (SRV-4; 20 N, 1.0 mm, 20 Hz). The counterpart material was a high carbon chromium steel ball (100 CR6-DIN) of φ12.7 mm.Fig.1 a-b shows the results of GD-OES measurement of composition depth profiles within the self-lubricating anodic Al2O3/MoS2 composite films formed on (a) pure Al (A1100) and (b) Al-Si-Cu casting alloy. By making only Mo intensity the same measurement condition, it was possible to compare the amount of MoS2 filled inside the anodized films on pure Al and Al-Si-Cu casting alloy. Strong Mo peaks were found on the surface of both pure Al and Al-Si-Cu casting alloy specimens. The, with weak intensity inside the alumina film. Whereas the Mo and 0.1concentrate and Al-Si-Cu casting alloy. In case of pure Al, distribution of Mo mainly accumulates on the surface with only weak intensity inside the alumina film, and the intensity of Mo becomes almost stable toward the inside of the film. Whereas in case of the Al-Si-Cu casting alloy, the intensity Mo is much higher than that of pure Al, with a gradual distribution across the composite films, indicating that more Mo is deposited inside the anodic alumina film. The enhancement of Mo amount is ascribed to the presence of MoS2 in the defects of the anodic alumina film formed by the intermetallic compound (AlCu) contained in the Al-Si-Cu casting alloy, which can also be confirmed by cross-sectional observation by FE-SEM..Fig.1 c shows dynamic friction coefficient vs. number of reciprocating slides of self-lubricating anodic Al2O3/MoS2 composite films. Both the pure Al and the Al-Si-Cu casting alloy maintained a low friction coefficient at the beginning and then showed a sharp rise at a certain point. It is considered that the self-lubricating film was completely worn and reached the base metal at the point where the friction coefficient sharply increased. It can be confirmed that the number of sliding times to reach the base metal is about 26000 times with pure Al and about 36000 times with the Al-Si-Cu casting alloy, and that the Al-Si-Cu casting alloy has a longer coating life. In addition, the friction coefficient of the self-lubricating films decreased from 0.15-0.25 for pure Al to around 0.1for the Al-Si-Cu casting alloy, thus indicating the excellent lubricating effect of MoS2, which can be attributed to the increase of the filling amount of MoS2 inside the anodic film, as shown in the results of GD-OES (Fig.1a-b). Figure 1

Improvement of wear resistance of aluminum alloy by HVOF method

This work is devoted to establishing the effect of High Velocity Oxygen-Fuel (HVOF) method for spraying coatings with vanadium carbide (VC) (as an alternative to galvanic chromium plating) on the wear resistance of obtained coatings in friction conditions with a rigidly fixed and non-fixed abrasive. The initial components for spraying coatings were powders of VC, ferrochrome (FeCr) and cobalt (Co). The powder compositions of the two (FeCr – VC) and (FeCr – VC – Co) systems were deposited on to a substrate of an aluminum alloy 7075. Each of compositions was mixed in a planetary mill for the mechanical alloying. A thickness of obtained coatings was 200 μm. It was discovered that (FeCr – VC) and (FeCr – VC – Co) coatings, obtained by the HVOF method with using of both gaseous (propane - oxygen) and liquid (kerosene – oxygen) fuels, have high wear resistance. The wear resistance of the coatings with using of friction method with rigidly bonded abrasive increases with the size of the VC carbide inclusions. In the presence of cobalt in the coating, the trend is similar, but its wear is bigger. Since cobalt does not form carbides, in the structure of such coating forms ductile inclusions based on it. As a result of the friction test using non-fixed abrasive, the wear resistance of coatings increased with decreasing VC carbide size in their structure and increased at addition of cobalt powder to powder composition for spraying.

Fabrication of Metal Matrix Composites via High-Speed Particle Implantation

This study deals with the improvement of the wear resistance of aluminum alloys by metal matrix composites (MMCs). The latter were fabricated by implanting high-speed solid particles into the metal surfaces. For that, stainless steel and Fe-based amorphous alloy particles were accelerated to the substrates using high-pressure nitrogen. The effect of multi-particle implantation, particle material properties and kinetic energy at impact, and pre-heating treatment of the substrate on particle implantation was investigated using numerical simulation. In addition, the effect of particle size on the MMCs microstructure, wear resistance, strengthening mechanism, and relative hardness was studied. The results showed that the method simultaneously achieved shot peening and metal matrix composite strengthening, that is, resulted in a double-strengthening effect. Furthermore, high-speed particle implantation effectively improved the wear resistance of the substrate: The wear volume of Fe-based amorphous alloy/Al MMCs was 5% of the untreated aluminum substrate and that of stainless steel/Al MMCs 14–44%. It is believed that laser-assisted particle implantation can be used to efficiently increase the thickness and surface properties of MMCs.

Experimental analysis of tribological characteristics of aluminium hybrid composites fabricated by using stir casting techniques

This paper focuses on the fabrication of the Aluminium hybrid composite because of its high flexibility properties. The aim of this project is to enhance the wear properties by enhancing the Wear resistance of Aluminium alloy by adding the different reinforcement. The reinforcement used here is that Alumina and CSC (Coconut Shell Charcoal) of varying proportions is fabricated using the stir casting techniques. The wear behaviour of the sample is then tested using Pin-On-Disc apparatus by considering the corresponding process parameters such as Load, Speed, and Time. The microstructure analysis is also carried out using the inverted microscope and thereby revealing that there is the proper distribution of the reinforcements.

Dry sliding wear analysis OF Al5083/CNT/Ni/MoB hybrid composite using DOE Taguchi method

Aluminium alloys with its low density and high strength to weight ratio have extensive applications in aerospace, marine and automobile industries. In this work Al5083/CNT/MoB/Ni hybrid composite has been compo casted to improve the corrosion resistance and to compensate the well-known low strength, deficient hardness and inadequate wear resistance of Aluminium alloys. Fabrication of the hybrid is done with 1.5 wt % of CNT, 8 wt% of Ni and varying wt% of MoB from 1 to 4 (composite A to D). Dry sliding wear analysis of composites is conducted on a pin on disc tribotester at room temperature using Taguchi L16 orthogonal array with varying load (10 N, 20 N, 30 N and 40 N), sliding velocity (0.5 m, 1.5 m, 2.5 m and 3.5 m) and wt% of MoB (1–4) as parameters. The significance and contributions of parameters on wear behavior is investigated by analysis of variance (ANOVA) and the correlation between parameters is obtained by a regression equation. Weight percentage of MoB is found to be the most contributing parameter (57.09%), followed by sliding velocity and load. The paper includes study and analysis of wear rate, micro wear mechanisms and transfer of materials involved with the tribosystem. Analysis of Optical microscopy, Scanning Electron Microscopy and EDX of the worn surface reveals that there is a shift in wear mechanism from adhesive to abrasive with increase in wt% of MoB. The three body rolling abrasion, the oxide tribo layer and the formation of Mechanical Mixed Layer (MML) between the sliding surfaces are observed to be the reasons for the decreased wear rate of the optimum composite. The result from experimentation shows close tolerance with statistical analysis.