Wear Resistance Research Articles

Optimization of wear and friction behaviour of fish scale powder filled natural fibre/glass fibre hybrid epoxy composite in dry sliding condition

Abstract The purpose of this research is to look at the wear and friction properties of a unique composite material made up of fish scale powder, natural fibres, and glass fibres embedded in an epoxy matrix. The growing demand in many industries for eco-friendly and sustainable materials has resulted in the development of hybrid composites that combine natural and synthetic reinforcements. The goal of this study is to improve the wear resistance and frictional qualities of composite material under dry sliding conditions. The wear and friction behaviour of the composite is optimized using the Response Surface and Taguchi approach, which entails constructing a set of trials based on a statistical model. The significant components, which include fish scale powder content, natural fibre type and content, and sliding parameters, are carefully varied to determine the best combination that results in the least amount of wear and friction. The accuracy of the regression models exceeded expectations. According to Taguchi’s findings, F and V have the largest impact on wear loss and friction, respectively. Fish scale powder has shown great promise as a filler for enhancing the wear resistance of composites, as seen by the study’s findings. The optimized composite has exceptional wear resistance and low friction, making it a suitable alternative for dry sliding applications.

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.

Electrochemical exfoliation of graphene nanosheets and development of a novel efficient Ni-CeO2-Gr ternary nanocomposite coatings for dual functional anti-corrosion and wear-resistance

Nickel-based coatings offer excellent corrosion, wear resistance, and mechanical strength, and can be further improved with additives, making them ideal for harsh environments like marine and chemical industries. In the present study, graphene (Gr) nanosheets were synthesized via electrochemical exfoliation and a novel Ni-CeO2-Gr nanocomposite coating was prepared by an electrochemical co-electrodeposition technique on a Cu substrate in a traditional Watts bath. The coatings (pure Ni, Ni-Gr, Ni-CeO2 and the ternary Ni-CeO2-Gr) were characterized using optical microscopy, scanning electron microscopy (SEM) coupled with energy-dispersive spectrometry (EDS), X-ray diffraction (XRD), Raman spectroscopy, Vickers microhardness and micro-scratch tests. The electrochemical properties of the coatings were evaluated by electrochemical impedance (EIS) and DC-polarization measurements in 0.5 M NaCl. SEM-EDS, Raman, and XRD analysis confirmed the successful synthesis of high-quality graphene and the incorporation of CeO2 nanoparticles and graphene nanosheets into the nickel coating matrix. It was found that the ternary Ni-CeO2-Gr coating exhibited a high microhardness (915.6 HV), improved cohesive strength and enhanced corrosion resistance (544 KΩ.cm−2) compared to pure Ni coatings (30 KΩ.cm−2) due to the synergistic effect of the graphene and CeO2 duplex layer within the Ni matrix, forming a robust anticorrosion barrier. These findings offer valuable insights into the designing highly efficient materials for corrosion protection.

Enhancing wear resistance of aluminum 6061 composites with fly ash: A sustainable approach for industrial applications

This study investigated the benefits of adding fly ash as a reinforcement material. The benefits included cost-effectiveness, improved quality, isotropic behavior, and environmental advantages. To improve self-lubrication and wettability behavior, Al6061 alloy composites were fabricated with different amounts of fly ash (0%, 2%, 4%, 6%, and 8% by weight), along with a fixed amount of graphite (3wt.%) and magnesium (2wt.%). Wear tests were conducted using Taguchi’s Design of Experiment (DoE) approach on the composites. The optimized composition with 6% fly ash exhibited the least wear rate under the test conditions of load = 10 N, sliding velocity = 3 m/s, and sliding distance = 2 km. SEM images revealed a uniform distribution of fly ash and graphite reinforcement in the matrix, contributing to enhanced wear resistance. The composites exhibited fewer scratches and plastically deformed surfaces, indicating a decrease in wear rate and increased wear resistance with higher fly ash content. ANOVA were used, and four parameters were identified to be critical, Composition at 34%, Sliding Distance at 27%, load at 23%, and Sliding Velocity at 12% contribution with a statistical confidence of 95%. This research contributes to developing cost-effective and environmentally sustainable materials with improved mechanical properties. It makes them suitable for various industrial applications, such as the automotive industry, where wear resistance is essential.

Enhanced wear resistance, corrosion behavior, and thermal management in magnesium alloys with PEO coatings

The harsh conditions encountered in aerospace applications, such as high operational temperatures, abrasive wear, and corrosive substances, present significant challenges to the performance and longevity of magnesium alloy components. To create a coating with superior wear resistance, corrosion resistance, and high emissivity, this study employs plasma electrolytic oxidation (PEO) technology to develop a nanocomposite coating doped with carbon nanotubes (CNTs) and hexagonal boron nitride (h-BN). The results demonstrate that the MgO-BN/CNTs coating with an emissivity of 0.82 reduces the equilibrium temperature of the 5 W LED junction by nearly 10 °C compared to the magnesium alloy substrate, showing improved radiative heat dissipation performance. Due to the ability of the porous structure to accommodate abrasive particles, coupled with the lubricating effect of h-BN and CNTs, the friction coefficient of the MgO-BN/CNTs coating is 0.57, which is 21 % lower than that of the MgO coating. Additionally, the coating exhibits excellent corrosion protection, attributed to the dense microstructure and chemical inertness of h-BN. The findings demonstrate that the strategic incorporation of h-BN and CNTs into PEO coatings effectively improves the wear resistance, corrosion resistance, and thermal management performance of magnesium alloys.

A Comprehensive Review on Wear Resistance and Fracture Toughness of Metal Tools for Baryte Mining and Processing: A Mechanistic Approach

A Comprehensive Review on Wear Resistance and Fracture Toughness of Metal Tools for Baryte Mining and Processing: A Mechanistic Approach

High-temperature tribological evaluation of cobalt-based laser cladded disc for automotive brake systems

This study investigates the high-temperature wear behavior of laser-cladded (LC) cobalt-based Stellite 6 alloy coatings and compares the wear resistance of the cladding layer to the grey cast iron (GCI) substrate material at three different elevated temperatures: 150 °C, 250 °C, and 350 °C. Wear mechanisms at elevated temperatures were analyzed using SEM-EDS and Raman Spectroscopy to understand the material removal processes and degradation for the discs and counterpart composite friction material pins, respectively.The results indicated a significant improvement in wear resistance for cobalt-based alloy cladding at high temperatures. Wear rates were reduced by 5.0 %, 43.0 %, and 16.0 % at 150 °C, 250 °C, and 350 °C, respectively. The LC - brake pin tribo-pair exhibited a continuous increase in friction coefficients (CoF) with an increase in testing temperatures. The wear mechanism for laser-cladded discs exhibited a combination of abrasive and adhesive wear, with abrasive wear prevailing at 150 °C and increased adhesive wear at 250 °C and 350 °C. However, at 350 °C, decomposition of phenolic resin and the adhesive wear mechanism, led to brake pin failure. For GCI discs oxidative wear was identified as the predominant wear mechanism. The improved knowledge of wear mechanisms on LC Stellite 6 against composite brake pins, is set to enhance surface modification of GCI for brake disc applications.

The Nano-Revolution in Rubber Bushings: Boosting Mechanical Performance

Abstract A new method for manufacturing rubber bushings with unique properties has been introduced. The method involves adding alumina nanoparticles at different ratios (0.2, 0.4, 0.6, 1, 1.5, 2, 2.5, and 3) Phr to a rubber recipe consisting of 30% natural rubber, 70% styrene-butadiene rubber. The recipe also contains a constant percentage of carbon black (51 Phr). The materials were mixed for (specific time) to ensure even distribution. Extensive testing has been conducted to ensure the cured rubber meets performance standards, including evaluations of tensile strength, tear propagation, wear resistance, hardness, elasticity, and resistance to fatigue. The bush material excelled in friction resistance and long-term fatigue performance. Adding 0.6 phr Nano-Alumina further enhanced its elasticity, strength, tear resistance, and resilience. At 3 phr of Al2O3 increased Elongation, Hardness, and Fatigue resistance value.

Effect of nanoparticles reinforcement of silicon dioxide derived from prosopis juliflora on Silver-Grey magnesium nanocomposite: utilization of silicon dioxide mechanical and tribological properties

Abstract The automotive and aviation industries require lightweight materials to enhance working efficiency. Composites combine materials such as aluminium, magnesium, titanium, steel, and copper with various forms of reinforcements to offer lightweight alternatives for a range of applications. The present investigation aims to fabricate a Silver-Grey Magnesium (Mg-25%Si) alloy-based nanocomposite with silicon dioxide (SiO2) nano reinforcement at weight % of 0, 3.25, 6.5 and 9.75 utilizing the two step stir casting method. Prosopis juliflora is utilized in the production of different weight percentages of SiO2 nano reinforcements. The microhardness, tensile, wear, and impact tests are performed on the Silver-Grey Magnesium nanocomposites (Mg-25%Si/SiO2) utilizing a computerized tensometer testing machine, a Vicker’s hardness tester, a pin-on-disc tribometer, and an Izod impact, respectively. The x-ray diffraction (XRD), Field Emission Scanning Electron Microscope (FESEM), and Energy-dispersive x-ray spectroscopy (EDAX) with elemental mapping microstructure were employed to scrutinize the tensile specimen fracture, EDAX, elemental mapping microstructure, wear, CoF, and worn surface characterization and impact strength analysis. When compared to the Silver-Grey Magnesium (Mg-25%Si) base alloy, the results of the Mg-25%Si/SiO2 nanocomposites demonstrated an increase in SiO2 nano reinforcements that significantly increased microhardness, tensile strength, wear resistance, and impact strength. The corresponding values are 113.36 VHN, yield and ultimate tensile strength of 603.25 MPa and 665.84 MPa, 0.00478 mm3 m−1, CoF of 0.38421 and 400 J m−1.

Preparation and performances of conductive, wear-resistant, and anti-corrosion coatings based on low content monodisperse SWCNTs

Single-walled carbon nanotubes (SWCNTs) are considered an ideal candidate material for multifunctional coatings because of their excellent electrical, thermal and mechanical properties. However, achieving uniform dispersion of SWCNTs while maintaining their structure and performance remains a significant challenge. The monodisperse SWCNTs (m-SWCNTs) can be obtained using a non-covalent PVP dispersant under the graded homogenization method. PVP acted as steric hindrance due to the π-π conjugate, thereby hindering the agglomeration and preventing the damage of SWCNTs. We incorporate low amounts of m-SWCNTs into fluorocarbon (FC) coatings to fabricate m-SWCNTs/FC composite coatings. We also investigate the effect of m-SWCNTs content on the electrical conductivity, corrosion resistance and wear resistance of the composite coating. Our results indicate that when the content of m-SWCNTs reaches at 0.25 wt%, the electrical resistivity of the m-SWCNTs/FC composite coating is 1.67 × 10−2 Ωm, significantly decreased by 9 orders of magnitude compared to FC coating. The conductive network would be formed by the high aspect ratio and non-damaged of m-SWCNTs to improve the conductivity. Additionally, the wear rate containing 0.15 wt% m-SWCNTs decreased by 50.1 % due to the improved strength and heat conduction to inhibit the adhesive wear. Furthermore, in comparison to bare steel, the corrosion current density of 0.15 wt% m-SWCNTs/FC composite coating is reduced by two orders of magnitude due to zigzag the corrosive path. Our studies suggest that the m-SWCNTs/FC composite coatings have a broad prospect in preparing large-scale, high-performance, and low-cost functional coatings.

Comprehensive evaluation of corrosion resistance and biocompatibility of ultrafine-grained TiMoNb alloy for dental implants

To address the limited wear resistance observed in traditional titanium alloys, we have developed an ultrafine-grained equiatomic TiMoNb compositionally complex alloy (CCA) with exceptional wear resistance. However, there is a significant lack of in vitro and in vivo evaluation of the TiMoNb CCA for biomedical applications. In this study, we comprehensively evaluate the corrosion behavior, tribo-corrosion performance, biocompatibility, and osseointegration of the TiMoNb alloy. Our findings indicate that the alloy exhibits strong corrosion resistance and stable tribo-corrosion behavior, attributed to the presence of Ti-rich nanoscale precipitates that impede tribo-corrosion-induced shear deformation, along with a protective nanoscale oxide layer. Furthermore, in vitro and in vivo evaluations demonstrate the excellent biocompatibility of the TiMoNb alloy and reveal its ability to promote the regeneration of defective femurs and its favorable bone osseointegration capability. Overall, our study underscores the potential of the TiMoNb alloy as a promising material for dental implants and provides valuable insights into the tribo-corrosion mechanisms of ultrafine-grained alloys.

Improving thermal shock and oxidation resistance of Cr3C2/WC-NiCr cermet coating by embedding large NiCrAlY superalloy particles

Cr3C2/WC-based cermet coating is widely used on the surface of mechanical equipment to strengthen its wear and corrosion resistance. Improving the high-temperature performance of cermet coating is the key to its industrial application. In this study, a novel type of bimodal microstructure cermet coating with the design of functional sites was fabricated via high-velocity air fuel (HVAF) spray technology. The toughness NiCrAlY superalloy particles are introduced into the traditional Cr3C2/WC-NiCr cermet structure to construct the thermal stress release site, which significantly improved the thermal shock resistance and thermal oxidation properties of the coating. The addition of NiCrAlY superalloy particle reduces the porosity of Cr3C2/WC-NiCr coating to 0.29 % and creates high-quality interface bonding and surface passivation layer. The newly structured cermet coating exhibits outstanding high-temperature performance. In a 1000 °C oxidation environment, the new coating remained intact after 120 h of exposure, while the traditional Cr3C2/WC-NiCr cermet coating exfoliated completely after 48 h of exposure. Further, in the thermal shock condition at 1000 °C, the lifetime of the new coating is 50 times greater than that of the traditional cermet coating, displaying excellent ability to relieve thermal stress. Additionally, the new coating shows good wear resistance and stability during high-temperature thermal exposure. After thermal exposure for 24 h and 72 h, the wear rates of the coating are 5.28 and 5.83 × 10−5 mm3 N−1 m−1, respectively, which is slightly lower than that of the as-sprayed coating. This study provides guidance for the improvement of high temperature resistance of thermally sprayed Cr3C2/WC-based cermet coatings.

Copper-Nickel/SiC composites for applications on contact electrodes

Novel copper-nickel matrix composites reinforced with silicon carbide (SiC) micro particles for metal contact applications were manufactured by powder metallurgy technology and were experimentally characterized. Cu and Cu alloys are commonly used as metal contact for either vacuum, oil, or SF6 in low-voltage circuit breaker devices, but their application in environments with the presence of oxygen is limited due to their tendency to form high-resistance copper oxides. Thus, the addition of Ni as an alloying element provides resistance to both humidity and several corrosive environments and increases the composites' hardness, mechanical strength, and wear resistance. Moreover, SiC was chosen due to its contribution to mechanical strength, mouldability, low production cost, and non-reactive nature at ordinary temperatures. Here, three SiC particle size distributions were considered, and it was found that the composites' physical properties are also dependent on the ceramic loading. After evaluating these properties, two specific SiC concentrations were potentially considered for electrode applications: 10 wt% and 20 wt%. The obtained hardness values are in the range of 55 – 65 HR30T which guarantees the necessary strength without detriment of the contact area whereas the welding is minimized. In addition to a homogeneous particle distribution in the solid material, specific wear resistance of ∼10-5 mm3N-1m-1 and electrical conductivities of ∼20 %IACS were obtained. Considering these parameters, Cu-Ni/SiC composites' performance is not compromised compared to commercial Ag/WC materials commonly used in metal contact applications.

Open-structured silica network based on silane-terminated telechelic polybutadiene for electric vehicle tires

The shift towards electric vehicles (EVs) is essential for a sustainable future. Tire manufacturers face challenges including accommodating extra weight, managing instant torque, reducing noise, and improving driving range. Meeting these demands involves substantially reducing the rolling resistance of tire tread composites while simultaneously enhancing their mechanical stiffness and wear resistance. To overcome these issues, an open-structured silica network based on silane-terminated liquid-like telechelic polybutadienes was introduced into rubber composites. This unique network consists of silica aggregates that are chemically bound together, but exhibit physical separation, enabling rubber chains to permeate. The infiltrated polymer chains were tightly constrained by the network, resulting in a notable increase in the crosslink density and mechanical strength of the composite. Furthermore, the tan δ values at 60 °C showed a notable decrease as a result of diminished interparticle friction caused by isolated silica structures and reduced mobility of polymer chains within the network. These findings provide the tire industry with crucial insights for the development of energy-efficient and durable tires for EVs. By addressing these specific requirements of EVs, our study paves the way for more sustainable tires and contributes to the broader adoption of EVs in a sustainable future.

Achievement of comprehensive wear and thermal property of cold spayed CuCrZr coating via gradient structure design

To address the inherent challenge of optimizing both strength and conductivity of the CuCrZr alloy, cold spraying is employed to enhance its surface with a comprehensive range of performance attributes. A novel gradient structure, featuring a SiC/CuCrZr layer at the top and an AlN/CuCrZr layer at the bottom, successfully fulfills the comprehensive requirements for wear resistance and thermal conductivity. Results show that the composite coating is composed of extensively deformed CuCrZr particles and undeformed ceramic particles and its microhardness and thermal conductivity closely adhere to the rule of mixtures. Additionally, the gradient coating shows the equivalent wear resistance to the SiC-CuCrZr coating. This study demonstrates the remarkable versatility of cold spraying in fabricating seamless gradient coating, while achieving predictable and controllable variations in microhardness and thermal conductivity across the coating’s thickness.

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.

Review on Nickel Nitride Composite Coatings

Abstract Nickel based composite coating has been widely used in many field applications such as wear and corrosion resistance since it is possible to improve its properties by depositing a variety reinforcement and process parameters. In this work, a variety of reinforced nitride particles such as TiN, AlN and Si were used to enhance the microstructure, mechanical and oxidation properties of nickel nitride composite coating in improving the coating density and surface morphology. The electrodeposition method was used to develop the composite coating with variety process parameters including temperature and current density. The coating stress was calculated from crystal structure data to investigate its involvement in the mechanical properties of coatings. The high temperature oxidation behavior of nickel nitride composite coatings was studied by heating process. The review highlights the reinforced nitride particles and process parameters improve the hardness and wear resistance of nickel based composite coating, however, the improvement also involves the coating stress. From study result of high temperature oxidation process, it obtained that the aluminum oxide remains within the coating indicating its role play in protecting substrate from corrosion. Experimental study on surface modification and microstructure of nickel based composite coating are highly expected and meet a great challenge for different applications with superior mechanical and tribological properties.

Synthesis and Purification of Nano-sized Titanium Carbide Particles through Vacuum Carbothermal Reduction for enhanced Mechanical, Microstructural Morphology, and Tribological Properties in Friction Stir Processed A356-based Aluminum Composites

This study focused on the synthesis and purification of nano-sized titanium carbide (TiC) particles through vacuum carbothermal reduction under a hydrogen/argon atmosphere. The process involved the production of carbon-coated titanium precursors, followed by heating under vacuum conditions at 1500°C for 2.5 hours. The resulting products underwent additional treatment in either a hydrogen/argon (1:1) mixed gas or pure hydrogen gas. Experimental findings revealed that TiC powders exhibiting a single phase are obtained within a molar ratio of Ti to C ranging from 1:2 to 1:4. Adjusting the molar ratio of Ti/C in the precursors allowed for controlled variation in the particle size of the synthesized TiC powders, ranging from 50 to 80 nm. Treatment in hydrogen/argon mixed gas at 850°C for 3 hours resulted in TiC products with an impressive purity of 99.40%. The subsequent incorporation of 5% Nano-TiC-3 (Ti to C ranging from 1:3) as reinforcement into an aluminum alloy by Friction stir process technique demonstrated a remarkable 19.41% improvement in tensile strength, highlighting the efficacy of this specific reinforcement. The nano-TiC-3 reinforced composite exhibited uniform distribution without porosity. Additionally, a notable 50.81% improvement in hardness and the best wear resistance were observed for the 5% Nano-TiC-3 reinforced aluminum composite. This comprehensive study contributes valuable insights into the synthesis, purification, and application of nano-sized TiC particles, paving the way for the development of high-performance aluminum-based composites with enhanced mechanical and tribological properties.

Low-Frequency Magnetic Incremental Permeability for the Non-destructive Evaluation of Hardness Profile After Carburization Treatment with Large Case Hardening Depth

Carburization treatment with large case hardening depth is a technical process to enhance steel parts' surface hardness and wear resistance. Accurate evaluation of this metallurgical treatment is crucial to prevent critical mechanical failures. Low-frequency magnetic incremental permeability (LF-MIP) emerges as a non-destructive surface technique well-suited for this purpose in the case of ferromagnetic parts. Although correlations between magnetic indicators obtained through LF-MIP characterization and deep carburization treatment have been demonstrated, they remain qualitative. In this study, we propose an innovative method to assess the entire hardness profile based on LF-MIP characterization. Experimental results and simulation data are integrated into a reference chart used for post-processing, enabling the prediction of hardness profiles for specimens in a blind test. With a relative Euclidean distance of less than 6% between the method's predictions and destructive tests conducted on specimens treated with medium, deep, and intense intensities, we consider the method validated.

Friction and wear characteristics of DLC-terminated coatings deposited on AlSi10Mg alloy produced by Additive Manufacturing

Al–Si alloys are attractive materials for the fabrication of mechanical components, mainly because of their high strength-to-density ratio. Though the advent of Selective Laser Melting (SLM) has potentially expanded the range of their applicability, their poor tribological performances limit their effective use. Identifying post-processing protocols and coating strategies enhancing these properties and compatible with large-scale production is fundamental to the industrial uptake of SLM-fabricated Al–Si parts. This work tests the possibility of depositing self-lubricating Diamond-Like Carbon (DLC)-terminated films on AlSi10Mg built by SLM and subjected to different surface finishing processes. The applied coating architectures consist of an electroless nickel‐phosphorus buffer layer deposited on the AlSi10Mg surface, plus a series of interlayers and a DLC top film grown by Plasma Assisted – Chemical Vapor Deposition. The wear resistance and frictional behavior of the samples are evaluated for different substrate pre-treatments and coating assemblies under two applied loads. Cast substrates, processed and coated in a similar way, are also studied for comparison. The DLC film lends good tribological performances to all the coating-substrate combinations explored, being mechanically assisted by the underlying Ni–P layer. The friction coefficients stabilize around 0.20 at the lowest load, independently of the sample surface roughness (Sq), which spans the range 0.47–4.6 μm. Conversely, the counterpart wear rates increase with roughness up to 10−5 mm3/(N⋅m). Both tribological parameters decrease by nearly 20 % and 70 %, respectively, after a tenfold increase in load. These results indicate that DLC-terminated multilayers are extremely efficient on AlSi10Mg even in the presence of significant roughness. Their application requires a limited number of well-established processing steps also in the case of SLM grown parts.