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Improving Tribological Properties of Cast Al-Si Alloys through Application of Wear-Resistant Thermal Spray Coatings

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Abstract

Flame Spray Thermal Spray coatings are low-cost, high-wear surface-treatment technologies. However, little has been reported on their potential effects on cast automotive aluminum alloys. The aim of this research was to investigate the tribological properties of as-sprayed NiCrBSi and WC/12Co Flame Spray coatings applied to two cast aluminum alloys: high-copper LM24 (AlSi8Cu3Fe), and low-copper LM25 (AlSi7Mg). Potential interactions between the mechanical properties of the substrate and the deposited coatings were deemed to be significant. Microstructural, microhardness, friction, and wear (pin-on-disk, microabrasion, Taber abrasion, etc.) results are reported, and the performance differences between coatings on the different substrates were noted. The coefficient of friction was reduced from 0.69-0.72 to 0.12-0.35. Wear (pin-on-disk) was reduced by a factor of 103-104, which was related to the high surface roughness of the coatings. Microabrasion wear was dependent on coating hardness and applied load. Taber abrasion results showed a strong dependency on the substrate, coating morphology, and homogeneity.

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Acknowledgments

The authors would like to thank Enterprise Ireland and the Dublin Institute of Technology for the opportunity to perform this study. In addition, the authors would like to thank the following persons for their assistance in this study: Prof. J. Gomes, Dept. de Engenharia Mecânica, Campus de Azurém, 4800-058 Guimarães, Portugal; Dr. E. Mihaylova, Centre for Industrial and Engineering Optics, Dublin Institute of Technology, Ireland; and Dr. S. Jerrams, Centre for Elastomer Research, Dublin Institute of Technology, Ireland.

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Authors and Affiliations

  1. Department of Mechanical Engineering, Dublin Institute of Technology, Bolton St, Dublin 1, Ireland

    David Culliton & David Kennedy

  2. College of Sciences and Health and Applied Electrochemistry Group, Dublin Institute of Technology, Kevin Street, Dublin 2, Ireland

    Anthony Betts

  3. Centro de Física, Universidade do Minho, Campus Azurém, 4800-058, Guimarães, Portugal

    Sandra Carvalho

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  1. David Culliton
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Correspondence to David Culliton.

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Culliton, D., Betts, A., Carvalho, S. et al. Improving Tribological Properties of Cast Al-Si Alloys through Application of Wear-Resistant Thermal Spray Coatings. J Therm Spray Tech 22, 491–501 (2013). https://doi.org/10.1007/s11666-013-9894-y

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