Surface characteristics underpinning fretting wear performance of heavily loaded duplex chameleon/PEO coatings on Al

Lin, M, Nemcova, A, Voevodin, AA, Korenyi-Both, A, Liskiewicz, TW ORCID: https://orcid.org/0000-0002-0866-814X, Laugel, N, Matthews, A and Yerokhin, A (2021) Surface characteristics underpinning fretting wear performance of heavily loaded duplex chameleon/PEO coatings on Al. Tribology International, 154. 106723. ISSN 0301-679X

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Abstract

© 2020 Elsevier Ltd Duplex coatings comprising MoS2/Sb2O3/graphite layer burnished on top of plasma electrolytically oxidised AA6082 alloy enhanced fretting wear resistance against alumina and steel whilst reducing friction from ~0.6 … 0.9 to ~0.08 … 0.1 in dry nitrogen and humid air. Transitions to stick-slip (~3 μm), partial slip (5–10 μm) and gross slip (>10 μm) showed an order of magnitude improvements over single-layer PEO coatings. In the latter mode, high initial contact pressures (~1.1 GPa) with steel counterpart under oxidising atmosphere increased friction due to generation of Fe/Al/Cr oxides/hydroxides in the contact region, leading micro-cracking in PEO coating followed by fatigue damage of aluminium substrate. Reducing contact pressure <1 GPa, retained topcoat lubricating behaviour, high wear resistance and eliminated fatigue damage after 104 cycles.