Fretting wear behavior of aluminum coatings

The aluminum bronze coating is a type of soft solid lubricant film with excellent performance. In this work, to improve the wear resistance and tribological behavior of the aluminum alloy, the aluminum bronze coatings were prepared on aluminum alloy substrates using the High- Velocity Oxygen Fuel (HVOF) system. Fretting wear tests were performed on the coatings at 200 °C with different frequencies to analyze the wear behavior. The worn surface was characterized by scanning electron microscope (SEM) and X-ray photoelectron spectroscopy (XPS). The results showed that as the frequency increased from 5 Hz to 15 Hz, the coefficient of friction increased from 0.653 to 0.929. It then decreased to 0.890 at 20 Hz. There was an overall trend of the coefficient of friction increasing and then decreasing. The worn surface’s morphology changed from pits to bulges. At a low frequency, the wear mechanism was abrasive wear with delamination. As the frequency increased, adhesive wear was observed and gradually became the dominant wear form. Oxidation occurred on the surface of the worn tracks caused by the high temperature and thermal effect of high-frequency micromotion. Due to the intensification of the oxidation phenomenon, oxidation films formed on the worn surface. The wear rate of the coating was significantly reduced. The oxide was identified as mainly CuO and Cu2O. The presented results confirmed that the aluminum bronze coating fabricated via HVOF exhibited a great resistance performance even at a high frequency.