Effect of Al2O3 nanoparticles additions on wear resistance of plasma electrolytic oxidation coatings on TC4 alloys

To enhance the tribological properties of TC4 alloy, the plasma electrolytic oxidation (PEO) method was utilized to prepare the coating incorporated various contents of Al2O3 nanoparticles (0, 3, 6, 9, 12 and 15 g/L) on TC4 alloy. The phase composition, chemical compositions, elemental distribution and microstructure of the coatings were investigated by using X-ray diffraction (XRD), X-ray photoelectron spectroscopy (XPS), scanning electron microscopy (SEM) with energy dispersive spectroscopy (EDS) and X-ray computer tomography (XCT). The results revealed that the introduction of Al2O3 nanoparticles into the electrolyte promoted the formation of Al2TiO5 phase in the PEO coatings, and most of the nanoparticles were embedded into the coatings which reduced porosity of the coatings, but increased surface roughness. Also, the increase in the addition of Al2O3 nanoparticles enhanced the microhardness of the PEO coatings due to the formation of Al2TiO5. The tribological behavior of the PEO coatings was improved significantly owing to the high microhardness and porous structure of the coatings. The primary wear mechanism of the coating with 12 g/L Al2O3 nanoparticles was abrasive wear as this coating formed a lubrication zone during the wear process. Besides, the friction coefficient and wear loss mass of the PEO coating prepared with 12 g/L Al2O3 nanoparticles additive exhibited the excellent wear resistance compared to its counterparts.