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Thick ceramic coatings were fabricated by microarc oxidation on 2024 aluminum alloy in a silicate solution. The phase composition and microhardness in the coatings were determined. The unlubricated tribological performance of the coatings was investigated using a SRV ball-on-disc friction and wear test system with reciprocating motion against sintered WC ball. The typical worn surfaces of the Al substrate and the ceramic coatings were observed by a scanning electron microscope. Under the same wear condition, the wear rates in different depth coatings are nearly similar. However, in a same depth of the coatings, wear rate gradually decreases with wear duration, and the lowest wear rate is less than 3.29×10−7 mm3/N m. During friction process, a WC transfer layer was formed on the tribo-contact area of the coatings, which takes advantage of decreasing the wear rate. The friction coefficient in a steady friction stage is about 0.52. After the Al alloy is treated by microarc oxidation, its wear resistance is improved over three orders of magnitude. The high wear resistance of the microarc oxidation coatings results from a nearly perfect distribution of α-Al2O3 and γ-Al2O3 phases in the coating.

Tribological Behavior of Microarc Oxidation Coatings on Aluminum Alloy