Effects of nanoceramic particle size and content on the wear resistance of micro-arc oxidation coatings for 2A12 aluminum alloy

The 2A12 aluminum alloy, renowned for its exceptional mechanical properties, encounters significant limitations in applications involving abrasive environments or frequent contact with other surfaces due to its inadequate wear resistance. This shortcoming substantially reduces the service life of components and escalate maintenance costs, highlighting the urgent need for advanced surface modification techniques. This study meticulously investigates the influence of nanoceramic particle size and content on the wear resistance of micro-arc oxidation (MAO) coatings, a surface modification technique renowned for forming dense, adherent ceramic layers on aluminum alloys. The systematic experimentation revealed that the incorporation of 150 nm α-Al₂O₃ nanoparticles into the MAO matrix achieves an optimal dispersion, leading to a substantial enhancement in wear resistance. The sample with a 5 g/L concentration of 150 nm α-Al₂O₃ nanoparticles doping in the MAO electrolyte demonstrated the lowest mass loss, underscoring its enhanced wear resistance. The enhanced microstructure, enriched with hard ceramic phases such as α-Al₂O₃ and mullite, plays a pivotal role in withstanding wear. Moreover, this study identified that an optimal balance of surface roughness and coating thickness is essential for achieving enhanced wear resistance. The findings of this research provide a strategy for the design of wear-resistant coatings tailored for high-performance applications across aerospace, automotive, and general engineering industries. By optimizing the particle size and concentration in MAO coatings, this study paves the way for the development of durable materials capable of thriving in demanding environments, thereby extending the service life and reducing maintenance requirements of components.