Wear behaviour of ceramic coating (Al₂O₃-40%TiO₂) in dry condition for automotive applications

The objective of the current research is to examine the effect of varying loads on the wear behaviour of Al 2 O 3 -40%TiO 2 ceramic coating deposited by flame spray process and to improve material functionality and increase lifecycle in a cost-effective method. To assess the wear behaviour of the deposition, wear test was conducted using a Pin-on-disk tribometer in accordance with ASTM G99 standards. This test was designed to analyse the wear experienced by the coating in practical applications. Surface morphology was examined using field emission scanning electron microscope (FESEM) and energy dispersion spectroscopy (EDS) technique while 3D-profilometer was utilised to further assess the surface roughness of the deposited coating. It was observed that specific wear rate of the deposition exhibited a decreasing trend with increasing load from 40 to 70 N and sliding velocity from 0.4 to 1 m/s. The lowest coefficient of friction was observed at 70 N and 1 m/s. Wear mechanism analysis revealed different types of wear, including abrasion, metal transfer, and brittle fracture, corresponding to the increasing load and sliding velocity. This study is significant for industries that require high-performance coatings for industries such as automotive, aerospace and manufacturing, where high-performance coatings are needed to withstand heavy loads and friction. The current research findings enhance wear resistance and reduce friction, helps manufacturers to adapt coating for specific operational requirements.