INVESTIGATION OF THE WEAR-RESISTANCE CHARACTERISTICS OF ALUMINA-ZIRCONIA-TITANIA-COATED AL-6061 ALLOY FOR DIFFERENT PROCESSING PARAMETERS

A ceramic coating is applied to the combustion chambers of diesel engines to reduce the heat transmission from the in-cylinder to the engine cooling system. Al alloy 6061 has moderate thermal stability and strength, which may not withstand the extreme heat and mechanical stresses generated in diesel engines. This necessitates protective coatings to enhance its wear resistance and thermal performance. Due to its strength and light weight, aluminum alloy 6061 is frequently utilized in commercial applications in the building, transportation, and related technical fields. For better qualities, coating powder made of alumina (Al2O3), zirconia (ZrO2), and titanium dioxide (TiO2) is applied to the engine cylinder’s substrate. The specimens were coated using the plasma-spray method. To ensure strong adhesion, a 50-µm-thick bond coat of NiCrAlY was applied to the substrate before adding the top coat. The surface and cross-section of the specimens were analyzed using a Field-Emission Scanning Electron Microscope. X-ray diffraction analysis was performed to determine the structural and crystalline details. The performance of the coated specimens was then evaluated and compared to the uncoated ones. The specimen coated with a mixture of 35% Al2O3, 15% ZrO2, and 50% TiO2 demonstrated the best performance, with a wear rate of 0.03612 mm3/Nm and a coefficient of friction of 0.357. This ceramic coating formulation is suggested for automotive parts that need enhanced wear and thermal resistance to extend their service life