Influence of low-temperature pack aluminizing on the wear behavior of Ti-6Al-4V alloy using the Taguchi method

Ti-6Al-4V, a two-phase α + β titanium alloy composed of 6% aluminum and 4% vanadium, is known for its exceptional strength, toughness, corrosion resistance, and biocompatibility, making it a superior and preferred material in automotive, biomedical, and aerospace applications. However, its wear resistance limits its broader use in particular demanding environments such as engine valve applications. In this study, aluminide coatings were applied to Ti-6Al-4V through pack cementation at 600°C and 800°C for 6 h, resulting in durable coatings that enhance wear resistance. The wear behavior of aluminized Ti-6Al-4V was evaluated using a reciprocating ball-on-flat test setup under discretely selected loads and sliding speeds, with a total sliding distance of 60 m. A full factorial experimental design was employed to investigate the effects of coating temperature, load, and sliding speed on the wear rate. Statistical analysis revealed that the optimal condition for minimizing the wear rate was a coating temperature of 800°C, a load of 7.5 N, and a sliding speed of 30 mm/s. Among the factors examined, the sliding speed exerted the most significant influence on the wear rate. These findings provide valuable insights into the wear behavior of aluminized Ti-6Al-4V and underscore the importance of surface treatment parameters in optimizing its tribological performance.