Investigation of wear characteristics of Ni-WC composite coating on AA6061 aluminium alloy deposited by TIG arc additive manufacturing process

Purpose This study aims to investigate the fabrication of high-performance Ni-WC composite coatings on AA6061 aluminium alloy using tungsten inert gas (TIG)-arc additive manufacturing combined with nickel (Ni) and tungsten carbide (WC). The main objective of this study is to enhance the surface properties of aluminium alloy AA6061, which is widely used in automotive and rail applications, but suffers from poor tribological properties. Design/methodology/approach The Ni-WC composite coating was developed on AA6061 aluminium alloy through a TIG cladding process. The micro-structure and phase analyses of the developed coated layer were conducted using scanning electron microscopy and X-ray diffraction. Mechanical and tribological performance was assessed using Vickers micro-hardness testing and pin-on-disc wear tests. Findings The Ni-WC composite coated layer exhibited uniform micro-structure, fine micro-cracks and well-dispersed WC particles, indicating rapid solidification and residual stress effects. The maximum micro-hardness of the Ni-WC cladded layer was 915 HV0.05, while the base material showed only 36 HV0.05. The lowest wear rate for the cladded layer was 7.28 × 10–8 g/N-m, whereas the substrate had wear rate of 92.67 × 10–8 g/N-m. Originality/value The results of this study demonstrate the effectiveness of TIG cladding for fabricating Ni-WC composite coatings to significantly improve the wear resistance and hardness of aluminium alloy AA6061. This study provides a cost-effective surface modification route suitable for high-friction engineering applications.