Enhancing Wear Resistance of EN-19 Steel with Physical Vapor Deposition (PVD) Coatings: Experimental and Statistical Analysis

To increase the durability of automobile components, this study investigates the wear behavior of EN-19 steel under various tribological environments, both with and without protective coatings. Physical vapor deposition (PVD) was used to produce the AlTiN and AlCrN coatings, which were then tested utilizing ball-on-disc studies at various loads, sliding velocities, and time durations. According to the results, AlCrN performed best, with coated specimens showing a considerable decrease in wear loss, while uncoated samples suffered the most wear. Coating type and time were found to be the primary determinants of wear, as determined by statistical analysis using the Box-Cox transformation, whereas load and velocity had secondary effects. Using contour and residual plots, regression modeling (λ = 0.7) produced accurate predictions. Compared with uncoated steel, AlCrN reduced overall wear by up to 55%, demonstrating its suitability for applications such as CV joints. The results demonstrate the significance of specific coatings in enhancing wear resistance and prolonging the useful life of engineering components.