Wear performance of composite dual-layer coated Al-12Si alloy: Effect of Al2Ce reinforcement and micro-arc oxidation

Kaba M., Cengiz S., Muhaffel F., Çimenoğlu H.

Materials Chemistry and Physics, vol.312, 2024 (SCI-Expanded) identifier

  • Publication Type: Article / Article
  • Volume: 312
  • Publication Date: 2024
  • Doi Number: 10.1016/j.matchemphys.2023.128633
  • Journal Name: Materials Chemistry and Physics
  • Journal Indexes: Science Citation Index Expanded (SCI-EXPANDED), Scopus, Academic Search Premier, Aerospace Database, Chemical Abstracts Core, Chimica, Communication Abstracts, Compendex, INSPEC, Metadex, Civil Engineering Abstracts
  • Keywords: Al matrix composite, Al-12Si, Al2Ce, Micro-arc oxidation, Wear
  • Istanbul Technical University Affiliated: Yes


An attempt has been made to enhance the wear resistance of Al-12Si alloy by forming a dual-layer coating consisting of an Al-12Si matrix composite layer (Al-12Si + ∼40 vol % Al2Ce) and an external composite oxide layer. While the hardness of monolithic Al-12Si alloy was ∼110 HV, the Al-12Si matrix composite layer has got hardness of ∼140 HV and exhibited ∼6 times higher sliding wear resistance due to the suppression of the plasticity-induced adhesive wear by Al2Ce particles. Applying micro-arc oxidation (MAO) as a post-treatment favoured an oxide layer (Al2O3) on the Al-12Si alloy and a composite oxide layer (CeO2 + Al2O3) on the Al-12Si matrix composite layer. The MAO coatings fabricated on the Al-12Si alloy and Al-12Si matrix composite layer, with hardness of ∼11 GPa and ∼13 GPa, respectively, provided more than two orders of magnitude increase in the wear resistance by shifting the wear mode to elasticity-dominated wear. However, the critical load imposing the complete detachment of the MAO coating by intense cracking and spallation during testing was determined as 3 N for the MAO'ed Al-12Si alloy and 5 N for the MAO'ed Al-12Si matrix composite layer. The wear resistance of the MAO coating of the Al-12Si matrix composite layer was ∼2 times higher than that of the MAO coating of the Al-12Si alloy below the critical test loads, where the coatings remain intact with the substrate.