Finite Element Analysis of Dry Friction Wear of Al-based Composite Coatings

doi:10.11901/1005.3093.2023.620

Chinese Journal of Materials Research

2024, Vol. 38

Issue (12): 941-949 DOI: 10.11901/1005.3093.2023.620

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Finite Element Analysis of Dry Friction Wear of Al-based Composite Coatings

WANG Huiming¹, WANG Jinlong¹, LI Yingju², ZHANG Hongyi³, LV Xiaoren¹(

)

1 College of Mechanical Engineering, Shenyang University of Technology, Shenyang 110870, China
2 Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110179, China
3 Shenyang Aerospace Mitsubishi Motors Automobile Engine Manufacturing Co., Ltd., Shenyang 110179, China

Cite this article:

WANG Huiming, WANG Jinlong, LI Yingju, ZHANG Hongyi, LV Xiaoren. Finite Element Analysis of Dry Friction Wear of Al-based Composite Coatings. Chinese Journal of Materials Research, 2024, 38(12): 941-949.

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Abstract

Al-based composite coatings with different Al₂O₃ contents (0%, 15%, 30%, 45%) were prepared on AZ91 Mg-alloy substrate by cold spraying technique, the deposition efficiency of Al₂O₃ and the porosity of the coatings were measured, and their reciprocating dry friction wear performance was examined in terms of wear gouge volume. Meanwhile, the effect of Al₂O₃ content, the applied load, and frequency on the friction and wear behavior of Al-based composite coatings were investigated. A finite element model of the Al-based composite coating was established, and the simulated values of the finite element wear volume were obtained by using the friction and wear subroutine (UMESHMOTION) embedded with the Archard model, which then were compared with those acquired from the friction and wear experiments. The results show that with the increasing Al₂O₃ content, the porosity of the composite coatings decreases, while the deposition efficiency of Al₂O₃ particles, and thereby the wear resistance of coatings increases. The simulated value of the finite element wear calculated by the model under this condition is 0.0249 mm³ for the coating with 15% Al₂O₃with a difference of 5.9574% compared to that acquired from the wear experiments, indicating the universality of the proposed model.

Key words: surface and interface in the materials magnesium alloy cold spray coating friction and wear FEA

Received: 28 December 2023

ZTFLH:

TH117

Fund: National Defense Science and Technology Key Laboratory Fund(JCKY61420052021)

Corresponding Authors: LV Xiaoren, Tel: 13504077230, E-mail: xrlvsut@126.com

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	WANG Huiming
	WANG Jinlong
	LI Yingju
	ZHANG Hongyi
	LV Xiaoren

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https://www.cjmr.org/EN/10.11901/1005.3093.2023.620 OR https://www.cjmr.org/EN/Y2024/V38/I12/941

Table 1 Chemical composition of AZ91 magnesium alloy (mass fraction, %)

Table 2 Processing parameters of cold spray

Fig.1 Wear simulation flow chart

Fig.2 SOLIDWORKS 3D solid model of reciprocating dry friction wear

Fig.3 Al-based composite coating model (a) 0% Al₂O₃; (b) 15% Al₂O₃; (c) 30% Al₂O₃; (d) 45% Al₂O₃

Table 3 Model material properties

Fig.4 AlE grid area

Fig.5 Al-based composite coating porosity

Fig.6 Composite coating Al₂O₃ deposition efficiency

Table 4 Friction coefficient of AZ91 magnesium alloy substrate and cold spray coating changes with load and frequency

Table 5 Wear amount of AZ91 magnesium alloy and its Al-based composite coating changes with load and frequency (mm³)

Table 6 Friction coefficient (K) under 2 N and 1 Hz operating conditions

Fig.7 Increased wear resistance of Al-based composite coatings compared to AZ91 matrix

Fig.8 Photos of wear scars of AZ91 magnesium alloy and Al-based composite coating at 10N and 1 Hz

Table 7 Grid-independent verification

Fig.9 Finite element simulation cloud of wear depth of Al-based composite coatings with different Al₂O₃ powder contents(a) 0% Al₂O₃; (b) 30% Al₂O₃; (c) 45% Al₂O₃

Table 8 Simulated and experimental values of wear amount of Al-based composite coatings with Al₂O₃ content of 0%, 30%, and 45% and their errors

Fig.10 Wear depth simulation cloud chart of 15% Al₂O₃ Al-based composite coating

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