Development of a wear resistant coating for aluminium

Funding: DFG

Duration: 07/24-03/27

Abstract:

The aim of this research project is to investigate a wear resistant coating for lightweight materials and to develop process parameters for safe and efficient processing of the coating.

The implementation of resource and energy efficiency requirements poses new challenges to existing material systems due to the need for lightweight construction in the context of the energy and mobility transition, as lightweight materials such as aluminium and titanium are increasingly being used. In many cases, the use of these lightweight materials is made impossible by wear attack in technical systems, as lightweight materials generally have very poor wear resistance.

A coating with an iron aluminide alloy could compensate for this disadvantage. Iron aluminides, which have very good wear resistance and are metallurgically very compatible with aluminium alloys, have a high potential to provide the required wear protection.

In addition, aluminides also show positive properties in areas such as heat resistance and are also of interest as a coating material against wear at high temperatures.

However, there is currently a considerable need for research in the area of processability and chemical composition in order to achieve sufficient toughness for safe process control and at the same time maintain wear resistance to various types of wear.

Firstly, the elements and their contents that positively influence the properties of the iron aluminide based alloy need to be determined.

A temperature control strategy for the component to be coated is also required. This means the temperature to which the component must be preheated and the conditions that must prevail during cooling in order for the coating to achieve the desired properties.

The interactions between the base material and the coating must also be considered.

The developed coating is characterised by a series of wear resistance tests.

The optimum coating is found when its wear properties are comparable to those of Stellite 12.