<p>Micro-arc oxidation (MAO) is established as a leading surface protective technique for improving the wear resistance of aluminum alloys. This review focuses on the influences of electrical parameters, electrolyte composition, pre- or post-treatments, and service environments including dry and lubricated sliding, elevated temperatures, fretting, and tribo-corrosion on the tribological performance of aluminum alloy-based MAO coatings. Prior to summarizing the prevailing wear mechanisms, correlations among processing conditions, coating microstructures, and wear behavior were compared quantitatively. MAO coatings can enhance the surface hardness of the substrate by approximately 100–200%. Through electrolyte design, nanoparticle incorporation, and tailored pre- or post-treatments, the coefficient of friction under dry sliding conditions could be lowered from 0.5–0.8 to 0.1–0.3 while wear rates are reduced by one to two orders of magnitude. Additionally, special consideration is given to the effect of coating porosity, the integrity of the dense inner layer, and the role of composite or sealed structures in determining durability under complex loading conditions. Current limitations related to inherent porosity, scalable processing, and energy consumption are evaluated. Finally, emerging developments in intelligent manufacturing, energy-efficient MAO technologies, and multifunctional coatings are proposed. This review seeks to establish a quantitative, mechanism-oriented foundation for designing high-performance MAO coatings and to facilitate their expanded industrial adoption.</p>

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Wear properties of micro-arc oxidation coatings on aluminum alloys

  • Chengxi Wang,
  • Hanqing Ni,
  • Vincent Ji,
  • Jilin Lei,
  • Wei Deng,
  • Peng Song,
  • Taihong Huang,
  • Xiaowei Zhang

摘要

Micro-arc oxidation (MAO) is established as a leading surface protective technique for improving the wear resistance of aluminum alloys. This review focuses on the influences of electrical parameters, electrolyte composition, pre- or post-treatments, and service environments including dry and lubricated sliding, elevated temperatures, fretting, and tribo-corrosion on the tribological performance of aluminum alloy-based MAO coatings. Prior to summarizing the prevailing wear mechanisms, correlations among processing conditions, coating microstructures, and wear behavior were compared quantitatively. MAO coatings can enhance the surface hardness of the substrate by approximately 100–200%. Through electrolyte design, nanoparticle incorporation, and tailored pre- or post-treatments, the coefficient of friction under dry sliding conditions could be lowered from 0.5–0.8 to 0.1–0.3 while wear rates are reduced by one to two orders of magnitude. Additionally, special consideration is given to the effect of coating porosity, the integrity of the dense inner layer, and the role of composite or sealed structures in determining durability under complex loading conditions. Current limitations related to inherent porosity, scalable processing, and energy consumption are evaluated. Finally, emerging developments in intelligent manufacturing, energy-efficient MAO technologies, and multifunctional coatings are proposed. This review seeks to establish a quantitative, mechanism-oriented foundation for designing high-performance MAO coatings and to facilitate their expanded industrial adoption.