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<p>Friction and wear remain critical challenges in engineering applications by leading to mechanical component failure and energy loss. Surface texturing has emerged as an effective strategy for regulating the tribological properties of materials. In this study, a Ni60 alloy coating was fabricated on a ZL109 substrate by plasma spray. The coating exhibited an average microhardness of 754.2 HV<sub>0.2</sub>, approximately nine times higher than that of the substrate, primarily due to the synergistic strengthening of an amorphous phase along with hard phases such as Cr<sub>7</sub>C<sub>3</sub> and Cr<sub>23</sub>C<sub>6</sub>. To determine the optimal texture morphology, a finite element model was established to compare stress distributions among circular, triangular, square, and linear-groove micro-textures under friction loadings. The circular texture exhibited superior stress dispersion capability due to its continuous curvature, showing the smallest total deformation at 2.92 × 10<sup>–4</sup>&#xa0;mm, and was therefore selected for further investigation. Based on this, circular dimple textures with aspect ratios of 0.1, 0.2, 0.3, and 0.4 were fabricated via laser processing. Molecular dynamics simulations were employed to reveal the atomic scale mechanisms governing texture-dependent wear behavior. Tribological experiments were conducted using a UMT-5 friction tester under dry (10 N, 3&#xa0;Hz) and oil-lubricated conditions (100 N, 5&#xa0;Hz). Results show that the texture with an aspect ratio of 0.2 exhibits optimal tribological performance under both conditions. Under dry friction, it effectively traps wear debris and relieves contact stress, resulting in a low and stable friction coefficient. MD simulations further confirm the atomic accumulation and limited shear-strain localization. Under oil lubrication, the texture enhances lubricant retention and film stability, achieving a minimum friction coefficient of 0.093 ± 0.003 and a wear depth of 9.2 ± 0.7&#xa0;μm. Analysis of the wear mechanisms indicates that dry friction is dominated by oxidative-abrasive wear, whereas oil-lubricated conditions involve adhesive wear coupled with mild abrasive wear mediated by third-body particles.</p>

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Synergistic regulation of laser surface texture aspect ratio on wear resistance of nickel-based alloy coatings through simulation and experimental study

  • 期刊论文

  • 发表日期：

    2026年7月24日

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  • Bingyuan Han,
  • Mengna Zhao,
  • Qingwei Huang,
  • Hao Huang,
  • Yonglin Zhao,
  • Shuying Chen

摘要

Friction and wear remain critical challenges in engineering applications by leading to mechanical component failure and energy loss. Surface texturing has emerged as an effective strategy for regulating the tribological properties of materials. In this study, a Ni60 alloy coating was fabricated on a ZL109 substrate by plasma spray. The coating exhibited an average microhardness of 754.2 HV0.2, approximately nine times higher than that of the substrate, primarily due to the synergistic strengthening of an amorphous phase along with hard phases such as Cr7C3 and Cr23C6. To determine the optimal texture morphology, a finite element model was established to compare stress distributions among circular, triangular, square, and linear-groove micro-textures under friction loadings. The circular texture exhibited superior stress dispersion capability due to its continuous curvature, showing the smallest total deformation at 2.92 × 10–4 mm, and was therefore selected for further investigation. Based on this, circular dimple textures with aspect ratios of 0.1, 0.2, 0.3, and 0.4 were fabricated via laser processing. Molecular dynamics simulations were employed to reveal the atomic scale mechanisms governing texture-dependent wear behavior. Tribological experiments were conducted using a UMT-5 friction tester under dry (10 N, 3 Hz) and oil-lubricated conditions (100 N, 5 Hz). Results show that the texture with an aspect ratio of 0.2 exhibits optimal tribological performance under both conditions. Under dry friction, it effectively traps wear debris and relieves contact stress, resulting in a low and stable friction coefficient. MD simulations further confirm the atomic accumulation and limited shear-strain localization. Under oil lubrication, the texture enhances lubricant retention and film stability, achieving a minimum friction coefficient of 0.093 ± 0.003 and a wear depth of 9.2 ± 0.7 μm. Analysis of the wear mechanisms indicates that dry friction is dominated by oxidative-abrasive wear, whereas oil-lubricated conditions involve adhesive wear coupled with mild abrasive wear mediated by third-body particles.