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<p>Integration of additive manufacturing with advanced surface engineering enables tailored mechanical and tribological properties. This study investigates atmospheric plasma-sprayed (APS) Al<sub>2</sub>O<sub>3</sub>–AlTi ceramic composite coatings on laser powder bed fusion (LPBF) Inconel 718. Coatings with 50:50, 60:40, and 70:30 weight ratios (Al<sub>2</sub>O<sub>3</sub>:AlTi) were evaluated for microhardness, wear resistance, and microstructural integrity. The 60:40 composition exhibited the highest hardness of 1531.9 HV, representing a 268% increase over the uncoated substrate 416.4 HV. Dry sliding pin-on-disc wear tests showed that 60:40 coating achieved the lowest normalized wear rate of 0.000963 mm<sup>3</sup>/m outperforming other coatings and the uncoated material. SEM and EDS analyses confirmed a well-bonded multilayer structure with minimal degradation in the optimized coating. Regression modelling using response surface methodology (<i>R</i><sup>2</sup> = 97.33%) revealed load and sliding distance as the dominant wear influencers. These findings highlight the effectiveness of Al<sub>2</sub>O<sub>3</sub>–AlTi coatings in improving the tribological performance of AM Inconel 718 for high-temperature applications</p>

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Enhanced mechanical and tribological performance of Al2O3–AlTi coated 3D printed Inconel 718

  • 期刊论文

  • 发表日期：

    2026年3月19日

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  • N Vinoth

摘要

Integration of additive manufacturing with advanced surface engineering enables tailored mechanical and tribological properties. This study investigates atmospheric plasma-sprayed (APS) Al2O3–AlTi ceramic composite coatings on laser powder bed fusion (LPBF) Inconel 718. Coatings with 50:50, 60:40, and 70:30 weight ratios (Al2O3:AlTi) were evaluated for microhardness, wear resistance, and microstructural integrity. The 60:40 composition exhibited the highest hardness of 1531.9 HV, representing a 268% increase over the uncoated substrate 416.4 HV. Dry sliding pin-on-disc wear tests showed that 60:40 coating achieved the lowest normalized wear rate of 0.000963 mm3/m outperforming other coatings and the uncoated material. SEM and EDS analyses confirmed a well-bonded multilayer structure with minimal degradation in the optimized coating. Regression modelling using response surface methodology (R2 = 97.33%) revealed load and sliding distance as the dominant wear influencers. These findings highlight the effectiveness of Al2O3–AlTi coatings in improving the tribological performance of AM Inconel 718 for high-temperature applications