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<p>This paper investigates the tribological performance of Zinc and Ethanol-based thermal spray coatings deposited on three different steel substrates: Sample A (Mild Steel), Sample B (Mn-steel alloy), and Sample C (Hadfield Steel) across coating thicknesses of 100–300&#xa0;μm. Under identical pin-on-disc testing conditions (30&#xa0;N, 500&#xa0;rpm), Zinc coatings exhibited a pronounced thickness-dependent rise in friction, with the Coefficient of friction increasing from 0.27 to 0.40 (a 48% increase) and a sensitivity of 0.00065 ΔCoefficient of friction/µm. Ethanol coatings, across all three samples, consistently showed lower friction values (0.20–0.21) with significantly reduced sensitivity (0.00030 Coefficient of friction /µm), ~ 54% lower than Zinc. Among the substrates, Sample A demonstrated the most stable frictional response, aligning with its lower hardness and smoother deformation behaviour, whereas Samples B and C showed higher variability due to increased hardness and work-hardening tendencies. Polynomial and SVR models achieved perfect predictive accuracy (R² = 1.000), and Ethanol coatings exhibited superior stability with a Friction Stability Index (FSI = 5.56 × 10⁶) nearly 10× higher than Zinc and a Tribological Efficiency Ratio (TER = 2.22 × 10⁷), ~ 14× greater. Extended predictions up to 500&#xa0;μm showed Zinc approaching saturation (peak Coefficient of friction ≈ 0.42), while Ethanol increased smoothly and linearly. Overall, across Samples A, B, and C, Ethanol coatings delivered lower friction, higher stability, reduced thickness sensitivity, and superior tribological efficiency, establishing them as a superior alternative to Zinc for diverse substrate applications.</p>

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Wear and coating performance analysis of zinc and ethanol on mild steel: thermal spray layers using experimental and machine learning approaches

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2026年5月20日

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  • Sridhar S. Jetty,
  • M. S. Vinay,
  • Saravana Bavan,
  • Y. P. Ravitej,
  • M. Rajanish,
  • H. L. Vinayaka

摘要

This paper investigates the tribological performance of Zinc and Ethanol-based thermal spray coatings deposited on three different steel substrates: Sample A (Mild Steel), Sample B (Mn-steel alloy), and Sample C (Hadfield Steel) across coating thicknesses of 100–300 μm. Under identical pin-on-disc testing conditions (30 N, 500 rpm), Zinc coatings exhibited a pronounced thickness-dependent rise in friction, with the Coefficient of friction increasing from 0.27 to 0.40 (a 48% increase) and a sensitivity of 0.00065 ΔCoefficient of friction/µm. Ethanol coatings, across all three samples, consistently showed lower friction values (0.20–0.21) with significantly reduced sensitivity (0.00030 Coefficient of friction /µm), ~ 54% lower than Zinc. Among the substrates, Sample A demonstrated the most stable frictional response, aligning with its lower hardness and smoother deformation behaviour, whereas Samples B and C showed higher variability due to increased hardness and work-hardening tendencies. Polynomial and SVR models achieved perfect predictive accuracy (R² = 1.000), and Ethanol coatings exhibited superior stability with a Friction Stability Index (FSI = 5.56 × 10⁶) nearly 10× higher than Zinc and a Tribological Efficiency Ratio (TER = 2.22 × 10⁷), ~ 14× greater. Extended predictions up to 500 μm showed Zinc approaching saturation (peak Coefficient of friction ≈ 0.42), while Ethanol increased smoothly and linearly. Overall, across Samples A, B, and C, Ethanol coatings delivered lower friction, higher stability, reduced thickness sensitivity, and superior tribological efficiency, establishing them as a superior alternative to Zinc for diverse substrate applications.