Microstructural, mechanical, room, and high temperature tribological properties of graphene oxide reinforced plasma sprayed alumina nanocomposite coatings

High-temperature tribological performance novel coatings are much in demand, which requires improving the wear performance of prevalent and widespread ceramic coatings used presently. Hence, graphene oxide (GO) reinforced alumina coatings (0.5–2 wt %) were deposited on steel substrates via atmospheric plasma spraying (APS), enhancing wear performance for high-temperature applications. With 1.5 wt% GO, coating density increased from 88.5 to 94.61%, elevating hardness and elastic modulus by ~ 47.5% and ~ 62.9%, respectively. Tribological analysis at room temperature and elevated temperatures (473 K, 673 K, 873 K) demonstrated a significant reduction in friction coefficient and wear rate compared to monolithic alumina coatings. The enhanced wear resistance is attributed to the tribo-chemical layer formation and increased hardness, suggesting potential for the development of high-temperature operating coatings. This coating is thought to have the potential to open the door to the development of high-temperature operating coatings.