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Journal of Inorganic Materials

Journal of Inorganic Materials

   

Friction and Wear Properties of Al2O3-GdAlO3 (GAP) Amorphous Ceramic Coatings under High Load Capacity

AI Yizhaotong1, REN Jiulong2, QIANG Linya3, ZHANG Xiaozhen3, YANG Kai2, GAO Yanfeng2   

  1. 1. The Key Laboratory of Inorganic Coating Materials CAS, Shanghai Institute of Ceramics, Chinese Academy of Sciences, Shanghai 201899, China;
    2. School of Materials Science and Engineering, Shanghai University, Shanghai 200444, China;
    3. School of Materials Science and Engineering, Jingdezhen Ceramic University, Jingdezhen 333403, China
  • Received:2025-01-13 Revised:2025-02-17
  • About author:AI Yizhaotong (1993-), female, engineer. E-mail: aiyizhaotong@mail.sic.ac.cn

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Abstract: Key components of aerospace power systems operating under extreme conditions, such as high loads, elevated temperatures, oxygen-rich environments, and wide-temperature-range alternating thermal shocks, impose stringent requirements on material mechanical properties, thermal stability, and oxidation resistance. Conventional thermally sprayed Al2O3 coatings, characterized by high hardness, excellent wear resistance, superior oxidation resistance, and good thermal stability, have been widely applied in aerospace, energy, and mechanical engineering fields. However, these coatings primarily consist of metastable γ-Al2O3 as the dominant crystalline phase, which exhibits inferior mechanical and thermal conductivity properties compared to α-Al2O3. This limitation hinders their effectiveness under extreme high-load conditions. To address this issue and enhance the overall coating performance, this study employs Atmospheric Plasma Spraying (APS) to fabricate an Al2O3-GdAlO3 (GAP) amorphous coating with a thickness of approximately 350 µm. The friction and wear behavior, along with the mechanical properties of the coating, were systematically investigated through a designed wear test under a load of 2000 N, a rotational speed of 500 r/min, and a duration of 1 h. Experimental results indicate that due to the high proportion of the amorphous phase and the optimized microstructure, the Al2O3-GAP coating exhibits excellent wear resistance and superior crack propagation resistance under high-speed and heavy-load friction conditions, significantly outperforming conventional polycrystalline Al2O3 coatings. Furthermore, the Al2O3-GAP coating demonstrates a lower and more stable friction coefficient, effectively reducing frictional surface temperature. This mitigates high-temperature oxidation and thermal damage while alleviating stress concentration effects. In summary, the Al2O3-GAP amorphous coating demonstrates remarkable advantages under high-load, high-speed friction conditions, providing a high-performance and reliable coating solution for the protection of critical aerospace power system components.

Key words: atmospheric plasma spraying, Al2O3-GdAlO3(GAP), amorphous ceramic coating, high-load wear resistance

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