Plasma-sprayed coatings are used widely for friction and wear control. These coatings are comprised of unique lamellar microstructure and differ considerably from conventional bulk materials. In this work, the friction and wear behavior of sintered and atmospheric plasma-sprayed (APS) molybdenum (PSMo), during sliding contact against an AISI 52100 ball, was studied under 10 N load, 10 mm/s sliding velocity and ambient atmosphere. The hypothesis on the genesis of friction by Suh and Sin (N.P.Suh, H.-C. Sin, Wear 69 (1981) 91–114.) has been examined for applicability to plasma-sprayed coatings. It was observed that plasma-sprayed Mo coatings display a time-dependent friction response similar to that for monolithic iron-based materials as reported in the literature. The initial coefficient of friction (COF) is related to plowing and thereby inversely related to surface hardness. The removal of wear debris from the sliding surfaces leads to a reduction in the COF, establishing that plowing and asperity deformation play a significant role in the genesis of friction during dry sliding contact. The peak in the COF for APS Mo occurs after 9 m of sliding as opposed to 25 m of sliding for sintered Mo due to an early occurrence of sub-surface failure at the inherently weak interlayer bond in plasma-sprayed coatings. This leads to an early onset of increased plowing and asperity deformation in APS Mo as compared to sintered Mo. The above results highlight the time-dependent friction response of thermal-sprayed coatings and distinguish their wear behavior with that of bulk monolithic materials and are significant for affecting improvements in the wear and friction behavior of thermal-sprayed coatings.
Wear – Elsevier
Published: Apr 1, 1999
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