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Hasan, Mahadi
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article
Oxygen concentration – a governing parameter for microstructural tailoring of duplex AlCrSiON coatings for superior mechanical, tribological, and anti-corrosion performance
Abstract
This study investigates the impact of increasing oxygen levels on physical, structural, and mechanical properties and tribological performance of duplex AlCrSiON coatings. AISI H13 steel and tungsten carbide substrates are coated using arc ion plating with increasing oxygen flow rates up to 200 sccm to deposit coatings with varying oxygen concentrations. High-resolution transmission electron microscopy, scanning electron microscopy, X-ray photoelectron spectroscopy, X-ray diffraction, and three-dimensional optical profilometry are used to study morphological and structural properties. Correspondingly, the coatings are assessed for hardness, adhesion strength, friction coefficient, and resistance against corrosion and wear. A 50 to 100 sccm oxygen flow rate appeared as an optimal range to receive lower surface roughness. Generally, the addition of oxygen has compromised hardness and friction coefficient but adhesion strength, wear and corrosion resistance improve with increasing oxygen concentrations. The immersion tests have identified pitting corrosion as a dominating failure mechanism for AlCrSiON coatings when exposed to molten A380 aluminium alloy. This corrosion resistance stemmed from their dense columnar microstructure, excellent thermal stability, the fcc-(Al, Cr)2O3 phase structure, and the presence of compact Cr2O3 and Al2O3 nanocrystals. This study demonstrates that controlled oxygen concentration is a crucial parameter for tuning the microstructure of AlCrSiON coatings to achieve superior mechanical, tribological, and anti-corrosion performance, particularly for high-pressure die-casting applications.