Influence of Graphite and Zirconia Addition on the Tribological Properties of Plasma-Sprayed Alumina Coatings

Al2O3, Al2O3-graphite and Al2O3-ZrO2 coatings were formed on the C45 steel rolls using atmospheric plasma spraying. The influence of graphite and zirconia addition on the surface morphology, phase composition and tribological properties under dry sliding conditions using 30 N load were analyzed. It was found that the addition of graphite or ZrO2 slightly affected the fraction of the alpha-Al2O3 and gamma-Al2O3 phases in the alumina coatings. The highest mass loss rate (similar to 8.84 x 10(-4) g/s) was obtained for the friction pair of C45 steel roll and steel plate. The friction coefficient of the Al2O3-graphite coating was slightly lower (up to 7%) compared to the coating of Al2O3-ZrO2. However, the friction pair of Al2O3-ZrO2 coating and steel plate demonstrated the highest wear resistance under dry sliding conditions. The increase in the wear resistance of the Al2O3-graphite and Al2O3-ZrO2 coatings is due to the formation of tribofilm in the sliding contact zone.