Abstract
Iron-based coatings with the incorporation of solid lubricants have been prepared by means of laser cladding, in an effort to control friction and decrease tool wear at high temperatures during metal forming applications. The choice of a Fe-based powder has been considered advantageous, as it can lead to decreased costs compared to nickel-based claddings previously studied by the authors, in addition to having a lower environmental impact. In particular, the incorporation of transition metal dichalcogenides such as MoS2 as precursors leads to the encapsulation of silver in Fe-based self-lubricating claddings, resulting in a uniform distribution of the soft metal across the thickness of the coating. Subsequent tribological evaluation of the claddings at high temperatures shows that the addition of lubricious compounds leads to lower friction at room temperature and significantly decreased wear up to 600 °C compared to the unmodified iron-based reference alloy, although higher than similar self-lubricating Ni-based claddings. In order to cast light into these observed differences, the corresponding microstructures, phase composition, and self-lubricating mechanisms have been studied and compared for Fe- and Ni-based claddings having both of them the addition of silver and MoS2. The results suggest a key role of the formation of protective tribolayers on the counter body during high temperature sliding contact. Additional simulation of the phase evolution during solidification reveals that the formation of different chromium- and nickel-based metal sulfides in Fe- and Ni-claddings during laser cladding by the decomposition of MoS2 plays a key role in determining their tribological behaviour at high temperatures.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
De Mello J D B, Binder C, Hammes G, Binder R, Klein A N. Tribological behaviour of sintered iron based self-lubricating composites. Friction 5(3): 285–307 (2017)
Luo J, Zhou X. Superlubricitive engineering—Future industry nearly getting rid of wear and frictional energy consumption. Friction 8(4): 643–665 (2020)
Fan X Q, Xue Q J, Wang L P. Carbon-based solid—liquid lubricating coatings for space applications—A review. Friction 3(3): 191–207 (2015)
Huai W J, Zhang C H, Wen S Z. Graphite-based solid lubricant for high-temperature lubrication. Friction 9(6): 1660–1672 (2021)
Meng Y G, Xu J, Jin Z M, Parkash B, Hu Y Z. A review of recent advances in tribology. Friction 8(2): 221–300 (2020)
Decrozant-Triquenaux J, Pelcastre L, Prakash B, Hardell J. Influence of lubrication, tool steel composition, and topography on the high temperature tribological behaviour of aluminium. Friction 9(1): 155–168 (2021)
Sliney H E. Plasma-sprayed metal-glass and metal-glass fluoride coatings for lubrication to 900 °C. ASLE Trans 17: 182–189 (1974)
Aouadi S M, Paudel Y, Simonson W J, Ge Q, Kohli B, Muratore C, Voevodin A A. Tribological investigation of adaptive Mo2N/MoS2/Ag coatings with high sulfur content. Surf Coatings Technol 203: 1304–1309 (2009)
Muratore C, Voevodin A A, Hu J J, Zabinski J S. Tribology of adaptive nanocomposite yttria-stabilized zirconia coatings containing silver and molybdenum from 25 to 700 °C. Wear 261:797–805 (2006)
Khadem M, Penkov O V., Yang H K, et al. Tribology of multilayer coatings for wear reduction: A review. Friction 5(3): 248–262 (2017)
Wang H D, Ma G Z, Xu B S, Yong Q S, He P F. Design and application of friction pair surface modification coating for remanufacturing. Friction 5(3): 351–360 (2017)
Chen J, An Y, Yang J, Zhao X Q, Yan F Y, Zhou H D, Chen J M. Tribological properties of adaptive NiCrAlY-Ag-Mo coatings prepared by atmospheric plasma spraying. Surf Coatings Technol 235: 521–528 (2013)
Ouyang J H, Li Y F, Wang Y M, Zhou Y, Murakami T, Sasaki S. Microstructure and tribological properties of ZrO2(Y2O3) matrix composites doped with different solid lubricants from room temperature to 800 °C. Wear 267: 1353–1360 (2009)
Kong L, Bi Q, Niu M, et al. ZrO2 (Y2O3)-MoS2-CaF2 self-lubricating composite coupled with different ceramics from 20 °C to 1000 °C. Tribol Int 64: 53–62 (2013)
Zhen J M, Cheng J, Tan H, Sun Q C, Zhu S Y, Yang J, Liu W M. Investigation of tribological characteristics of nickel alloy-based solid-lubricating composites at elevated temperatures under vacuum. Friction 9(5): 990–1001 (2021)
Kang X, Yu S, Yang H L, Sun Y, Zhang L. Tribological behavior and microstructural evolution of lubricating film of silver matrix self-lubricating nanocomposite. Friction 9(5): 941–951(2021)
Garrido A H, González R, Cadenas M, HernándezBattez A. Tribological behavior of laser-textured NiCrBSi coatings. Wear 271: 925–933 (2011)
Fernández M R, García A, Cuetos J M, González R, Noriega A, Cadenas M. Effect of actual WC content on the reciprocating wear of a laser cladding NiCrBSi alloy reinforced with WC. Wear 324: 80–89 (2015)
Riveiro A, Mejías A, Lusquiños F, del Val J, Comesaña R, Pardo J, Pou J. Laser cladding of aluminium on AISI 304 stainless steel with high-power diode lasers. Surf Coatings Technol 253: 214–220 (2014)
Information. https://web.archive.org/web/*/www.lcc.fi/pdf/Process_basics_and_coating_properties.pdf, 2017.
Dubourg L, Archambeault J. Technological and scientific landscape of laser cladding process in 2007. Surf Coatings Technol 202: 5863–5869 (2008)
Toyserkani E, Khajepour A, Corbin S. Laser cladding equipment. In Laser Cladding. Boca Raton: CRC Press LLC, 2005: 41–80.
Torres H, Vuchkov T, Slawik S, Gachot C, Prakash B, Rodríguez Ripoll M. Self-lubricating laser claddings for reducing friction and wear from room temperature to 600 °C. Wear 408–409: 22–33 (2018)
Torres H, Slawik S, Gachot C, Prakash B, Rodríguez Ripoll M. Microstructural design of self-lubricating laser claddings for use in high temperature sliding applications. Surf Coatings Technol 337: 24–34 (2018)
Niu W, Sun R, Lei Y. Microstructure and wear properties of laser clad NiCrBSi-MoS2 coating. Frict Wear Res 2: 1–5 (2014)
Yang M S, Liu X B, Fan J W, et al. Microstructure and wear behaviors of laser clad NiCr/Cr3C2-WS2 high temperature self-lubricating wear-resistant composite coating. Appl Surf Sci 258: 3757–3762 (2012)
Yan H, Zhang J, Zhang P L, Yu Z S, Li C G, Xu P Q, Lu Y L. Laser cladding of Co-based alloy/TiC/CaF2 self-lubricating composite coatings on copper for continuous casting mold. Surf Coatings Technol 232: 362–369 (2013)
Xu J, Liu W, Zhong M. Microstructure and dry sliding wear behavior of MoS2/TiC/Ni composite coatings prepared by laser cladding. Surf Coatings Technol 200: 4227–1232 (2006)
Arias-González F, del Val J, Comesaña R, Penide J, Lusquiños F, Quintero F, Riveiro A, Boutinguiza M, Pou J. Fiber laser cladding of nickel-based alloy on cast iron. Appl Surf Sci. 374: 197–205 (2016)
Kumar V, Kumar S, Anand M, Kumar V, Das A K. Fiber Laser Cladding of WS2 + Cr on SS316 Substrate and its Characterization. Mater Today Proc 22: 1645–1651 (2019)
Piasecki A, Kotkowiak M, Kulka M. Self-lubricating surface layers produced using laser alloying of bearing steel. Wear 376–377: 993–1008 (2017)
OuYang C S, Liu X B, Luo Y S, Liang J, Wang M, Chen D Q. Preparation and high temperature tribological properties of laser in-situ synthesized self-lubricating composite coating on 304 stainless steel. J Mater Res Technol 9: 7034–7046 (2020)
Awasthi R, Limaye P K, Kumar S, Kushwaha R P, Viswanadham C S, Srivastava D, Soni N L, Patel R J, Dey G K. Wear characteristics of Ni-based hardfacing alloy deposited on stainless steel substrate by laser cladding. Metall Mater Trans A Phys Metall Mater Sci 46:1237–1252 (2015)
Jin L, Edrisy A, Riahi AR. Analysis of Ti-6Al-4V adhesion to AISI 52100 steel and TiN during unlubricated sliding contact. Tribol Int 90: 278–286 (2015)
Li J L, Xiong D S. Tribological properties of nickel-based self-lubricating composite at elevated temperature and counterface material selection. Wear 265: 533–539 (2008)
Lin F H, Xia Y Q, Feng X. Conductive and tribological properties of TiN-Ag composite coatings under grease ubrication. Friction 9(4): 774–788 (2021)
Xiao J K, Wu Y Q, Zhang W, Chen J, Zhang C. Friction of metal-matrix self-lubricating composites: Rrelationships among lubricant content, lubricating film coverage, and friction coefficient. Friction 8(3): 517–530 (2020)
Zhang Y P, Li P P, Ji L, Liu X H, Wan H Q, Chen L, Li H X, Jin Z L. Tribological properties of MoS2 coating for ultra-long wear-life and low coefficient of friction combined with additive g-C3N4 in air. Friction 9(4): 789–801 (2021)
Torres H, Varga M, Rodríguez Ripoll M. High temperature hardness of steels and iron-based alloys. Mater Sci Eng A 671: 170–181 (2016)
Ghiotti A, Bruschi S, Borsetto F. Tribological characteristics of high strength steel sheets under hot stamping conditions. J Mater Process Technol 211: 1694–1700 (2011)
Yanagida A, Azushima A. Evaluation of coefficients of friction in hot stamping by hot flat drawing test. CIRP Ann-Manuf Technol 58: 247–250 (2009)
Pelcastre L, Hardell J, Prakash B. Galling mechanisms during interaction of tool steel and Al-Si coated ultra-high strength steel at elevated temperature. Tribol Int 67: 263–271 (2013)
Cora ÖN, Ağcayazi A, Namiki K, Sofuoğlu H, Koç M. Die wear in stamping of advanced high strength steels— Investigations on the effects of substrate material and hard-coatings. Tribol Int 52: 50–60 (2012)
Dohda K, Yamamoto M, Hu C L, Dubar L, Ehmann K F. Galling phenomena in metal forming. Friction 9(4): 665–685 (2021)
Venema J, Hazrati J, Atzema E, Matthews D, van den Boogaard T. Multiscale friction model for hot sheet metal forming. Friction 10(2): 316–334 (2022)
Torres H, Vuchkov T, Ripoll M R, Prakash B. Tribological behaviour of MoS2-based self-lubricating laser cladding for use in high temperature applications. Tribol Int 126: 153–165 (2018)
Tomoshige R, Niitsu K, Sekiguchi T, Oikawa K, Ishida K. Some tribological properties of SHS-produced chromium sulfide. Int J Self-Propagating High-Temperature Synth 18: 287–292 (2009)
Torres H, Caykara T, Rojacz H, et al. The tribology of Ag/MoS2-based self-lubricating laser claddings for high temperature forming of aluminium alloys. Wear 442–443: 203110 (2020)
Torres H, Rodríguez R M, Prakash B. Self-lubricating laser claddings for friction control during press hardening of Al-Si-coated boron steel. J Mater Process Technol 269: 79–90 (2019)
Yadav P, Lee D B. Corrosion of Inconel 690 in N2—0.1%H2S gas at 700–800 °C. Met Mater Int 23: 893–899 (2017)
ASM International Handbook Committee. Ni (Nickel) Binary Alloy Phase Diagrams. In ASM Metals Handbook Volume 3: Alloy Phase Diagrams. Baker H, Ed. Materials Park: ASM International, 1992: 1212–1250.
Lei Y, Sun R, Tang Y, Niu W. Microstructure and phase transformations in laser clad CrxSy/Ni coating on H13 steel. Opt Lasers Eng 66:181–186 (2015)
ASM International Handbook Committee. Fe (Iron) Binary Alloy Phase Diagrams. In ASM Metals Handbook Volume 3: Alloy Phase Diagrams. Baker H, Ed. Materials Park: ASM International, 1992: 826–877.
Torres H, Varga M, Adam K, Rodríguez Ripoll M. The role of load on wear mechanisms in high temperature sliding contacts. Wear 364–365:73–83 (2016)
Tudela I, Cobley A J, Zhang Y. Tribological performance of novel nickel-based composite coatings with lubricant particles. Friction 7(2): 169–180 (2019)
Bai L Y, Wan S H, Yi G W, Shan Y, The Pham S, Tieu A K, Li Y, Wang R D. Temperature-mediated tribological characteristics of 40CrNiMoA steel and Inconel 718 alloy during sliding against Si3N4 counterparts. Friction 9(5): 1175–1197 (2021)
Li J L, Xiong D S, Huo M F. Friction and wear properties of Ni-Cr-W-Al-Ti-MoS2 at elevated temperatures and self-consumption phenomena. Wear 265: 566–575 (2008)
Colgan D C, Powell A V. A combined time-of-flight powder neutron and powder X-ray diffraction study of ternary chromium sulfides VxCr3−xS4 (0 < x < 1.0). J Mater Chem 6:1579–1584 (1996)
Acknowledgements
This work was funded by the Austrian COMET Programme (Project K2 InTribology, Grant No. 872176) in addition to M-ERA.NET (project 872381 HOTselflub) and has been carried out within the “Austrian Excellence Center for Tribology” (AC2T research GmbH). The authors would also like to acknowledge Tribotecc GmbH for kindly providing the MoS2 powder used in the preparation of the self-lubricating claddings.
Author information
Authors and Affiliations
Corresponding author
Additional information
Hector TORRES. He holds a BSc degree in physics and works at the Austrian Excellence Center for Tribology since 2012. In 2019 he received his Ph.D. degree from Luleå University of Technology. His main research topics include high temperature tribology, friction, and self-lubricating materials prepared by means of laser cladding.
Tugce CAYKARA. She holds a Tribos—Joint European master degree in tribology of surfaces and interfaces and a bachelor in science with a major in chemical engineering from Istanbul University. She has conducted her doctoral studies at the University of Minho in modification of polymer surfaces to render antibacterial properties. Her research interests include soft and hard matter tribology in addition to antiadhesive multifunctional surfaces.
Jens HARDELL. He obtained his MSc degree in mechanical engineering in 2005 from Luleå University of Technology. In 2009, he completed his Ph.D. in machine elements at Luleå University of Technology. He became associate professor at the Division of Machine Elements, Luleå University of Technology, in 2014 as well as head of Division in 2016 and full professor at the Division of Machine Elements in 2021. He has been a visiting professor at Université de Lyon, Ecole Nationale d’Ingénieurs de Saint-Etienne in France. His main research and teaching interests include high temperature tribology, friction and wear in dry contacts, tribomaterials, surface engineering for friction and wear control, wear and failure analysis, and machine components.
Janne NURMINEN. He holds a Ph.D. on laser cladding and has been working for research and development in materials science for more than 20 years. He has about 10 published peer- reviewed papers, with most of his work being done for the industry. His research interests include welding, coatings, wear, corrosion, and hot isostatic pressing. Currently he works for Castolin Eutectic in Switzerland.
Braham PRAKASH. He obtained his BSc Eng (mechanical) degree from Punjab Engineering College, Chandigarh (India), and M Tech (mechanical engineering) as well as Ph.D. (tribology) degrees from Indian Institute of Technology Delhi (India). He is a professor emeritus at the Division of Machine Elements of Luleå University of Technology in Sweden since 2019 and a distinguished visiting professor at the Department of Mechanical Engineering of Tsinghua University in China since 2018. He has earlier been professor and head of Tribolab at the Division of Machine Elements of Luleå University of Technology from 2002 to 2019. He has also been a faculty member at Indian Institute of Technology Delhi from 1981 to 2002, a visiting professor at Tokyo University of Science, Japan (2016) and Indian Institute of Technology, Ropar, India (2010–2013), Japan Society for the Promotion of Science (JSPS) postdoctoral fellow, Chiba Institute of Technology, Japan (1998–2000) and visiting researcher at Tokyo Institute of Technology, Japan (1985).
Professor Prakash has over 45 years of experience, both in academia and industry. His research and teaching activities cover several aspects of tribology such as high temperature tribology, friction and wear of materials, solid and boundary lubrication, surface engineering, tribology of machine components, tribology of wheel-rail interface, tribotesting, and analysis and solution of tribological problems. He has mentored over 10 postdoc researchers, 18 Ph.D. candidates, and numerous students. He has made over 250 contributions in reputed journals, international conferences, and books.
Manel RODRÍGUEZ RIPOLL. He leads the research area “Wear Reduction Strategies for Industry” at the Austrian Excellence Center for Tribology. His main research focuses on surface engineering for reducing wear in extreme environments. Current topics of research are the design of self-lubricating materials, surface protection in tribocorrosive environments for offshore and biomedical applications and the tribochemical formation of two-dimensional solid lubricants. He graduated in physics in Barcelona, Spain and holds a Ph.D. in mechanical engineering from the Karlsruhe Institute of Technology, Germany. He has published over 80 peer-reviewed articles, one book, one book chapter, and three patents.
Rights and permissions
Open Access This article is licensed under a Creative Commons Attribution 4.0 International License, which permits use, sharing, adaptation, distribution and reproduction in any medium or format, as long as you give appropriate credit to the original author(s) and the source, provide a link to the Creative Commons licence, and indicate if changes were made.
The images or other third party material in this article are included in the article’s Creative Commons licence, unless indicated otherwise in a credit line to the material. If material is not included in the article’s Creative Commons licence and your intended use is not permitted by statutory regulation or exceeds the permitted use, you will need to obtain permission directly from the copyright holder.
To view a copy of this licence, visit http://creativecommons.org/licenses/by/4.0/.
About this article
Cite this article
Torres, H., Caykara, T., Hardell, J. et al. Tribological performance of iron- and nickel-base self-lubricating claddings containing metal sulfides at high temperature. Friction 10, 2069–2085 (2022). https://doi.org/10.1007/s40544-021-0578-1
Received:
Revised:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s40544-021-0578-1