A comprehensive experimental study and numerical analysis of coefficient of friction of nanocomposite coatings

A comprehensive study of nanocomposite coating friction behaviour in oscillating-reciprocating simulations with steel balls is presented. Graphene/Nickel (Ni/GPL) and pure Nickel (Ni) coatings have been studied. SEM, EDS, and AFM analyses of coatings pre-test were performed to characterise the coatings in addition to tests to compare the coefficients of friction 'COF' between pure Ni and Ni/GPL. Based on microscopic characterisation of wear tracks, wear on counter carbon steel balls, and "U-shaped" wear depth profiles of wear tracks, it was determined that Ni had a higher coefficient of friction than Ni/GPL. A novel 2-D predictive numerical model was developed to examine the wear of nanocomposite coatings that integrates the microstructural and lubrication concepts. Predictions from newly developed model and the experimental results are in close agreement. While significant research has been conducted to understand the frictional performance of nanocomposite coatings, a novel and reliable predictive model is still needed for analyzing nanocomposite coatings COF in the context of design. The research will impact the automotive, aerospace, renewable energy, high-end manufacturing, and renewable energy sectors.