Two-step mask in-situ forming (CFx)n-TiO2/ZrO2 alternate coatings with different width ratios by electrohydrodynamic atomization

This paper utilizes a two-step mask process to prepare the crosswise lubricant-hard alternating coatings of (CFx) n-TiO2/ZrO2 with different width ratios, based on the electro-fluid in-situ forming technique. The research explored the micro morphologies, mechanical performance, sliding friction against 304 balls and wear properties of the coatings. A comparison was made with the (CFx)n-TiO2/ZrO2 composite laminate coating. X-ray diffraction and X-ray photoelectron spectroscopy results indicated the presence of Ti-O-Zr chemical bonds within the sintered TiO2/ZrO2 composite coatings. Dry friction tests revealed that the sample with a lubricant-hard coating width ratio of 2:1 (AT-D), exhibited the highest interfacial bonding performance (-53.2 N) and the longest wear life (-10658 s). The sample featuring a lubricant-hard coating width ratio of 1:1 (AT-C), displayed the lowest friction coefficient (-0.13) and the smallest coating wear rate of 2.04x10-7 mm3 N-1 mm- 1. These disparities could be attributed to the varying continuity of the self-lubricating film and the actual contact area between the mating components induced by different lubricant-hard coating width ratios.