Influence of quartz-mullite synergy from fly ash and quarry dust on the hardness and tribological behavior of anodic oxide coatings

Hard anodizing has long been employed to enhance the hardness and durability of anodic oxide coatings for various industrial applications. However, conventional anodic oxide coatings suffer from low wear resistance and mechanical properties, limiting their performance in demanding environments. To overcome these shortcomings, ceramic reinforcements have been introduced to enhance coating properties, but their high cost restricts large-scale implementation. This study explores cost-effective alternatives by incorporating industrial waste materials, specifically fly ash and quarry dust, which contain quartz and mullite. The XRD analysis confirmed the successful incorporation of quartz and mullite phases at 100 g/L fly ash and 100 g/L quarry dust, showing similar effects to 100 g/L of high-purity commercial quartz and mullite. Incorporating 100 g/L fly ash particles reduced surface roughness by 3.7 % compared to 100 g/L high purity commercial quartz and 5.64 % (100 g/L high purity commercial mullite), while for quarry dust increased roughness by 23.24 % and 5 %, respectively. These variations are attributed to the electrophoretic effects and mechanical entrapment. Additionally, high percentage of mullite in the fly ash (16 % mullite) and quarry dust (9.5 % mullite) led to different increment in surface hardness value of the composite oxide coating. The 100 g/L of fly ash demonstrated an outstanding improvement in reduction of specific wear rate approximately 31.82 % and 16.17 %, respectively, with respect to the 100 g/L high purity commercial quartz and 100 g/L high purity commercial mullite. Wear track analysis substantiated that all composite oxide coating mainly were subjected to abrasive wear mechanisms. Overall, the dual role of quartz and mullite enhances both mechanical and tribological properties, making these coatings suitable for industrial applications while promoting sustainability through waste utilization.

Text 124198.pdf - Published Version Restricted to Repository staff only Download (19MB) Official URL or Download Paper: https://www.sciencedirect.com/science/article/pii/...

Actions (login required)

View Item