Tribological investigation and process optimization of dry sliding wear behavior for WS₂ solid lubricant layer deposition on Al 6061-T6 surface

Abstract

Purpose This tribological investigation aims to identify the effect of WS2 deposition on the Al 6061 surface and optimize the dry sliding conditions to enhance the friction and abrasion wear behavior. Design/methodology/approach WS2-deposited Al 6061-T6 surface was considered for this tribological investigation. The design of the experiment was based on the Box–Behnken design of the response surface methodology approach, which is used to evaluate the interaction effect of input parameters on friction coefficient (COF) and specific wear rate (SWR). The abrasive wear behavior of WS2 deposition against SiC emery sheet was explored through pin-on-disc experimentation by varying applied load (L), sliding velocity (V) and distance (D). Using analysis of variance and regression model, COF and SWR were predicted. Findings Based on composite desirability criteria, multi-objective optimization was performed to minimize the COF and SWR. The obtained optimal sliding conditions are L = 10 N, V = 2 m/s and D = 949.49 m. The validation test results indicate that the experimental and predicted data are in good conformance. For optimized conditions, worn surface characterization was done using a scanning electron microscope with energy dispersive spectroscopy, and X-ray diffraction analysis was performed to ensure the formation of WS2 phases on worn-out surfaces. Furthermore, a counter body surface with collected wear debris has been analyzed. Originality/value Almost the industries are now focused on a new surface modification technique, which improves the surface and tribological characteristics. This research work specifically relates the tribological effect of WS2 deposition on an Al 6061-T6 surface through a novel electrical discharge deposition approach and optimizes the dry sliding conditions to improve the frictional and abrasive wear resistance.