article · The Physics of Metals and Metallography
Hard anodising in sulphuric acid is commonly used to boost the wear resistance of aluminium alloys, but thermal ageing limits its effectiveness on aluminium, copper, and magnesium alloys. To address this, graphene powder was added to the sulphuric acid anodising solution to improve surface hardness and wear resistance on an Al Cu Mg alloy. The resulting oxide layer was evaluated using electron microscopy, energy dispersive spectrometry, X-ray diffraction, and infrared spectroscopy, alongside tribometer and profilometer wear testing. Introducing graphene into the electrolyte increased the anodic layer thickness to 400 micrometres and the hardness to 405 HV. The modification also delivered substantial surface improvements by lowering the friction coefficient to 0.36 and reducing the wear rate to 3.10 to the power of minus 4 cubic millimetres per newton metre.
Aluminium alloys are valuable for their light weight, but wear and friction often limit their operational lifespan. By demonstrating that a graphene-modified anodising bath can substantially boost surface hardness and lower wear rates, this work highlights a practical method to make aluminium components more durable in demanding mechanical environments.
This process could enable surface engineering and metal finishing sectors to produce more durable Al Cu Mg alloy components for wear-prone applications. The findings reflect applied laboratory-tested research, demonstrating clear performance metrics in controlled tests, though the abstract does not indicate production scale trials or immediate steps toward industrial deployment.
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Abstract Anodizing improves the wear resistance of aluminum alloys, and hard anodizing in sulfuric acid further enhances it. However the thermal ageing process limits the effectiveness of hard anodization on the Al–Cu–Mg alloy in terms of hardness and wear resistance. Therefore, this study attempts to achieve optimal hardness through anodizing and improve the wear resistance of the Al–Cu–Mg aluminum alloy upon hard anodization by adding graphene powder to the sulfuric acid solution. The obtained oxide layer was characterised using the following scanning techniques: electron microscopy (SEM), energy dispersive spectrometry (EDS), X-ray diffraction (XRD), and Fourier-transform infrared (FTIR) spectroscopy. The wear test was conducted using a tribometer (CSM). Finally, the wear behaviour was analysed by profilometer and SEM. The presence of graphene increased the anodic layer thickness and hardness to 400 µm and 405 HV, respectively with the significantly reduced friction coefficient and wear rate to 0.36 and 3.10–4 (mm3/(N m)), respectively.
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DOI: 10.1134/s0031918x24603238
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