Tenfold Enhancement of Wear Resistance by Electrosynthesis of a Nanostructured Self-Lubricating Al2O3/Sn(S)?MoS2 Composite Film on Al?Si?Cu Casting Alloys
Jiacheng Liu, Song-Zhu Kure-Chu, Shuji Katsuta, Mengmeng Zhang, Shaoli Fang, Takashi Matsubara, Yoko Sakurai, Takehiko Hihara, Ray H. Baughman, Hitoshi Yashiro, Long Pan, Wei Zhang, Zheng Ming Sun
{"title":"Tenfold Enhancement of Wear Resistance by Electrosynthesis of a Nanostructured Self-Lubricating Al2O3/Sn(S)?MoS2 Composite Film on Al?Si?Cu Casting Alloys","authors":"Jiacheng Liu, Song-Zhu Kure-Chu, Shuji Katsuta, Mengmeng Zhang, Shaoli Fang, Takashi Matsubara, Yoko Sakurai, Takehiko Hihara, Ray H. Baughman, Hitoshi Yashiro, Long Pan, Wei Zhang, Zheng Ming Sun","doi":"10.1002/sstr.202400172","DOIUrl":null,"url":null,"abstract":"Enhancing tribological performance through nanostructure control is crucial for saving energy and improving wear resistance for diverse applications. We introduce a new electrochemical approach that integrates aluminum (Al) anodization, tin alternating current (AC) electrodeposition, and anodic MoS<sub>2</sub> electrosynthesis for fabricating nanostructured Al<sub>2</sub>O<sub>3</sub>/Sn(S)<span></span>MoS<sub>2</sub> composite films on Al<span></span>Si<span></span>Cu casting alloys. Our unique process uses Sn-modified MoS<sub>2</sub> deposition to form robust solid lubricant MoS<sub>2</sub>–SnS electrodeposits within the nanochannels and microsized voids/defects of anodic alumina matrix films on the base materials, resulting in a bilayered Al<sub>2</sub>O<sub>3</sub>/SnS<span></span>MoS<sub>2</sub> and MoS<sub>2</sub>–SnS–Sn composite film. The AC-deposited Sn enhances conductivity in the anodic alumina matrix film, acts as catalytic nuclei for Sn@SnS@MoS<sub>2</sub> core-shell nanoparticles and a dense top layer, and serves as a reductant for the direct synthesis of hybrid solid lubricant MoS<sub>2</sub>–SnS from MoS<sub>3</sub> by anodic electrolysis of MoS<sub>4</sub><sup>2−</sup> ions. The resulting nanocomposite film provides a two-fold increase in lubricity (friction coefficient (COF) μ = 0.14 ⇒ 0.07) and a ten-fold improvement in wear resistance (COF μ < 0.2) compared to conventional Al<sub>2</sub>O<sub>3</sub>/MoS<sub>2</sub> film formed by anodizing and reanodizing. The effectiveness of the Al<sub>2</sub>O<sub>3</sub>/Sn(S)<span></span>MoS<sub>2</sub> composite is further validated through real automotive engine piston tests.","PeriodicalId":21841,"journal":{"name":"Small Structures","volume":null,"pages":null},"PeriodicalIF":0.0000,"publicationDate":"2024-07-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":"0","resultStr":null,"platform":"Semanticscholar","paperid":null,"PeriodicalName":"Small Structures","FirstCategoryId":"1085","ListUrlMain":"https://doi.org/10.1002/sstr.202400172","RegionNum":0,"RegionCategory":null,"ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":null,"EPubDate":"","PubModel":"","JCR":"","JCRName":"","Score":null,"Total":0}
引用次数: 0
Abstract
Enhancing tribological performance through nanostructure control is crucial for saving energy and improving wear resistance for diverse applications. We introduce a new electrochemical approach that integrates aluminum (Al) anodization, tin alternating current (AC) electrodeposition, and anodic MoS2 electrosynthesis for fabricating nanostructured Al2O3/Sn(S)MoS2 composite films on AlSiCu casting alloys. Our unique process uses Sn-modified MoS2 deposition to form robust solid lubricant MoS2–SnS electrodeposits within the nanochannels and microsized voids/defects of anodic alumina matrix films on the base materials, resulting in a bilayered Al2O3/SnSMoS2 and MoS2–SnS–Sn composite film. The AC-deposited Sn enhances conductivity in the anodic alumina matrix film, acts as catalytic nuclei for Sn@SnS@MoS2 core-shell nanoparticles and a dense top layer, and serves as a reductant for the direct synthesis of hybrid solid lubricant MoS2–SnS from MoS3 by anodic electrolysis of MoS42− ions. The resulting nanocomposite film provides a two-fold increase in lubricity (friction coefficient (COF) μ = 0.14 ⇒ 0.07) and a ten-fold improvement in wear resistance (COF μ < 0.2) compared to conventional Al2O3/MoS2 film formed by anodizing and reanodizing. The effectiveness of the Al2O3/Sn(S)MoS2 composite is further validated through real automotive engine piston tests.