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
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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.

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电合成纳米结构自润滑 Al2O3/Sn(S)?MoS2复合膜可将铝硅铜铸造合金的耐磨性提高十倍
通过纳米结构控制来提高摩擦学性能对于各种应用中节约能源和提高耐磨性至关重要。我们介绍了一种新的电化学方法,该方法将铝(Al)阳极氧化、锡交流电(AC)电沉积和阳极 MoS2 电合成整合在一起,用于在 AlSiCu 铸造合金上制造纳米结构的 Al2O3/Sn(S)MoS2 复合薄膜。我们的独特工艺采用 Sn 改性 MoS2 沉积,在基体材料上阳极氧化铝基体薄膜的纳米通道和微小空隙/缺陷内形成坚固的固体润滑剂 MoS2-SnS 电沉积,从而形成双层 Al2O3/SnSMoS2 和 MoS2-SnS-Sn 复合薄膜。交流沉积的锡增强了阳极氧化铝基质膜的导电性,可作为 Sn@SnS@MoS2 核壳纳米粒子和致密顶层的催化核,还可作为还原剂,通过阳极电解 MoS42- 离子,从 MoS3 直接合成混合固体润滑剂 MoS2-SnS。与通过阳极氧化和再阳极氧化形成的传统 Al2O3/MoS2 薄膜相比,生成的纳米复合薄膜的润滑性提高了两倍(摩擦系数 (COF) μ = 0.14 ⇒ 0.07),耐磨性提高了十倍(COF μ < 0.2)。Al2O3/Sn(S)MoS2 复合材料的有效性通过实际汽车发动机活塞测试得到了进一步验证。
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