Tribo-oxidation mechanism of gradient nanostructured Inconel 625 alloy during high-temperature wear

The tribo-oxidation layer is typically formed at the contact interface of high temperature wear, which exhibits a significant effect on the friction behavior of gradient nanostructured (GNS) materials. This study systematically investigated the wear resistance, near-surface microstructure, and compositional changes of ultra-thick GNS Inconel 625 alloy subjected to surface mechanical rolling treatment (SMRT) under high-temperature sliding wear conditions. The experimental results indicated that as the temperature increased to 500 °C, a tribo-oxidation layer was formed on the surface of the GNS sample, thereby resulting in an abnormal increase in the coefficient of friction (COF) and a rapid decrease in the wear rate. The gradient nanostructures facilitated oxidation diffusion channels, promoting the formation of a protective Cr₂O₃ film and spinel oxides, reducing the wear rate. At lower temperatures, a rapidly formed Cr₂O₃ film shielded the matrix, forming a tribo-oxidation layer composed of Cr₂O₃ and nickel. At 800 °C, the tribo-oxidation layer exhibited complex structures, including glaze, spinel oxide, Cr₂O₃, and Cr₂O₃/Ni mixed layers. This complexity was attributable to the oxidation diffusion rate of the gradient nanostructures and tribo-oxide layers. The findings not only elucidated the tribo-oxidation mechanism of GNS nickel-based superalloys but also offered valuable insights for designing wear-resistant materials.