Controlled Laser Sintering as a Strategy for Improved Tribological Performance of Ni-Cr-Ti₃SiC₂ Coatings ^†

The poor tribological and mechanical performance of Al alloys hinders their use in practical applications where low COF and high durability are required. This study examined and evaluated a novel laser-sintered Ni-Cr coating to improve the load-carrying capacity and tribological performance of an Al alloy (Al 6061) substrate. The authors demonstrate that laser sintering cycle count is a decisive process variable governing coating dispersion, microstructural consolidation, and tribological performance in Ni-Cr coatings fabricated via Selective Laser Sintering (SLS). Increasing the laser cycle count progressively refined the surface morphology, improved coating dispersion, and strengthened interparticle bonding. As a result, the average durability after three cycles was seven times that after one laser cycle, accompanied by markedly improved COF. To further improve durability and load-carrying capacity, Ti₃SiC₂ was introduced into the Ni-Cr coating. The coating containing 10 wt% Ti₃SiC₂ exhibited a 20-fold increase in durability, extending the time to failure to approximately 70,000 s (700 m) while maintaining a low coefficient of friction (~0.48) compared with the coating containing no Ti₃SiC₂. The greater durability of the Ni-Cr-10wt%Ti₃SiC₂ coating in this novel study was attributed to improved adhesion to the substrate, better particle distribution during sintering, and greater load-carrying capacity. While further process changes do not yield feasible samples, this study showed that surface properties can be improved within the available small-process regime. Overall, laser sintering of a Ni-Cr-10wt%Ti₃SiC₂ coating shows promise as a means to improve the tribological and mechanical performance of Al 6061. This study should aid researchers and other stakeholders in fabricating well-adhering, durable, and tribotactic composite coatings on Al6061 and similar material systems.