Date of Award


Publication Type

Doctoral Thesis

Degree Name



Electrical and Computer Engineering


Engineering, Materials Science.




Adhesion and transfer of aluminum to the surfaces of tool coatings that are potential candidates for dry machining of Al-Si alloys were investigated. First, 319 Al alloy pins were tested against various industrial coatings (CrN, TiB2, TiAlN, TiN, and TiCN) using a pin-on-disc tribometer. The analyzed Scanning Electron Microscope (SEM) images of the wear tracks were used to rank the coatings according to the amount of Al transferred on their surfaces. In general, the TiB2 and TiCN coatings exhibited the least amount of Al transfer on their surfaces compared to the other coatings. Second, the tribological behaviour of the diamond-like carbon (DLC) coatings against Al was investigated since aluminum has much lower tendency to adhere to DLC in ambient air compared to other hard coatings tested. Magnetron sputtered non hydrogenated DLC coatings were tested against 319 Al, tungsten carbide (WC) and sapphire (Al20O3) at 120, 300 and 400°C and under various test atmospheres including air (0-85% RH), vacuum, inert gases (Ar, He and N2) and 40% H2-60% He. Although much softer than WC and Al2O3, 319 Al alloy inflicted the most severe wear of non-hydrogenated DLC especially at elevated temperatures. Non-hydrogenated DLC coatings showed high coefficient of friction, (COF), (0.45-0.75) and high wear rates in inert gases and vacuum compared to ambient air (COF= 0.09-0.16). Very low COF values (0.01-0.02) were observed in 40% H2-60% He mixture. The low COF values in ambient air and in 40% H2-60% He mixture were associated with formation of carbonaceous transfer layers on counterfaces. Formation of easy-to-shear transfer layer together with adsorption and dissociation of the atmospheric water on the sliding surfaces were suggested as the possible mechanisms that minimize COF in ambient air. To elucidate the effect of material properties on adhesion, 1100 Al, Cu, and Ti were tested against CrN, non-hydrogenated DLC, and TiB2 coatings in ambient air and argon. Cu exhibited the least amount of transfer to all three coatings. Chemical affinity towards the counterface, yield strength, and thermal conductivity were found as the most critical properties that determine adhesion and transfer between a given material pair during dry sliding contact.Dept. of Electrical and Computer Engineering. Paper copy at Leddy Library: Theses & Major Papers - Basement, West Bldg. / Call Number: Thesis2005 .K66. Source: Dissertation Abstracts International, Volume: 66-11, Section: B, page: 6214. Thesis (Ph.D.)--University of Windsor (Canada), 2005.