An innovative combination of coating techniques and laser texturing can not only increase the wear resistance of high-loaded lightweight components, but also influence the running-in behaviour and reduce friction under different tribological loadings. In this talk, we will present the results of a successful project, which combines a highly wear-resistant ceramic-like surface, achieved through PEO (plasma electrolytical oxidation) on different Aluminium casting alloys with incorporated polymers and a modification by the DLIP technology (direct laser interference patterning) [1].

The influence of DLIP structures on the tribological behaviour of hybridized nanoceramic and polymer surfaces [2], formed on casting Al alloys, is examined by pin-on-disc tests under different lubricated and dry sliding conditions. Therefore, line-like structures with spatial periods between 1.0 µm to 3.5 µm could be produced on the ceramic and polymer surfaces as well. Furthermore, the positive impact of such surface solutions on the friction behaviour under novel low-viscosity oils (e.g., 0W8) is introduced in terms of the examination of Stribeck curves as well as high temperature (up to 150 °C) and velocity tests (up to 1 m/s). The impact on the changed topography and morphology due to the laser structure process is determined by SEM and EDX analysis and correlated to the tribological behaviour.

The investigations showed, that the combination of the DLIP technology and the hybridized surfaces led to a positive running-in behaviour, a huge durability in terms of wear resistance for the lightweight substrate as well as for the tribological counter body and a low friction not only under low viscosity oil but also under dry conditions. Therefore, such surface solutions are forward-looking candidates for e.g., novel power units in the automotive industry.

As the industrial application the possibility of structuring and hybridizing bore holes is shown, whereas such a surface is shown to withstand a tribological test for over 1000 h, showing almost no wear and stable low friction over the whole testing period.

[1] A.F. Lasagni, T. Roch, D. Langheinrich, M. Bieda, A. Wetzig, Large Area Direct Fabrication of periodic Arrays using Interference Patterning, Physics Procedia 12 (2011) 214–220. https://doi.org/10.1016/j.phpro.2011.03.125.

[2] A. Buling, J. Zerrer, Lifting Lightweight Metals to a New Level—Tribological Improvement by Hybrid Surface Solutions on Aluminium and Magnesium, Lubricants 8 (2020) 65. https://doi.org/10.3390/lubricants8060065.