Tribological performance of anodized AlSi12Cu1(Fe) diecasting alloy: Effects of microstructure, roughness, and anodic layer defects

This study investigates the wear behavior of anodized AlSi12Cu1(Fe) diecast alloy, focusing mainly on the influence of the initial surface microstructure, anodizing parameters, and anodic layer integrity. Furthermore, this study explores how the microstructure of the alloy changes from the as-diecast surface to the ground surface after removing 1 mm of material. The results indicate that the anodized ground surfaces possess a thicker anodic layer than the anodized as-diecast surfaces, attributable to the increased α-Al content. Wear testing highlights the key effects of anodic layer properties, such as cavities and microhardness, on the wear rate of anodized samples, as well as the impact of the underlying alloy microstructure. Anodized as-diecast surfaces have higher wear resistance. SEM and EDS analyses confirmed a transition in wear mechanisms from brittle fractures and abrasive wear in the anodic layer to plastic deformation in the exposed substrate, especially on anodized ground surfaces.