Mechanical and Tribological Evaluation of Zinc/Zinc-Zirconia Composite Coatings on Ti6Al4V Alloys

Zinc plays a vital role in supporting prenatal and postnatal growth and development. Moreover, for over a century, zinc and its alloys have been extensively used as coatings to enhance the surface properties of various metals. However, zinc coatings alone exhibit limited resistance to frictional loads, which necessitates their combination with ceramic particles. Particle reinforced composite coatings have emerged as a promising solution to further enhance the mechanical and tribological properties of metals. This study focuses on the electroplating of zinc and zinc reinforced with ZrO₂ onto Ti₆Al₄V alloys, exploring the impact of coating parameters on the thickness and mechanical behavior of the coatings. Through a comprehensive analysis, including electron microscope examination (SEM) of the microstructure, tribometer measurements, scratch resistance test, adhesion strength analysis and atomic force microscope (AFM) assessment of surface roughness, the performance of the coated Ti₆Al₄V alloys is investigated. The results demonstrate that the Zn–ZrO₂ composite coated specimen exhibits the lowest minimum wear rate. Additionally, an increase in the incorporation of ZrO₂ particles correlates with a decrease in the wear rate.