Microstructure and mechanical properties of multiphase layer formed during depositing Ti film followed by plasma nitriding on 2024 aluminum alloy

In this study, a novel method was develop to fabricate an in situ multiphase layer on 2024 Al alloy to improve its surface mechanical properties. The method was divided into two steps, namely depositing pure Ti film on 2024 Al substrate by using magnetron sputtering, and plasma nitriding of Ti coated 2024 Al in a gas mixture comprising of 40% N2-60% H2. The microstructure and mechanical properties of the multiphase layer prepared at different nitriding time were investigated by using X-ray diffractometer (XRD), scanning electron microscopy (SEM), transmission electron microscope (TEM), microhardness tester and pin-on-disc tribometer. Results showed that multiphase layer with three sub-layers (i.e. the outmost TiN0.3 layer, the intermediate Al3Ti layer and the inside Al18Ti2Mg3 layer) can be obtained. The thickness of the Al18Ti2Mg3 layer increased faster than TiN0.3 and Al3Ti layer with increasing nitriding time. The hardness of the layer has reached about 593 HV, which is much higher than that of 2024 Al substrate. The wear rate of the coated samples decreased 53% for 4 h nitriding and 86% for 12 h nitriding, respectively, compared with that of the uncoated one. The analysis of worn surface indicated that the coated 2024 Al exhibited predominant abrasive wear, whereas the uncoated one showed severe adhesive wear.