The effect of Zn–40Al–2Cu–xSi (x = 4 and 8 wt-%) tungsten inert gas (TIG) surfaced coatings and multi-pass friction stir processing (FSP) on the tribological properties of Zn–40Al–2Cu alloy was studied. The coatings had a well-modified microstructure comprising of finely dispersed primary Si particles (SiP). These particles act as in-situ reinforcements, improving coating resistance against the friction-induced strains applied during sliding wear. The results of dry sliding wear showed that, at the applied pressures of 0.25, 0.5, and 0.75 MPa, the wear resistance of 4-pass FSPed coatings containing 4 wt-% Si is higher than that of the base alloy by 27, 47, and 57%, respectively. This can be attributed to the substrate strengthening and formation of compacted tribolayers on the surface of FSPed samples.
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