目的 探究基体表面粗糙度对Ti掺杂MoS2薄膜摩擦磨损性能的影响及其磨损机理,为后续2Cr13基体配磨副表面状态设计提供参考。方法 通过磁控溅射法在表面粗糙度（Ra）范围为0.2~0.7 μm的2Cr13基体表面制备Ti掺杂的MoS2薄膜,并在大气环境下进行干摩擦摩擦磨损实验。通过扫描电子显微镜、金相显微镜、能谱仪、白光干涉仪对实验后的薄膜磨痕形貌及对摩球的磨斑形貌进行观察分析。结果 通过分析基体粗糙度为0.2 μm的薄膜的磨痕表面形貌可知,主要为黏着磨损,其平均摩擦因数和对摩球磨斑面积最大,而其磨损率在所有试样中处于居中位置;当基体的粗糙度增至0.5~0.6 μm范围时,其平均摩擦因数、薄膜磨损率及对摩球磨斑面积都最小;当基体粗糙度进一步升至0.7 μm时,薄膜的磨损率（8.793 01× 10-7 mm3·N-1·m-1）最大,而其平均摩擦因数（0.092）较小,对摩球磨斑面积（4.125×104 μm2）略有升高,但比Ra 0.2 μm下的对摩球的磨斑面积小。结论 基于分子-机械摩擦理论,揭示了基体不同粗糙度对镀膜后表面摩擦磨损的影响机制,在低粗糙度（0.2 μm）下,分子间的作用力主导摩擦阻力,黏着磨损显著;在中粗糙度（0.4~0.6 μm）,工件在不同摩擦阻力的作用下,其磨损机制为黏着磨损和磨粒磨损,其中Ra 0.4 μm的工件仍以黏着磨损为主。随着基体粗糙度的增加,Ra 0.6 μm工件表面的磨损机制逐渐转变为以磨粒磨损为主,在Ra 0.5~0.6 μm范围内制备的Ti掺杂MoS2薄膜展现出最优的综合性能;在高粗糙度（0.7 μm）下,由机械啮合阻力主导,薄膜磨损剧烈,磨损机制主要为磨粒磨损。在不同基体表面粗糙度状态下,薄膜的摩擦磨损机制存在显著差别,为提升以摩擦磨损性能为目标的基体表面状态提供了关键依据。
Abstract
To meet the technical requirements of high performance and prolonged service life for specialized lubricating films in extreme space environments, it is imperative to satisfy the tribological property criteria of substrate-coating systems on critical component surfaces. The surface topography of substrates constitutes a critical constraint restricting the enhancement of tribological properties through coating deposition. This study focuses on the significant influence of substrate roughness on the tribological behavior of MoS2-Ti composite coatings deposited on 2Cr13 stainless steel substrates. Through systematic investigation of the coefficient of friction (COF), wear rate, and wear mechanisms under varying surface roughness conditions, the variation in wear mechanisms associated with different substrate topographies are revealed. These findings establish theoretical foundations and engineering guidelines for surface pretreatment and lubrication design of aerospace precision moving components.
This study investigates how 2Cr13 substrate roughness (Ra 0.2-0.7 μm) affects Ti-MoS2 films prepared by magnetron sputtering (substrate preheating 200 °C, base vacuum 3 mPa) under dry sliding. Ball-on-disk tests (5 N load, 0.105 m/s) reveal three regimes: Ra 0.2 μm shows severe adhesion (μ=0.144), Ra 0.5-0.6 μm optimizes friction-wear balance (μ=0.077-0.101, 53% lower wear rate than Ra 0.7 μm), and Ra 0.7 μm causes abrasive damage (μ=0.092). SEM/EDS analysis demonstrates that Ra 0.5-0.6 μm reduces film wear by 40% vs Ra 0.2 μm through discontinuous transfer films. This study identifies Ra 0.5 μm as the optimal surface roughness parameter within the experimental design gradient (Ra 0.2-0.7 μm) for engineering 2Cr13 components with MoS2 films. Experimental results reveal three wear regimes governed by substrate topography. At Ra 0.2 μm, adhesive interactions is dominating, producing the highest friction coefficient (μ=0.144) and the maximum counterpart damage area (5.558×10-4 μm²). SEM-EDS analysis shows continuous transfer films containing 20.3% oxygen, matching oxidative adhesion mechanisms. White-light profilometry reveals shallow wear tracks with material pile-up near contact zones. At intermediate roughness levels (Ra 0.5-0.6 μm), friction coefficients decrease to 0.101-0.077, and film wear rate reaches the minimum (4.387 68×10-7 mm3·N-1·m-1). Reduced wear area (3.331×10-4 and 3.523×10-4 μm2) is linked to discontinuous transfer films, where MoS2 layers have the minimize shear stress. High roughness (Ra 0.7 μm) causes severe abrasive wear (wear rate 8.793 01× 10-7 mm3·N-1·m-1) but moderate friction (μ=0.092) due to debris-induced lubrication, with significant ploughing effects in wear scars. The molecular-mechanical friction theory explains these transitions, showing the balance between adhesive interactions and abrasive damage. For Ra 0.2 μm, the maximum contact area intensifies adhesion. Intermediate roughness optimizes asperity geometry, suppressing ploughing. White-light measurements show better film retention at Ra 0.5 μm than Ra 0.7 μm. At Ra 0.7 μm, sharp asperities generate abrasive debris that reduces friction via rolling mechanisms, evidenced by partial debris coverage in wear scars. This study identifies Ra 0.5 μm as the optimal surface roughness parameter (Ra 0.2-0.7 μm), demonstrating superior tribological properties with a 53% lower wear rate than Ra 0.7 μm and 40% reduced counterpart damage compared with Ra 0.2 μm. This is systematically validated through controlled tribological testing. Practical implementation protocols are developed through systematic parameter optimization, focusing on surface quality controls and performance validation criteria.
The methodology demonstrates that controlled substrate roughness enables regulation of adhesive-abrasive balance in solid lubricant systems, providing both fundamental insights into wear mechanism transitions. The methodology integrating substrate roughness control with multi-scale characterization provides practical engineering guidelines for optimizing solid lubricant performance in precision mechanical systems, particularly under dry sliding conditions. Experimental results confirm that optimal surface preparation achieves a 53% wear rate reduction and 40% smaller film wear compared with extreme roughness conditions, offering practical solutions for precision components requiring wear resistance enhancement.
关键词
基体表面粗糙度 /
Ti掺杂MoS2薄膜 /
2Cr13基体 /
摩擦磨损 /
磨损机制 /
干摩擦
Key words
substrate surface roughness /
Ti-doped MoS2 film /
2Cr13 substrate /
friction and wear /
wear mechanism /
dry friction
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基金
国家自然科学基金（52275453）;上海市科委政府间国际合作项目（23190712100）
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