Enhancement of Wear Resistance in Steel Alloys for Automotive Industry Applications

Thesis Abstract

The increasing demand for durable and reliable steel components in the automotive industry necessitates advancements in wear-resistant materials, addressing the persistent challenge of material degradation under high-contact stresses. This study aims to enhance the wear resistance of steel alloys used in automotive applications through the development and characterization of modified alloy compositions and surface treatments. Specific objectives include (1) analyzing the current wear performance of standard automotive steel alloys, (2) exploring the influence of alloying elements such as chromium, molybdenum, and vanadium on wear properties, (3) investigating the effectiveness of various surface modification techniques—including carburization, nitriding, and electrodeposition—on wear resistance, and (4) developing predictive models to correlate alloy composition, surface treatment parameters, and wear performance. Adopting a mixed-methods research design, the study integrates experimental laboratory analyses with quantitative statistical modeling. The population comprises automotive-grade steel alloys procured from three leading steel manufacturers, with a sample size of 150 specimens prepared through standardized metallurgical processes, ensuring representation of different alloy compositions and surface treatment conditions. Physical testing involved wear experiments conducted via a pin-on-disk tribometer under controlled load, sliding speed, and temperature conditions consistent with real-world automotive applications, with each experimental condition replicated three times to ensure reliability. Data collection employed advanced characterization techniques, including scanning electron microscopy (SEM) for surface morphology analysis, energy dispersive X-ray spectroscopy (EDX) for compositional verification, and microhardness testing to assess surface modifications. Wear measurements were obtained through mass loss analysis and surface profilometry, while statistical analysis utilized ANOVA to determine significant differences among treatment groups and regression analysis to develop predictive models of wear performance. Expected findings suggest that specific alloying strategies—particularly increased chromium and vanadium contents—significantly improve wear resistance, especially when coupled with optimized surface treatments such as carburization and nitriding. It is anticipated that surface modification techniques will markedly reduce wear rates by forming hard, tribologically favorable surface layers, with synergistic effects observed when combining alloying elements with surface treatments. The multivariate regression models are expected to predict wear behavior based on alloy composition and treatment parameters with high accuracy, providing valuable insights for material optimization. This research will contribute to the body of knowledge by systematically delineating the relationship between alloy chemistry, surface engineering, and wear performance specific to automotive steel applications. It bridges the gap between laboratory-scale surface modification techniques and industrial implementation, offering a data-driven basis for manufacturing practices aimed at enhancing component longevity. Moreover, the study applies the Theory of Tribological Material Behavior to explain observed phenomena and predict future material performance. The main conclusion emphasizes that tailored alloy compositions and surface treatments can substantially improve the wear resistance of steel alloys used in automotive contexts, leading to longer service life and reduced maintenance costs. Based on these findings, recommendations include adopting specific alloying strategies combined with selected surface treatments in industrial production lines and developing standardized processing protocols to maximize wear performance. The study further suggests avenues for future research, such as exploring nano-coatings and the effects of operational environmental variables on wear mechanisms, to advance the durability of automotive steels in increasingly demanding transportation environments.