The wear property and wear process of FC250 cast iron coated with manganese phosphate sliding against SKH51 steel were studied by using oscillating-wear test rig and SEM-EDX surface analysis. The materials appeared on the friction surface indicate that the wear process can be divided into three phases, wear of the coating, wear of the mixed layer (consisting of a coating and cast iron) and wear of the cast iron. The parameter M, the exposure ratio of iron to a coating on the friction surface measured by SEM-EDX quantitative analysis, was found to characterize each phase quantitatively. It was observed that the change of wear rate is related to parameter M. The best anti-wear property of the coated iron is found in the second phase of the wear process, where the exposure ratio on the friction surface is 40% to 80%, and the wear rate became less than 1/100 of that of cast iron without a coating.
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