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This research aimed to obtain a C-based coating electrochemically applied on an AA6063 alloy. Two electrochemical cells were designed and manufactured to obtain the C-based coating film on flat and cylindrical samples. Structural and microstructural characterizations were performed along with fatigue and corrosion performance testing. The structural and microstructural characterization revealed that the C-based coating deposited on AA6063 corresponded to carbon nanofibers and/or polycrystalline graphite. The performance testing showed an increase in fatigue life along with a decrease in corrosion resistance. The fracture surfaces of the fatigued samples were inspected by Scanning Electron Microscopy and 3D optical microscopy to correlate them with fatigue life estimation. The aforementioned process is a step towards the future development of a complete coating system that will overcome corrosion susceptibility. The carbon film obtained by this electrochemical route has not previously been reported elsewhere.

The present research deals with the comparative wear behavior of a mechanically milled Al-6061 alloy and the same alloy reinforced with 5 wt.% of Al2O3 nanoparticles (Al-6061-Al2O3) under different dry sliding conditions. For this purpose, an aluminum-silicon-based material was synthesized by high-energy mechanical alloying, cold consolidated, and sintered under pressureless and vacuum conditions. The mechanical behavior was evaluated by sliding wear and microhardness tests. The structural characterization was carried out by X-ray diffraction and scanning electron microscopy. Results showed a clear wear resistance improvement in the aluminum matrix composite (Al-6061-Al2O3) in comparison with the Al-6061 alloy since nanoparticles act as a third hard body against wear. This behavior is attributed to the significant increment in hardness on the reinforced material, whose strengthening mechanisms mainly lie in a nanometric size and homogeneous dispersion of particles offering an effective load transfer from the matrix to the reinforcement. Discussion of the wear performance was in terms of a protective thin film oxide formation, where protective behavior decreases as a function of the sliding speed.