Enhancing Heavy-Duty Automobile Gear Surfaces with Cr2O3-Reinforced Coatings: Performance Analysis and Simulation

Abstract

Heavy-duty vehicle gears play a vital role in transmission systems, but the harsh operating conditions they endure often lead to surface wear and deformation. To mitigate these effects, gears must possess optimal hardness and wear resistance. The use of surface coatings has proven to be an effective strategy for enhancing gear performance. In this study, a Cr2O3-reinforced coating was applied to gear surfaces using supersonic flame spraying technology. Microstructural, elemental, and phase analyses were carried out using X-ray diffraction (XRD), scanning electron microscopy (SEM), and energy-dispersive spectroscopy (EDS) to evaluate the coating’s properties. The results revealed significant improvements in hardness, adhesion, and wear resistance, with the coated gear exhibiting a more compact surface microstructure. To further assess performance, solid models of both coated and uncoated gears were developed using ANSYS software. Static and fatigue life analyses indicated that the coated gear experienced reduced deformation and a longer service life. This study highlights the effectiveness of Cr2O3-reinforced coatings in the durability and overall performance of heavy-duty automotive gears.