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Tribological performance of Orvar 2M tool steel coated with ALWIN XC for improved forging tool durability Cover

Tribological performance of Orvar 2M tool steel coated with ALWIN XC for improved forging tool durability

Materials Science-Poland
Volume 43 (2025): Issue 4 (December 2025)
By: Marek Hawryluk  
Open Access
|Dec 2025

Figures & Tables

Figure 1

Dry abrasive test setup T-07: (a) Photo of the testing and measurement apparatus and (b) test concept: 1 – test sample, 2 – rubber roller, and 3 – electrocorundum.
Dry abrasive test setup T-07: (a) Photo of the testing and measurement apparatus and (b) test concept: 1 – test sample, 2 – rubber roller, and 3 – electrocorundum.

Figure 2

View of (a) DUCOM tribotester and (b) schematic of wear tracks on the disc and ball indicating the analyzed locations.
View of (a) DUCOM tribotester and (b) schematic of wear tracks on the disc and ball indicating the analyzed locations.

Figure 3

Comparison of dry abrasive test results – relative abrasive wear resistance K b.
Comparison of dry abrasive test results – relative abrasive wear resistance K b.

Figure 4

Surface profile of the Orvar 2M sample after 30 min of testing in the dry abrasive test for two selected specimens.
Surface profile of the Orvar 2M sample after 30 min of testing in the dry abrasive test for two selected specimens.

Figure 5

Surface profile of the Orvar 2M + AlWIN sample after: (a) 30 min of testing in a dry abrasive and (b) 60 min of tests.
Surface profile of the Orvar 2M + AlWIN sample after: (a) 30 min of testing in a dry abrasive and (b) 60 min of tests.

Figure 6

Surface morphology of the samples after tribological testing: (a) Orvar 2M steel (sample nos 1–4), (b) Orvar 2M steel with ALWIN XC coating (sample nos 1–4), (c) detailed view of sample no. 4 (noncoated-only Orvar 2M), (d) detailed view of sample no. 4 (Orvar 2M + AlWIN_XC); numbers 1–4 denote individual test samples; scale bars are indicated in the detailed images.
Surface morphology of the samples after tribological testing: (a) Orvar 2M steel (sample nos 1–4), (b) Orvar 2M steel with ALWIN XC coating (sample nos 1–4), (c) detailed view of sample no. 4 (noncoated-only Orvar 2M), (d) detailed view of sample no. 4 (Orvar 2M + AlWIN_XC); numbers 1–4 denote individual test samples; scale bars are indicated in the detailed images.

Figure 7

Microscopic observations of wear tracks on the ball and disc after the ball-on-disc test at 200°C.
Microscopic observations of wear tracks on the ball and disc after the ball-on-disc test at 200°C.

Figure 8

Measurement sheets from 3D scanning of selected areas of the sample after the ball-on-disc test at 200°C for three zones.
Measurement sheets from 3D scanning of selected areas of the sample after the ball-on-disc test at 200°C for three zones.

Figure 9

Coefficient of friction for Orvar 2M steel with AlWIN XC coating at 200°C.
Coefficient of friction for Orvar 2M steel with AlWIN XC coating at 200°C.

Figure 10

Metallographic cross-section of the sample (ball-on-disc, 200°C), etched: (a) 200× magnification, (b) 500× magnification; Orvar 2M (1.2344) steel with nanocrystalline ALWIN XC coating and TiC interlayer.
Metallographic cross-section of the sample (ball-on-disc, 200°C), etched: (a) 200× magnification, (b) 500× magnification; Orvar 2M (1.2344) steel with nanocrystalline ALWIN XC coating and TiC interlayer.

Figure 11

HV0.1 hardness distributions on cross-sections after the ball-on-disc test.
HV0.1 hardness distributions on cross-sections after the ball-on-disc test.

Figure 12

Compilation of EDS mapping of the disc wear track (Test 1, 200°C).
Compilation of EDS mapping of the disc wear track (Test 1, 200°C).

Figure 13

Compilation of EDS mapping of the ball wear track (Test 1, 200°C).
Compilation of EDS mapping of the ball wear track (Test 1, 200°C).

Figure 14

Surface microstructure after the tribological test. Areas of coating wear and mechanical damage – Test 1, 200°C.
Surface microstructure after the tribological test. Areas of coating wear and mechanical damage – Test 1, 200°C.

Dry abrasive test results for the tested materials_

MaterialWear – average value (g)Density (g/cm3)RotationsCoefficient K b
C45 (reference sample)0.0627.866001.000
Orvar 2M0.1557.781,8001.188
Orvar 2M + AlWIN 30 min0.0017.781,800184.107
Orvar 2M + AlWIN 60 min0.027.783,60018.411

Summary of abrasive wear results from the tribological tests_

Test no.Temperature T (°C)Sliding distance S (m)Volumetric wear Z obj (m3)Wear index W z (m3/N*m)
Test 12005009.51 × 10−11 9.51 × 10−15
Test 24001501.06 × 10−10 3.53 × 10−14
Test 36001501.67 × 10−10 5.57 × 10−14

Tribological test parameters_

Conditions/test no.Disc temperature T (°C)Test duration t (s)Sliding distance s (m)Load F (N)Rotational speed v (m/s)Wear track radius r (m)
Test 12005,000500100.10.006
DOI: https://doi.org/10.2478/msp-2025-0045 | Journal eISSN: 2083-134X | Journal ISSN: 2083-1331
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Language: English
Page range: 107 - 121
Submitted on: Dec 23, 2025
|
Accepted on: Dec 28, 2025
|
Published on: Dec 31, 2025
Published by: Wroclaw University of Science and Technology
In partnership with: Paradigm Publishing Services
Publication frequency: 4 issues per year
Keywords:
Hot-work tool steel,
PVD AlWIN XC coating,
Tribological testing,
Abrasive wear,
Hot forging
Related subjects:
Materials sciences,
Materials sciences, other,
Nanomaterials,
Functional and smart materials,
Materials characterization and properties

© 2025 Marek Hawryluk, published by Wroclaw University of Science and Technology
This work is licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 License.

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