78 Vol. 03, Iss. 1 (2025) 78-86, DOI: 10.61552/JME.2025.01.005 Journal of Materials and Engineering www.jme.aspur.rs Study on Wear Characteristics of Surfaces Coated with HVOF and Aluminium Alloy Using Multi-Body Dynamics Analysis R. Suresh a, *, K.M. Vinay b , M. Prasanna Kumar c , H.K. Madhusudan d a Department of Mechanical Engineering, University BDT College of Engineering, Davanagere, Karnataka state, India, b Department of Industrial and Production Engineering, University BDT College of Engineering, Davanagere, Karnataka state, India, c Department of Mechanical Engineering, VTU-CPGS, Mysore. Karnataka state, India, d Department of Mechanical Engineering, KLE Technological university Hubli, Karnataka state, India. Keywords: Wear simulation Archard HVOF coating Comsol A B S T R A C T The objective of this study was to compare and analyze the wear behaviors of High-Velocity Oxy-Fuel (HVOF) NiCr-B4C sprayed coated Al6061MMC and Al6061 alloy. Surface coatings are widely used for their excellent wear resistance and low friction performance. Wear prediction is crucial for the engineering application of these components. In this work, the wear simulation approach using COMSOL, a commercial finite element (FEA) program, is presented. The findings presented here are based on a stabilized model obtained through several software iterations exploring different options. The wear depth of Al6061 alloy and HVOF Coated Al6061MM is evaluated using the linear Archad's wear law. The pins on disc components are assumed to have 3-dimensional flexible shapes and the contact surfaces exhibit elastic-plastic material behavior. The impact of debris and oxide production pathways is considered by utilizing a wear coefficient (k) derived from experimental investigation. HVOF-sprayed coatings based on Ni80Cr20-B4C have shown promising tribological characteristics for wear applications. The results of the finite element simulation are in good agreement with the experimental result. © 2025 Journal of Materials and Engineering * Corresponding author: R. Suresh E-mail: sumohi@gmail.com Received: 23 April 2024 Revised: 22 May 2024 Accepted: 15 June 2024 1. INTRODUCTION Wear is a highly intricate phenomenon that can be classified based on its failure mechanism, including adhesive wear, abrasive wear, surface fatigue, and corrosion. Adhesive wear occurs when rough surfaces interact, resulting in the transfer of metal from one surface to another. However, due to the lack of consideration for chemical interactions between bodies or surfaces in finite element programs, these types of wear are not discussed in this paper.