This study investigated the tribological behavior of polyamide-imide (PAI) composite coatings containing various combinations of solid lubricants (graphite and activated carbon), silicon nitride, and epoxy binders. Eight different coating formulations were prepared and tested under low (200 mN) and high (200 N) load conditions. Surface analysis showed that the graphite formulations displayed plate-like structures, whereas the activated carbon formulations exhibited irregular, porous textures. Pure carbon coatings demonstrated excellent friction stability but poor wear resistance under high loads. The addition of silicon nitride and epoxy improved wear resistance, with 1.2 wt% carbon formulations reducing wear depth by up to 61% and wear rate by up to 60% compared to pure carbon formulations. An inverse relationship between the carbon content and wear resistance was observed. The wear mechanisms differed between graphite (delamination and platelet exfoliation) and activated carbon formulations (selective phase removal and plastic deformation). These results demonstrate that optimal tribological performance depends on the balance between the carbon content, additive interactions, and processing parameters.
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