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Direct Metal Deposition (DMD) is a rapid prototyping technique used to fabricate and repair metallic prototypes. It can be used in the production of complex geometries and unique parts. In functional automotive applications wear characteristics hold key importance. In the present study, an analysis on the influence of various parameters (coating thickness, load and temperature) on the wear characteristics of Direct Metal Deposited (DMD) Inconel 625 coating has been carried out using a Design of Experiments (DOE). ANOVA calculations were performed to find out which of these parameters showed significant influence on the wear properties. It was found that load was the most significant parameter influencing the wear characteristics .Similarly load was found to be most influencing parameter for co efficient of friction. The trend was found to follow when verified at 30 second, 3 minutes, 60 minutes and 120 minutes.

The present work compares the tribological properties of ZnO (Zinc Oxide) nanoparticle based lubricant with ZDDP (zinc dialkyl dithiophosphate) based lubricant. The nanolubricant was prepared by mixing the nanoparticles in base oil followed by ultrasonification and ZDDP based lubricant was prepared by mixing ZDDP and stirring with base oil. Base oil used was mineral base oil. Both the lubricants were tested at three different temperatures, loads and roughness values. The test was carried out on AISI 52100 steel samples prepared by wire cutting and were grinded to three different levels of surface roughness. Friction and wear tests were performed using a reciprocating sliding tribo-tester at three different loads and temperatures. Taguchi orthogonal array was used to reduce the number of experiments. SEM, EDS and AFM analysis were carried out to study the surface wear phenomenon.