Dual-functional self-lubricating and corrosion-protective Al2O3–TiO2 coatings enabled by dodecenylsuccinic anhydride-modified oil reservoirs

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Thermal-sprayed ceramic coatings often suffer from high friction and limited corrosion protection due to their brittle asperities and inherent microporous structure. In this work, a dual-functional oil-impregnated composite coating was developed by vacuum-impregnating porous 97% Al 2 O 3 –3% TiO 2 (AT3) ceramic coatings with a dodecenylsuccinic anhydride (DDSA)-formulated anti-rust oil (ARO). The porous AT3 skeleton served as an oil-storage micro-reservoir, while DDSA improved lubricant retention and boundary-layer stability. Under externally dry sliding conditions without additional lubricant supply, the AT3-ARO coating reduced the average friction coefficient from 0.658 (bare AT3) to 0.098 and decreased the wear rate to 5.756 × 10 −7 mm 3 /(N·m). Electrochemical measurements in artificial seawater showed that the impregnated ARO also improved the static corrosion-protection behavior, with the charge transfer resistance reaching 6.34 × 10 8 Ω·cm 2 . FTIR, XPS, and ToF-SIMS analyses supported the presence of DDSA-derived oxygen-containing/carboxylate-related species after sliding, while AFM pull-off force measurements and n-hexane rinsing tests indicated enhanced interfacial interaction and more stable lubricant retention for AT3-ARO compared with AT3-PAO. These results demonstrate that DDSA-modified oil reservoirs are an effective strategy for improving the self-lubricating and static corrosion-protective functions of porous thermal-sprayed AT3 coatings.