Search results for: surface wear

Authors: Yunhan Zhang, Xiaopeng Li, Zhongxiao Peng

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Additive manufacturing (AM) possesses several key characteristics, including high design freedom, energy-efficient manufacturing process, reduced material waste, high resolution of finished products, and excellent performance of finished products. These advantages have garnered widespread attention and fueled rapid development in recent decades. AM has significantly broadened the spectrum of available materials in the manufacturing industry and is gradually replacing some traditionally manufactured parts. Similar to components produced via traditional methods, products manufactured through AM are susceptible to degradation caused by wear during their service life. Given the prevalence of 316L stainless steel (SS) parts and the limited research on the tribological behavior of 316L SS samples or products fabricated using AM technology, this study aims to investigate the degradation process and wear mechanisms of 316L SS disks fabricated using AM technology. The wear mechanisms and tribological performance of these AM-manufactured samples are compared with commercial 316L SS samples made using conventional methods. Additionally, methods to enhance the tribological performance of additive-manufactured SS samples are explored. Four disk samples with a diameter of 75 mm and a thickness of 10 mm are prepared. Two of them (Group A) are prepared from a purchased SS bar using a milling method. The other two disks (Group B), with the same dimensions, are made of Gas Atomized 316L Stainless Steel (size range: 15-45 µm) purchased from Carpenter Additive and produced using Laser Powder Bed Fusion (LPBF). Pin-on-disk tests are conducted on these disks, which have similar surface roughness and hardness levels. Multiple tests are carried out under various operating conditions, including varying loads and/or speeds, and the friction coefficients are measured during these tests. In addition, the evolution of the surface degradation processes is monitored by creating moulds of the wear tracks and quantitatively analyzing the surface morphologies of the mould images. This analysis involves quantifying the depth and width of the wear tracks and analyzing the wear debris generated during the wear processes. The wear mechanisms and wear performance of these two groups of SS samples are compared. The effects of load and speed on the friction coefficient and wear rate are investigated. The ultimate goal is to gain a better understanding of the surface degradation of additive-manufactured SS samples. This knowledge is crucial for enhancing their anti-wear performance and extending their service life.

Keywords: degradation process, additive manufacturing, stainless steel, surface features

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Authors: Hessam Mortezaei, Saeid Joudakian

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In this paper, the wear problem on rider rings of boil off gas compressor has been studied. This kind of oil free double acting compressor has free floating piston (FFP) technology and as a result of that it should have the lowest possible wear on its rider rings. But a design problem had caused a complete wear of rider rings after one month of continuous operation. In this case study, the source of this problem was recognized and solved.

Keywords: piston rider, rings, gas distribution, pressure wear

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Authors: Noboru Wakamoto, Kiyotaka Obunai, Kazuya Okubo, Toru Fujii

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The aim of this study is to moderate the dependence of counter frictional coefficient on temperature between counter surfaces and to reduce the wear of C/C composites at low temperature. To modify the C/C composites, Silica (SiO₂) powders were added into phenolic resin for carbon precursor. The preform plate of the precursor of C/C composites was prepared by conventional filament winding method. The C/C composites plates were obtained by carbonizing preform plate at 2200 °C under an argon atmosphere. At that time, the silicon carbides (SiC) were synthesized around the surfaces and the internal vacancies of the C/C composites. The frictional coefficient on the counter surfaces and specific wear volumes of the C/C composites were measured by our developed frictional test machine like pin-on disk type. The XRD indicated that SiC was synthesized in the body of C/C composite fabricated by current method. The results of friction test showed that coefficient of friction of unmodified C/C composites have temperature dependence when the test condition was changed. In contrast, frictional coefficient of the C/C composite modified with SiO₂ powders was almost constant at about 0.27 when the temperature condition was changed from Room Temperature (RT) to 300 °C. The specific wear rate decreased from 25×10^-6 mm²/N to 0.1×10^-6 mm²/N. The observations of the surfaces after friction tests showed that the frictional surface of the modified C/C composites was covered with a film produced by the friction. This study found that synthesizing SiC around surface and internal vacancies of C/C composites was effective to moderate the dependence on the frictional coefficient and reduce to the abrasion of C/C composites.

Keywords: C/C composites, friction coefficient, wear, SiC

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Authors: Ashish Ankus Yerunkar, Ravi Terkar

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Study aimed at evaluating the best process environment which could simultaneously satisfy requirements of both quality as well as productivity with special emphasis on reduction of cutting tool flank wear, because reduction in flank wear ensures increase in tool life. The predicted optimal setting ensured minimization of surface roughness. Purpose of this paper is focused on the analysis of optimum cutting conditions to get lowest surface roughness in turning SCM 440 alloy steel by Taguchi method. Design for the experiment was done using Taguchi method and 18 experiments were designed by this process and experiments conducted. The results are analyzed using ANOVA method. Taguchi method has depicted that the depth of cut has significant role to play in producing lower surface roughness followed by feed. The Cutting speed has lesser role on surface roughness from the tests. The vibrations of the machine tool, tool chattering are the other factors which may contribute poor surface roughness to the results and such factors ignored for analyses. The inferences by this method will be useful to other researches for similar type of study and may be vital for further research on tool vibrations, cutting forces etc.

Keywords: surface roughness (ra), machining, dry turning, taguchi method, turning process, anova method, mahr perthometer

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Authors: David Robert Irvine

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In the dental restoration sector, there has been a shift to using zirconia. With the ever increasing need to decrease lead times to deliver restorations faster the zirconia is machined in its pre-sintered state instead of grinding the very hard sintered state. As with all machining, there is tool wear and while investigating the tooling used to machine pre-sintered zirconia it became apparent that the wear rate is based more on material build up and abrasion than it is on plastic deformation like conventional metal machining. It also came to light that the tool material can currently not be selected based on wear resistance, as there is no data. Different works have analysed the effect of the individual wear mechanism separately using similar if not the same material. In this work, the testing method used to analyse the wear was a modified from ISO 8688:1989 to use the pre-sintered zirconia and the cutting conditions used in dental to machine it. This understanding was developed through a series of tests based in machining operations, to give the best representation of the multiple wear factors that can occur in machining of pre-sintered zirconia such as 3 body abrasion, material build up, surface welding, plastic deformation, tool vibration and thermal cracking. From the testing, it found that carbide grades with low trans-granular rupture toughness would fail due to abrasion while those with high trans-granular rupture toughness failed due to edge chipping from build up or thermal properties. The results gained can assist the development of these tools and the restorative dental process. This work was completed with the aim of assisting in the selection of tool material for future tools along with a deeper understanding of the properties that assist in abrasive wear resistance and material build up.

Keywords: abrasive wear, cemented carbide, pre-sintered zirconia, tool wear

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Authors: Mohammad Farooq Wani

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Tribological characterization of ZrN coatings deposited on titanium modified austenitic stainless steel (alloy D-9) substrates has been investigated. The coatings were deposited in the deposition temperature range 300–873 K, using the pulsed magnetron sputtering technique. Scratch adhesion tests were carried out using Rc indenter under various conditions of load. Detailed tribological studies were conducted to understand the friction and wear behaviour of these coatings. For all tribological studies steel and ceramic balls were used as counter face material. 3D-Surface profiles of all wear tracks was carried out using 3D universal profiler.

Keywords: ZrN, Surafce coating, thin film, tribology, friction and wear

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Authors: N. Seemuang, T. McLeay, T. Slatter

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Worn tools have a direct effect on the surface finish and part accuracy. Tool condition monitoring systems have been developed over a long period and used to avoid a loss of productivity resulting from using a worn tool. However, the majority of tool monitoring research has applied expensive sensing systems not suitable for production. In this work, the cutting sound in turning machine was studied using microphone. Machining trials using seven cutting conditions were conducted until the observable flank wear width (FWW) on the main cutting edge exceeded 0.4 mm. The cutting inserts were removed from the tool holder and the flank wear width was measured optically. A microphone with built-in preamplifier was used to record the machining sound of EN24 steel being face turned by a CNC lathe in a wet cutting condition using constant surface speed control. The sound was sampled at 50 kS/s and all sound signals recorded from microphone were transformed into the frequency domain by FFT in order to establish the frequency content in the audio signature that could be then used for tool condition monitoring. The extracted feature from audio signal was compared to the flank wear progression on the cutting inserts. The spectrogram reveals a promising feature, named as ‘spindle noise’, which emits from the main spindle motor of turning machine. The spindle noise frequency was detected at 5.86 kHz of regardless of cutting conditions used on this particular CNC lathe. Varying cutting speed and feed rate have an influence on the magnitude of power spectrum of spindle noise. The magnitude of spindle noise frequency alters in conjunction with the tool wear progression. The magnitude increases significantly in the transition state between steady-state wear and severe wear. This could be used as a warning signal to prepare for tool replacement or adapt cutting parameters to extend tool life.

Keywords: tool wear, flank wear, condition monitoring, spindle noise

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Authors: Yang Liu, Mathias Agmell, Aylin Ahadi, Jan-Eric Stahl, Jinming Zhou

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Tool wear and tool geometry have significant effects on the residual stresses in the component produced by high-speed machining. In this paper, Coupled Eulerian and Lagrangian (CEL) model is adopted to investigate the residual stress in high-speed machining of Inconel718 with a CBN170 cutting tool. The result shows that the mesh with the smallest size of 5 um yields cutting forces and chip morphology in close agreement with the experimental data. The analysis of thermal loading and mechanical loading are performed to study the effect of segmented chip morphology on the machined surface topography and residual stress distribution. The effects of cutting edge radius and flank wear on residual stresses formation and distribution on the workpiece were also investigated. It is found that the temperature within 100um depth of the machined surface increases drastically due to the more friction heat generation with the contact area of tool and workpiece increasing when a larger edge radius and flank wear are used. With the depth further increasing, the temperature drops rapidly for all cases due to the low conductivity of Inconel718. Consequently, higher and deeper tensile residual stress is generated on the superficial. Furthermore, an increased depth of plastic deformation and compressive residual stress is noticed in the subsurface, which is attributed to the reduction of the yield strength under the thermal effect. Besides, the ploughing effect produced by a larger tool edge radius contributes more than flank wear. The magnitude variation of the compressive residual stress caused by various edge radius and flank wear have a totally opposite trend, which depends on the magnitude of the ploughing and friction pressure acting on the machined surface.

Keywords: Coupled Eulerian Lagrangian, segmented chip, residual stress, tool wear, edge radius, Inconel718

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Authors: Gurjinder Singh Randhawa, Jonny Garg, Sukhraj Singh, Gurmeet Singh Cheema

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A major problem related to the use of rotavator is wear of rotavator blades due to abrasion by soil hard particles, as it seriously affects tillage quality and agricultural production economy. The objective of this study was to increase the wear resistance by covering the rotavator blades with two different hard facing electrodes. These blades are generally produced from low carbon or low alloy steel. During the field work i.e. preparing land for the cultivation these blades are subjected to severe wear conditions. Comparative wear tests on a regular rotavator blade and two kinds of hardfacing with electrodes were conducted in the field. These two different hardfacing electrodes, which are designated HARD ALLOY-400 and HARD ALLOY-650, were used for hardfacing. The wear rate in the field tests was found to be significantly different statistically. When the cost is taken into consideration; HARD ALLOY-650 and HARD ALLOY-400 have been found to be the best hardfacing electrodes.

Keywords: hardfacing, rotavator blades, hard alloy-400, abrasive wear

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Authors: Salete Martins Alves, José Josemar de Oliveira Junior

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The current efforts on design of lubricants are based in attending the new requirement of modern equipment with the focus on the choice of base oil and additives. Nowadays, there are different types of lubricant oils’ bases, such as mineral oils, synthetic oils, re-refined oils and vegetable oils. The lubrication in the boundary condition is controlled mainly by EP additives that interact with the surface forming very thin films. Therefore, the study’s goal is to evaluate the action of three EP additives, with different percentage of sulfur, on friction and wear reduction. They were evaluated in mineral and synthetic oils. Lubricants were prepared with synthetic and mineral oils and added 3 % and 5 % of EP additives. The friction and wear characteristics were studied using HFRR test. In this test, a normal load of 10 N was applied at a frequency of 20 Hz. The analysis of results has appointed that the percentage of sulfur in mineral oil has influenced on wear reduction. However, synthetic oil had good performance with low sulfur content.

Keywords: boundary lubrication, EP additives, sulfur, wear

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Authors: Ana Paula Gomes Nogueira, Pietro Tonolini, Andrea Bonfanti

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Automotive braking systems must convert kinetic into thermal energy by friction. Nowadays, the disc brake system is the most widespread configuration on the automotive market, which its specific configuration provides a very efficient heat dissipation. At the same time, both discs and pads wear out. Different wear mechanisms can act during the braking, which makes the understanding of the phenomenon essential for the strategies to be applied when an increased lifetime of the components is required. In this study, a specific characterization approach was conducted to analyze the worn surfaces of commercial pad friction materials and its conterface cast iron disc after dynobench tests. Scanning electronic microscope (SEM), confocal microscope, and focus ion beam microscope (FIB) were used as the main tools of the analysis, and they allowed imaging of the footprint of the different wear mechanisms presenting on the worn surfaces. Aspects such as the temperature and specific ingredients of the pad friction materials are discussed since they play an important role in the wear mechanisms.

Keywords: wear mechanism, surface characterization, brake tests, friction materials, disc brake

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Authors: H. Zengin, M. E. Turan, Y. Turen, H. Ahlatci, Y. Sun

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This study aimed for improving wear resistance of AM60 magnesium alloy by Ti addition (0, 0.2, 0.5, 1wt%Ti). An electric resistance furnace was used to produce alloys. Pure Mg together with Al, Al-Ti and Al-Mn were melted at 750 ⁰C in a stainless steel crucible under controlled Ar gas atmosphere and then poured into a metal mould preheated at 250 ⁰C. Microstructure characterizations were performed by light optical (LOM) and scanning electron microscope (SEM) after the wear test. Wear rates and friction coefficients were measured with a pin-on-disk type UTS-10 Tribometer test device under a load of 20N. The results showed that Ti addition altered the morphology and the amount of b-Mg₁₇Al₁₂ phase in the microstructure of AM60 alloy. b-Mg₁₇Al₁₂ phases on the grain boundaries were refined with increasing amount of Ti. An improvement in wear resistance of AM60 alloy was observed due to the alteration in the microstructure by Ti addition.

Keywords: magnesium alloy, titanium, SEM, wear

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Authors: D. Kabeya Nahum, L. Y. Kabeya Mukeba

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In this work, the design of surface defects some support of the anchor rod ball joint. The future adhesion contact was rocking in manufacture machining, for giving by the numerical analysis of a short simple solution of thermo-mechanical coupled problem in process engineering. The analysis of geometrical evaluation and the quasi-static and dynamic states are discussed in kinematic dimensional tolerances onto surfaces of part. Geometric modeling using the finite element method (FEM) in rough part of such phase provides an opportunity to solve the nonlinearity behavior observed by empirical data to improve the discrete functional surfaces. The open question here is to obtain spherical geometry of drain wear with the operation of rolling. The formulation with (1 ± 0.01) mm thickness near the drain wear semi-finishing tool for studying different angles, do not help the professional factor in design cutting metal related vibration, friction and interface solid-solid of part and tool during this physical complex process, with multi-parameters no-defined in Sobolev Spaces. The stochastic approach of cracking, wear and fretting due to the cutting forces face boundary layers small dimensions thickness of the workpiece and the tool in the machining position is predicted neighbor to ‘Yakam Matrix’.

Keywords: FEM, geometry, part, simulation, spherical surface engineering, tool, workpiece

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Authors: Ching Yern Chee

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Various loading of nano silica is added into polyurethane (PU) and then coated on porcelain substrate. The wear and friction properties of the porcelain substrates coated with polyurethane/nano silica nano composite coatings were investigated using the reciprocating wear testing machine. The friction and wear test of polyurethane/nano silica coated porcelain substrate was studied at different sliding speed and applied load. It was found that the optimum composition of nano silica is 3 wt% which gives the lowest friction coefficient and wear rate in all applied load ranges and sliding speeds. For 3 wt% nano silica filled PU coated porcelain substrate, the increment of sliding speed caused higher wear rates but lower frictions coefficient. Besides, the friction coefficient of nano silica filled PU coated porcelain substrate decreased but the wear rate increased with the applied load.

Keywords: porcelain, nanocomposite coating, morphology, friction, wear behavior

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Authors: Dler Abdullah Ahmed, Zozan Ahmed Mohammed

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Wear as an unavoidable phenomenon in stainless steel contact sliding parts is investigated In this work. Two grades of austenitic AISI 304, and S31254, as well as duplexes of S32205, and AISI 2507, were chosen to compare their wear behavior in temperatures ranging from room temperature to 550°C. The experimental results show that AISI 304 austenitic and AISI 2205 duplex stainless steel had lower wear resistance compared with S31254 and AISI 2507 in various temperatures. When the temperature rose to 140°C, and the wear rate of all grades increased, AISI 304 had the highest at 7.028x10-4 mm3/Nm, and AISI 2507 had the lowest at 4.9033 x 10-4 mm3/Nm. At 300°C, the oxides began to form on the worn surfaces, causing the wear rate to slow. As a result, when temperatures exceeded 300°C, the specific wear rate decreased significantly in all specimens. According to the XRD patterns, the main types of oxides formed on worn surfaces were magnetite, hematite, and chromite.

Keywords: wear, stainless steel, temperature, groove, oxide

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Authors: Dler Abdullah Ahmed, Zozan Ahmed Mohammed

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Wear as an unavoidable phenomenon in stainless steel contact sliding parts is investigated In this work. Two grades of austenitic AISI 304, and S31254, as well as duplexes of S32205, and AISI 2507, were chosen to compare their wear behavior in temperatures ranging from room temperature to 550°C. The experimental results show that AISI 304 austenitic and AISI 2205 duplex stainless steel had lower wear resistance compared with S31254 and AISI 2507 in various temperatures. When the temperature rose to 140°C, and the wear rate of all grades increased, AISI 304 had the highest at 7.028x10-4 mm3/Nm, and AISI 2507 had the lowest at 4.9033 x 10-4 mm3/Nm. At 300°C, the oxides began to form on the worn surfaces, causing the wear rate to slow. As a result, when temperatures exceeded 300°C, the specific wear rate decreased significantly in all specimens. According to the XRD patterns, the main types of oxides formed on worn surfaces were magnetite, hematite, and chromite.

Keywords: wear, stainless steel, temperature, groove, oxide

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Authors: Liqiang Gong, Hanguang Fu

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In order to further improve the wear resistance of Hypereutectic High Chromium Cast iron (HHCCI), the effects of different Cu contents on the microstructure and properties of HHCCI were systematically studied. It was found that with the increase of Cu content, the carbide size was refined, and the increase of Cu content led to the increase of austenite and the decrease of hardness in as-cast HHCCI. After heat treatment at 1050 °C, the hardness of HHCCI increased significantly compared with as-cast. And with the increase of Cu content, the hardness of HHCCI increased first and then decreased, and the hardness was the highest when 0.5 wt.% Cu was added. The increase of copper content promotes the precipitation of secondary carbides and makes the interface between α-Fe and M23C6-type secondary carbides a semi-coherent boundary. With the increase of Cu content, the wear loss of HHCCI decreased after heat treatment at 1050 °C, and the wear resistance improved. When the Cu content increased to 1.0 wt.%, the wear resistance of HHCCI was the best, which was 2.6 times that of copper-free HHCCI. The continued increase of copper content has no obvious effect on the wear resistance of HHCCI. In addition, a small amount of Cu tends to adsorb on the (0001) preferential growth surface of M₇C₃-type carbides, thereby refining the carbides. From the First-principles calculations, the solid solution strengthening effect of Cu on the matrix and the adsorption and refinement of carbides were revealed, and the influence mechanism on the wear resistance of HHCCI was characterized.

Keywords: hypereutectic high chromium cast iron, cu alloying, carbides, wear resistance, first-principles calculations

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Authors: Yashvir Singh

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Around the globe, there is demand for the development of bio-based lubricant which will be biodegradable, non -toxic and environmental friendly. This paper outlines the friction and wear characteristics of Pongamia oil (PO) contaminated bio-lubricant by using pin-on-disc tribometer. To formulate the bio-lubricants, PO was blended in the ratios 15, 30 and 50% by volume with the base lubricant SAE 20 W 40. Tribological characteristics of these blends were carried out at 3.8 m/s sliding velocity and loads applied were 50, 100, 150 N. Experimental results showed that the lubrication regime that occurred during the test was boundary lubrication while the main wear mechanisms were abrasive and the adhesive wear. During testing, the lowest wear was found with the addition of 15% PO, and above this contamination, the wear rate was increased considerably. With increase in load, viscosity of all the bio-lubricants increases and meets the ISO VG 100 requirement at 40 ^oC except PB 50. The addition of PO in the base lubricant acted as a very good lubricant additive which reduced the friction and wear scar diameter during the test. It has been concluded that the PB 15 can act as an alternative lubricant to increase the mechanical efficiency at 3.8 m/s sliding velocity and contribute in reduction of dependence on the petroleum based products.

Keywords: friction, load, pongamia oil, sliding velocity, wear

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Authors: Merzak Laribi, Abdelmadjid Kasser

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Thermal spraying processes are widely used to produce coatings on original constructions as well as in repair and maintenance of long standing structures. A lot of efforts forwarding to develop thermal spray coatings technology have been focused on improving mechanical characteristics, minimizing residual stress level and reducing porosity of the coatings. The specific aim of this paper is to determine either residual stresses distribution or wear resistance of stainless steel coating thermally sprayed on a carbon steel substrate. Internal stresses determination was performed using an extensometric method in combination with a simultaneous progressive electrolytic polishing. The procedure consists of measuring micro-deformations using a bi-directional extensometric gauges glued on the substrate side of the materials. Very thin layers of the deposits are removed by electrochemical polishing across the sample surface. Micro-deformations are instantaneously measured, leading to residual stresses calculation after each removal. Wear resistance of the coating has been determined using a ball-on-plate tribometer. Friction coefficient is instantaneously measured during the tribological test. Attention was particularly focused on the influence of a post-annealing at 850 °C for one hour in vacuum either on the residual stresses distribution or on the wear resistance behavior under specific wear and lubrication conditions. The obtained results showed that the microstructure of the obtained arc sprayed stainless steel coating is classical. It is homogeneous and contains un-melted particles, metallic oxides and also pores and micro-cracks. The internal stresses are in compression in the coating. They are more or less scattered between -50 and -270 MPa on the surface and decreased more at the interface. The value at the surface of the substrate is about –700 MPa, partially due to the molten particles impact with the substrate. The post annealing has reduced the residual stresses in both coating and surface of the steel substrate so that the hole material becomes more relaxed. Friction coefficient has an average value of 0.3 and 0.4 respectively for non annealed and annealed specimen. It is rather oil lubrication which is really benefit so that friction coefficient is decreased to about 0.06.

Keywords: residual stresses, wear resistance, stainless steel, coating, thermal spraying, annealing, lubrication

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Authors: Bharat Kumar, Deepak Kumar, Vijay Chaudhry

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Zirconium alloys are generally used for designing the core components of nuclear reactors due to their good mechanical and tribological properties. Some core components are subjected to flow-induced vibrations resulting in wear of these components due to their interaction with one another. To simulate these conditions, low amplitude reciprocating wear tests are conducted at room temperature and high temperature (260 degrees Celsius) between Zr-2.5Nb alloy and SS-410. The tests are conducted at a frequency range of 5 Hz to 25 Hz and an amplitude range of 200 µm to 600 µm. Friction and wear responses were recorded and correlated with the change in parameters. Worn surfaces are analysed using scanning electron microscopy (SEM) and optical profilometer. Elemental changes on the worn surfaces were determined using energy dispersive spectroscopy (EDS). The coefficient of friction (COF) increases with increasing temperature and decreases with increasing frequency. Adhesive wear is found to be the dominant wear mechanism which increases at high temperature.

Keywords: nuclear reactor, Zr-2.5Nb, SS-410, friction and wear

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Authors: Sandeep Singh Sandhua, Karanvir Singh Ghuman, Arun Kumar

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Stellite 21 is cobalt based super alloy used in improving the wear performance of stainless steel engineering components subjected to harsh environmental conditions. This piece of research focuses on the wear analysis of satellite 21 cladded on AISI 304 L substrate using SMAW process. Bead on plate experiments were carried out by varying current and electrode manipulation techniques to optimize the dilution and microhardness. 80 Amp current and weaving technique was found to be optimum set of parameters for overlaying which were further used for multipass multilayer cladding of AISI 304 L substrate. The wear performance was examined on pin on dics wear testing machine under room temperature conditions. The results from this study show that Stellite 21 overlays show a significant improvement in the frictional wear resistance after TIG remelting. It is also established that low dilution procedures are important in controlling the metallurgical composition of these overlays which has a consequent effect in enhancing hardness and wear resistance of these overlays.

Keywords: surfacing, stellite 21, dilution, SMAW, frictional wear, micro-hardness

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Authors: A. Mekroud, A. Khemis, M. S. Mecibah

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The tribological behavior of a pin of paramagnetic material (aluminum), rolling on a rotating disk made of ferromagnetic material (steel XC48) in the presence of an externally applied alternating magnetic field, with the passage of electric current were studied. All tests were performed using a conventional tribometer pin- disk. Structural characterization of the surfaces in contact, oxides and wear debris, by X-ray diffraction (θ-2θ angle), showed the significant effect of magnetic field on the activation of the contact surface of the pin in no ferromagnetic material. The absence of the magnetic field causes a change of wear mode.

Keywords: structural characterization of the surfaces, oxides and wear debris, X-ray diffraction

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Authors: Catherine Kuforiji, Michel Nganbe

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The abrasive wear of composite materials is a major challenge in highly demanding wear applications. Therefore, this study focuses on fabricating, testing and assessing the properties of 50wt% SS316L stainless steel–50wt% Al2O3 particle composites. Composite samples were fabricated using the powder metallurgy route. The effects of the powder metallurgy processing parameters and hard particle reinforcement were studied. The microstructure, density, hardness and toughness were characterized. The wear behaviour was studied using pin-on-disc testing under dry sliding conditions. The highest hardness of 1085.2 HV, the highest theoretical density of 94.7% and the lowest wear rate of 0.00397 mm3/m were obtained at a milling speed of 720 rpm, a compaction pressure of 794.4 MPa and sintering at 1400 °C in an argon atmosphere. Compared to commercial SS316 and fabricated SS316L, the composites had 7.4 times and 11 times lower wear rate, respectively. However, the commercial 90WC-10Co showed 2.2 times lower wear rate compared to the fabricated SS316L-Al2O3 composites primarily due to the higher ceramic content of 90 wt.% in the reference WC-Co. However, eliminating the relatively high porosity of about 5 vol% using processes such as HIP and hot pressing can be expected to lead to further substantial improvements of the composites wear resistance.

Keywords: SS316L, Al2O3, powder metallurgy, wear characterization

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Authors: Hatim Laalej, Salvador Sumohano-Verdeja, Thomas McLeay

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Monitoring of tool wear in milling operations is essential for achieving the desired dimensional accuracy and surface finish of a machined workpiece. Although there are numerous statistical models and artificial intelligence techniques available for monitoring the wear of cutting tools, these techniques cannot pin point which cutting edge of the tool, or which insert in the case of indexable tooling, is worn or broken. Currently, the task of monitoring the wear on the tool cutting edges is carried out by the operator who performs a manual inspection, causing undesirable stoppages of machine tools and consequently resulting in costs incurred from lost productivity. The present study is concerned with the development of a flute tracking system to segment signals related to each physical flute of a cutter with three flutes used in an end milling operation. The purpose of the system is to monitor the cutting condition for individual flutes separately in order to determine their progressive wear rates and to predict imminent tool failure. The results of this study clearly show that signals associated with each flute can be effectively segmented using the proposed flute tracking system. Furthermore, the results illustrate that by segmenting the sensor signal by flutes it is possible to investigate the wear in each physical cutting edge of the cutting tool. These findings are significant in that they facilitate the online condition monitoring of a cutting tool for each specific flute without the need for operators/engineers to perform manual inspections of the tool.

Keywords: machining, milling operation, tool condition monitoring, tool wear prediction

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Authors: Sarabjeet Singh Sidhu, Ajay Batish, Sanjeev Kumar

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This paper reports the optimal process conditions for machining of three different types of metal matrix composites (MMCs): 65vol%SiC/A356.2; 10vol%SiC-5vol%quartz/Al and 30vol%SiC/A359 using PMEDM process. Metal removal rate (MRR), tool wear rate (TWR), surface roughness (SR) and surface integrity (SI) were evaluated after each trial and contributing process parameters were identified. The four responses were then collectively optimized using the technique for order preference by similarity to ideal solution (TOPSIS) and optimal process conditions were identified for each type of MMCS. The density of reinforced particles shields the matrix material from spark energy hence the high MRR and SR was observed with lowest reinforced particle. TWR was highest with Cu-Gr electrode due to disintegration of the weakly bonded particles in the composite electrode. Each workpiece was examined for surface integrity and ranked as per severity of surface defects observed and their rankings were used for arriving at the most optimal process settings for each workpiece.

Keywords: metal matrix composites (MMCS), metal removal rate (MRR), surface roughness (SR), surface integrity (SI), tool wear rate (TWR), technique for order preference by similarity to ideal solution (TOPSIS)

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Authors: Alain Kusmoko, Druce Dunne, Huijun Li

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Stellite 6 was deposited by laser cladding on a chromium bearing substrate (P91) with energy inputs of 1 kW (P91-1) and 1.8 kW (P91-1.8). The chemical compositions and microstructures of these coatings were characterized by atomic absorption spectroscopy, optical microscopy and scanning electron microscopy. The microhardness of the coatings was measured and the wear mechanism of the coatings was assessed using a pin-on-plate (reciprocating) wear testing machine. The results showed less cracking and pore development for Stellite 6 coatings applied to the P91 steel substrate with the lower heat input (P91-1). Further, the Stellite coating for P91-1 was significantly harder than that obtained for P91-1.8. The wear test results indicated that the weight loss for P91-1 was much lower than for P91-1.8. It is concluded that the lower hardness of the coating for P91-1.8, together with the softer underlying substrate structure, markedly reduced the wear resistance of the Stellite 6 coating.

Keywords: friction and wear, laser cladding, P91 steel, Stellite 6 coating

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Authors: Buddha Ratna Shrestha, Jimmy Faivre, Xavier Banquy

Abstract:

By precisely controlling the molecular interactions between anti-wear macromolecules and bottle-brush lubricating molecules in the solution state, we obtained a fluid with excellent lubricating and wear protection capabilities. The reason for this synergistic behavior relies on the subtle interaction forces between the fluid components which allow the confined macromolecules to sustain high loads under shear without rupture. Our results provide rational guides to design such fluids for virtually any type of surfaces. The lowest friction coefficient and the maximum pressure that it can sustain is 5*10-3 and 2.5 MPa which is close to the physiological pressure. Lubricating and protecting surfaces against wear using liquid lubricants is a great technological challenge. Until now, wear protection was usually imparted by surface coatings involving complex chemical modifications of the surface while lubrication was provided by a lubricating fluid. Hence, we here research for a simple, effective and applicable solution to the above problem using surface force apparatus (SFA). SFA is a powerful technique with sub-angstrom resolution in distance and 10 nN/m resolution in interaction force while performing friction experiment. Thus, SFA is used to have the direct insight into interaction force, material and friction at interface. Also, we always know the exact contact area. From our experiments, we found that by precisely controlling the molecular interactions between anti-wear macromolecules and lubricating molecules, we obtained a fluid with excellent lubricating and wear protection capabilities. The reason for this synergistic behavior relies on the subtle interaction forces between the fluid components which allow the confined macromolecules to sustain high loads under shear without rupture. The lowest friction coefficient and the maximum pressure that it can sustain in our system is 5*10-3 and 2.5 GPA which is well above the physiological pressure. Our results provide rational guides to design such fluids for virtually any type of surfaces. Most importantly this process is simple, effective and applicable method of lubrication and protection as until now wear protection was usually imparted by surface coatings involving complex chemical modifications of the surface. Currently, the frictional data that are obtained while sliding the flat mica surfaces are compared and confirmed that a particular mixture of solution was found to surpass all other combination. So, further we would like to confirm that the lubricating and antiwear protection remains the same by performing the friction experiments in synthetic cartilages.

Keywords: bottle brush polymer, hyaluronic acid, lubrication, tribology

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Authors: Jaswinder Kumar, Kulbir Singh Sandhu

Abstract:

Friction stir processing (FSP) is a solid-state surface processing technique. A single-pass FSP was performed on Aluminum alloy at combinations of different tool rotational speeds with cylindrical threaded pin profiled tool. The effect of these parameters on tribological properties was studied. The wear resistance is found to be increased from base metal to a single pass FSP sample. The results revealed that with an increase in tool rotational speed, the wear rate increases. The high heat generation causes matrix softening, which results in an increased wear rate; on the other hand, high heat generation leads to coarse grains, which also affected tribological properties. Furthermore, Microstructure results showed that FSPed alloy has a more refined grain structure as compare to the base material, which may be resulted in enhancement of hardness and resistance to wear in FSP.

Keywords: friction stir processing, aluminium alloy, microhardness, microstructure

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Authors: Bruno Bacci Fernandes, Stephan Mändl, Ataíde Ribeiro da Silva Junior, José Osvaldo Rossi, Mário Ueda

Abstract:

Nitrogen implantation in aluminum and its alloys is acquainted for the difficulties in obtaining modified layers deeper than 200 nm. The present work addresses a new method to overcome such a problem; although, the coating with nitrogen and oxygen obtained by plasma immersion ion implantation (PIII) into a 7075 aluminum alloy surface was too shallow. This alloy is commonly used for structural parts in aerospace applications. Such a layer was characterized by secondary ion mass spectroscopy, electron microscopy, and nanoindentation experiments reciprocating wear tests. From the results, one can assume that the wear of this aluminum alloy starts presenting severe abrasive wear followed by an additional adhesive mechanism. PIII produced a slight difference, as shown in all characterizations carried out in this work. The results shown here can be used as the scientific basis for further nitrogen PIII experiments in aluminum alloys which have the goal to produce thicker modified layers or to improve their surface properties.

Keywords: aluminum alloys, plasma immersion ion implantation, tribological properties, hardness, nanofatigue

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Authors: Sheng-Long Lee, Tse-An Pan

Abstract:

In this study, an optical microscope (OM), electron microscope (SEM), electrical conductivity meter (% IACS), hardness test, and wear test were subjected to analyze the microstructure of the wrought Al-11Si-3Cu-0.5Mg alloys. The effect of eutectic silicon morphology and alloy hardness on wear properties was investigated. The results showed that in the cast state, the morphology of eutectic silicon modified by strontium and antimony is lamellar and finer fibrous structure. After homogenization, the eutectic Si modified by Sr coarsened, and the eutectic Si modified by Sb refined due to fragmentation. The addition of modifiers, hot rolling, and solution aging treatment can control eutectic silicon morphology and hardness. The finer eutectic silicon and higher hardness have better wear resistance. During the wearing process, a protective oxide layer, also known as Mechanical Mixed Layer (MML), is formed on the surface of the alloy. The MML has higher stability and cracking resistance in Sr-modified alloys than in Sb-modified alloys. The study found that the wearing behavior of Al-11Si-3Cu-0.5Mg alloy was enhanced by the combination of adding Sr with lower solution time and T6 peak aging.

Keywords: Al-Si-Cu-Mg alloy, eutectic silicon, heat treatment, wear property

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