Abrasive Wear Resistance Research Articles

Effect of Electrofriction Treatment on Microstructure, Corrosion Resistance and Wear Resistance of Cladding Coatings

In recent years, the issue of increasing the wear resistance of the working bodies of agricultural machinery designed for cutting and breaking the soil has received special attention. The surface layers of working bodies of agricultural machinery during operation are subjected to intensive abrasive wear, which leads to rapid wear of equipment and a reduction in its service life. The induction cladding method using materials such as Sormait-1 is widely used to increase the wear resistance of tool working surfaces. However, after coating, additional heat treatment is required to improve the physical and mechanical properties of the material and increase its durability. In electrofriction technology (EFT) hardening, the surfaces of the parts are subjected to melting under the influence of electric arcs. In this work, three types of surface treatment of L53 steel have been investigated: induction cladding using Sormait-1, electrofriction treatment, and a combination of induction cladding followed by electrofriction treatment. The microstructure was analyzed using optical microscopy and scanning electron microscopy. Erosion and abrasion tests were carried out in accordance with ASTM G65 and ASTM G76-04 international standards to evaluate the wear resistance of the materials under mechanical stress. A dendritic structure was formed after the induction cladding of the Sormait-1 material, but subsequent electrofriction treatment resulted in a reduction of this dendritic structure, which contributed to an increase in the hardness of the material. However, the highest hardness, reaching 965 HV, was recorded after electrofriction treatment of L53 steel. This is explained by needle martensite in the structure, which is formed as a result of quenching. Further, the influence of structural characteristics and hardness on erosion and abrasion wear resistance was examined. The analysis showed that the material microstructure and hardness have a decisive influence on the improvement of wear resistance, especially under conditions of intensive erosion and abrasive friction.

Microstructural, mechanical and wear behaviour of AA7075/ZrSiO4 surface composite developed via multi pass friction stir processing

ABSTRACT The microstructural, mechanical, and wear behaviour of the ZrSiO4-reinforced AA7075 surface composites fabricated through friction stir processing was analysed. The microstructure of the friction stir processed surface composite shows refined grain 52 μm, 20 μm and 5 μm after 1, 2 and 3 FSP pass which also leads to the uniform dispersion of reinforced ZrSiO4 particles in the A7075 surface as revealed by SEM, EDS, and XRD. The microhardness and tensile strength of the FSP surface composite were significantly improved by 35% and 54%, respectively, with the effect of ZrSiO4 particles, after six passes as compared to the substrate material. The slurry abrasive wear resistance of the surface composite after six FSP passes increased to 95% as compared to the A7075 substrate material. Similarly, the slurry erosive wear resistance was improved with increasing slurry rotating speed, but as slurry concentration increased at six passes, the wear rate decreased further due to self-colloids occurring between the slurry particles. Hence, slurry erosive wear resistance was increased by up to 220% as compared to substrate material. Hence, the novel fabrication of friction stir processed surface composite will be very beneficial for aerospace and marine structural components and the fabrication process is very robust and cost-efficient.

Optimization of Laser Cladding Process Parameters and Analysis of Organizational Properties of Mixer Liners.

Aiming to address the wear and replacement inconvenience of concrete mixer liners, this study utilizes a laser cladding system to clad Fe60 alloy powder on the liner. It investigates the influence of different process parameters on the forming quality of the Fe60 alloy powder cladding layer. The optimal process parameters were obtained by weighted comprehensive evaluation, and single-layer multi-pass cladding experiments were carried out under the optimal process parameters to investigate the effects of a 30%, 40%, and 50% lap rate on the surface flatness and forming quality of the cladding layer. Using a metallographic microscope, a scanning electron microscope analysis of the macro morphology and microstructure of the cladding layer was conducted, a DPT-5 penetration flaw detector was used to observe the cracks on the surface of the multi-channel cladding, a microhardness tester and friction and wear experimental machine were used for the hardness of the cladding layer, and an abrasive wear resistance test was conducted. The results show that under the process parameters of a laser power of 900 W, powder feeding speed of 7 g/min, scanning speed of 600 mm/min, and 50% lap rate, the average microhardness of the fused cladding layer reaches 742 HV, which is 1.8 times higher than that of the liner plate, and the coefficient of friction is 0.57, which improves the liner plate's wear resistance performance and service life.

Abrasive Wear Resistance of High-Entropy AlCoCuFeNi Alloy in SiC Mixture

Abrasive Wear Resistance of High-Entropy AlCoCuFeNi Alloy in SiC Mixture

A Tribological Study of CrN and TiBN Hard Coatings Deposited on Cobalt Alloys Employed in the Food Industry

In this work, a comparative study of the tribological performance of two hard coatings, CrN/TiBN, was conducted for research purposes and industrial applications in food products, particularly for food packaging into cans using the double hermetic sealing process. CrN and TiBN coatings were successfully deposited on a base-cobalt metal substrate of a CoCrW commercial alloy using physical vapor deposition by arc evaporation (AEPVD) technology to improve the tribological properties of the commercial alloy, including wear and corrosion resistance, lower coefficient of friction, and overall durability. This research focuses on conducting scratch and abrasion wear resistance tests in dry conditions; specifically, it pursues to evaluate the wear corrosion properties, known as tribocorrosion performance, on CrN/TiBN hard coatings. The experimental results show that the CrN coating (2.9 μm) is slightly thicker than the TiBN coating (2.7 μm), with a 47 N critical load. It also shows a lower coefficient of friction (CoF) in a dry environment, while the TiBN coating showed total detachment and a high coefficient of friction in a dry environment condition. Tribocorrosion testing in brine aqueous solution indicated that CrN coating shows a high friction coefficient with a higher open circuit potential value (Ecorr), and TiBN shows the lowest corrosion potential (Ecorr) and the lowest friction coefficient. This suggests that CrN could provide better corrosion protection for commercial cobalt alloys and improve tool performance during the food canning process in brine environments.

Influence of the Reinforcement Phase Composition on the Structure and Abrasive Wear Resistance of Aluminum Matrix Composites Reinforced with B4C and SiC

Influence of the Reinforcement Phase Composition on the Structure and Abrasive Wear Resistance of Aluminum Matrix Composites Reinforced with B4C and SiC

Evaluation and analysis of abrasive wear resistance of hybrid roller bearings under lubricant contamination

Abrasive wear is a common failure mode of rolling bearings. To enhance the resistance of traditional all-steel bearings to abrasive wear, the structure of traditional all-steel cylindrical thrust roller bearings has been appropriately adjusted, and hybrid roller bearings have been formed by replacing some of the steel rollers in the traditional bearings with ceramic rollers. The frictional performance of hybrid roller bearings under lubricant contamination conditions was analyzed, and the wear reduction mechanism was discussed. The results show that under the condition of lubricant contamination, replacing the appropriate amount of ceramic rollers not only helps reduce friction and decrease wear but also contributes to improving the overall temperature rise of the bearing. Furthermore, when the total amount of contaminants is constant, a specific threshold exists for the impact of replacing the number of rolling elements on reducing mass loss. For a substantial reduction in wear with hybrid roller bearings, the replacement rollers should constitute at least one-fifth of the total number of rollers. The wear reduction observed in hybrid roller bearings results from a combination of crushing and refinement, grinding and finishing, and self-healing mechanisms.

Технология получения вакуумных ионно-плазменных износостойких покрытий

A review of the technologies of vacuum ion plasma (VIP) coating spraying based on the reasonability of science intensity, its criteria and evaluation methods is carried out. The technological features of producing VIP coatings are viewed with the emphasis on the process of coating formation on a substrate, which occurs under the impact of the most powerful forces in nature, i.e. these are forces of interatomic interaction. This leads to a very high level of cohesive strength of the coatings, which results in wear resistance and corrosion resistance. This leads to a very high level of cohesive strength of the coatings, succeeding in wear and corrosion resistance. Methods of research, diagnosis and testing of VIP coatings, due to the peculiarities of their structure and properties, include, as a rule, equipment and techniques of leading world manufacturers in the field of electron microscopy, microrentgen spectral analysis, diffraction analysis, X-ray photoelectron spectrometry, continuous and dynamic indentation, bench testing of unique properties. With respect to scientific and practical activities of the authors, examples of coatings of various nature (nitride, carbon, metalloceramic), different architectures (monolayer – single-phase, multilayer – 2D composites, dispersed – 3D composites) and various applications (wear–resistant, tribotechnical, antierosion, thermal barrier) are given. In particular, some types of nitride coatings TiN, TiAlN, CrAlSiN, which are characterized by high hardness H  24 GPa and abrasive wear resistance, are in the focus. However, in conditions of relatively smooth sliding friction, only the multiphase nanostructured CrAlSiN coating retains wear resistance. In conditions of drop-impact erosion, nanocompositional multilayer VIP coatings of TiN/MoN composition demonstrate the highest resistance, which compete with the recognized champion in this field - welded plates of stellite VZK (WCoCr). Despite the fact that the thickness of the VIP coatings viewed in the paper is a film of 1...10 microns, whereas the stellite plates have a thickness of at least 4 mm. In conclusion, it is noted that VIP technology continues to develop new materials, for example, to create diamond-like coatings or coatings made of high-entropy alloys. VIP technology corresponds to a high level of science intensity, and VIP coatings are promising for putting to use in mechanical engineering.

Influence of Chemical Composition of Abrasive Materials and Strength of Interlayer Boundaries on Impact and Abrasive Wear Resistance of Layered Composite Materials

Influence of Chemical Composition of Abrasive Materials and Strength of Interlayer Boundaries on Impact and Abrasive Wear Resistance of Layered Composite Materials

On Three Body Abrasive Wear Resistance of Eggshell and Marble Powder Reinforced Hybrid Sustainable Polymer Composites

On Three Body Abrasive Wear Resistance of Eggshell and Marble Powder Reinforced Hybrid Sustainable Polymer Composites

Microstructural evolution and mechanical behavior of WC–4wt.%TiC–3wt.%TaC–12wt.%Co refractory cermet consolidated by spark plasma sintering of mechanically activated powder mixtures

The paper studied the structural features and physicomechanical properties of the WC–4wt.%TiC–3wt.%TaC–12wt.%Co composite refractory hard alloy system obtained by spark plasma sintering (SPS) from a preliminarily mechanically activated powder. It has been shown that preliminary mechanical activation in a planetary mill contributed to the comminution of agglomerates and the formation of a monomodal particle size distribution with a predominance of the submicron fraction, which intensifies the densification processes during subsequent consolidation by the SPS method. Kinetic analysis of the SPS process showed a two-stage sintering pattern with intense densification at temperatures above 790 °C due to rearrangement of WC, TiC, TaC particles and melting of the cobalt binder. It has been found that the SPS method does not lead to the formation of undesirable secondary phases in the entire sintering temperature range. A sintering temperature of 1200 °C is optimal for achieving the best structural homogeneity, density and mechanical properties, providing optimal distribution of carbide phases and the cobalt binder. The microstructure of the sample obtained at 1200 °C represents a refractory skeleton of WC grains with TiC and TaC carbide particles uniformly distributed throughout the volume. Improved fluidity of the melted cobalt binder and its mobile redistribution contribute to increased compactness of the structure and reduced porosity of the material. Samples sintered at 1200 °C possess high physicomechanical characteristics: relative density 99.99 %, hardness HV30 1623.2, bending strength 1125.1 MPa, fracture toughness 10.5 MN⋅m1/2. The abrasive wear resistance of a newly synthesized hard material was evaluated through a turning operation. Results showed durability, indicating promise for cutting tool applications and the need for further research to fully characterize the performance of this novel material.

Achieving the Superior Abrasive Wear Resistance in ZTAP/Fe Composites from the Theoretical Calculations Guided Designing of Metallurgical Interface Transition Layer

Using the first-principles calculations and phonon QHA method, the thermodynamic stability, mechanical and thermophysical properties of binary Ni-Ti phases are obtained. The most thermodynamically feasible binary Ni3Ti phase with a superior elasticity and mechanical tensile strength is designed as the interfacial transition layer between ZTA ceramic particles and iron matrix. A high-Cr white cast iron matrix composite reinforced with ZTA particles is fabricated via infiltration casting process. The microstructures and three-body abrasive wear resistance of the composite are investigated. The obtained ZTAP/Fe composite has a compact metallic Ni3Ti metallurgical transition layer with a small amount of AlNi2Ti and TiO phases in the interfacial region, leading to a strongly adhesion between iron matrix and ZTA ceramic particles due to the presence of covalent Ti-O, Fe-O and Zr-O bonds. The composite exhibits the relative wear resistance 12.9 times higher than that of reference Cr15 specimen. The wear mechanism of the ZTAP/Fe composite is mainly attributed to the removal of iron matrix under the SiO2 abrasives, as revealed from the secondary electron images and laser scanning confocal topography.

The effects of heat treatment on the mechanical properties of 450 HB wear resistant steel

The effects of heat treatment on the mechanical properties of 450 HB wear resistant steel produced by Usiminas steelworks in the form of heavy plates were investigated. The results showed that when tempering temperature is lower than 200°C, there are no significant changes in hardness, tensile properties and absorbed energy in Charpy V-notch test. With further increase in temperature up to 400°C, hardness, tensile strength, total elongation and impact toughness exhibited a slight downward trend. For heating carried out from 400°C to 600°C, a very significant drop in hardness and tensile strength and an increase in total elongation and absorbed energy values were observed. The abrasive wear resistance, evaluated by dry-sand rubber wheel test, increased with the heating up to 500°C. With the additional rise in temperature to 600°C, the abrasive wear resistance decreased, reaching a similar level to the reference state (steel in as-delivered condition).

Role of Quenching Temperature Selection in the Improvement of the Abrasive (Al2O3) Wear Resistance of Hybrid Multi-Component Cast Irons.

In this paper, enhancing the tribological characteristics of novel cast metallic materials-hybrid multi-component cast irons-by applying a strengthening heat treatment is described. The experimental materials were the cast alloys of a nominal composition (5 wt.% W, 5 wt.% Mo, 5 wt.% V, 10 wt.% Cr, 2.5 wt.% Ti, Fe is a balance) supplemented with 0.3-1.1 wt.% C and 1.5-2.5 wt.% B (total of nine alloys). The heat treatment was oil-quenching followed by 200 °C tempering. The quench temperature (QT) varied in the range of 900-1200 °C, with a step of 50 °C (with a 2-h holding at QT). The correlation of the QT with microstructure and properties was estimated using microstructure/worn surface characterization, differential scanning calorimetry, hardness measurement, and three-body-abrasive wear testing (using Al2O3 particles). The as-cast alloys had a multi-phase structure consisting of primary and/or eutectic borocarbide M2(B,C)5, carboborides M(C,B), M7(C,B)3, M3(C,B), and the matrix (ferrite, martensite, pearlite/bainite) in different combinations and volume fractions. Generally, the increase in the quenching temperature resulted in a gradual increase in hardness (maximally to 66-67 HRC) and a decrease in the wear rate in most alloys. This was due to the change in the phase-structure state of the alloys under quenching, namely, the secondary carboboride precipitation, and replacing ferrite and pearlite/bainite with martensite. The wear rate was found to be inversely proportional to bulk hardness. The maximum wear resistance was attributed to QT = 1150-1200 °C, when the wear rate of the alloys was lowered by three to six times as compared to the as-cast state. With the QT increase, the difference in the wear rate of the alloys decreased by three times. The highest abrasive resistance was attributed to the alloys with 1.1 wt.% C, which had a 2.36-3.20 times lower wear rate as compared with that of the reference alloy (13 wt.% Cr cast iron, hardness of 66 HRC). The effects of carbon and boron on hardness and wear behavior are analyzed using the regression models developed according to the factorial design procedure. The wear mechanisms are discussed based on worn surface characterization.

Abrasive Wear Resistance of Nodular Cast Iron After Selected Surface Heat and Thermochemical Treatment Processes

Abrasive Wear Resistance of Nodular Cast Iron After Selected Surface Heat and Thermochemical Treatment Processes

Analysis of Tribological Properties of Hardfaced High-Chromium Layers Subjected to Wear in Abrasive Soil Mass.

This article presents the results of abrasion wear resistance tests of wear-resistant steel and surfacing under laboratory conditions and natural operation. Abrasion wear resistance determined on the basis of the study by determining geometrical characteristics of the alloying additives using computer image analysis methods, as well as examining the changes occurring on the surface of the workpieces and their wear intensity. Based on the results obtained from laboratory tests, it was noted that AR steel exhibited 14 times greater wear than the padding weld. This wear is affected by alloy additives, which, for the padding weld, are chromium additives. The microstructure image shows that soil mass had a destructive effect mainly on the matrix of the material, whereas in the areas with high concentrations of chromium precipitates, this effect was significantly weaker. The operational test results showed that within the area of the tine subjected to hardfacing, the material loss was lower than that for the same area of the tine in the as-delivered state. For the hardfaced tine, a 7% loss of volume was noted in relation to the operating part before testing and following the friction process. However, for the operating part in the as-delivered state, this difference amounted to 12%.

Machinability improvement by in-operando Tool Protection Layers through designed steel alloying: The case of manganese steel

Improvements in machinability by alloying of the workpiece often adversely impact the end user properties of a material. For example, the common use of non-metallic inclusions can lead to improved tool life during turning or milling, but often adversely affects weldability, corrosion, and wear resistance. A cutting tool material meets kilometers of workpiece material during a machining operation. Hence elements in small quantities in the workpiece may insignificantly affect the end user properties but may have large effects on tool wear. One such effect is the formation of refractory and wear resistant reaction products between the workpiece and tool. Such reaction products forming on tool surfaces may lead to improved machinability. This paper proposes the use of small amounts of alloying to induce such a Tool Protection Layer. Additionally, the paper develops a computational framework for designed alloying which balances formation of Tool Protection Layers, its in-process retention, and the functional properties of the alloy. The method has been validated for a case of manganese steel. The calculations were validated first by a wide range of diffusion experiments. Then by industrial turning of cast alloys, by comparing one reference and two newly designed alloys based on the alloying concept. The alloy with 0.003 mol fractions of Al resulted in more than 3 times increase in tool life, due to in-operando formation of Al2O3 Tool Protection Layer. The designed manganese steel maintained its functional properties with respect to abrasive wear resistance and retained its ability to work harden.

Effect of filling materials on the tribological performance of polytetrafluoroethylene in different wear modes

AbstractAs it is known, Polytetrafluoroethylene (PTFE) is one of the most preferred polymeric materials for tribological applications. This study investigates the performance of PTFE and its composites under different tribological conditions. The effects of short glass fiber (GF), carbon particle (CP) and bronze particle (BP) reinforcement agents and their hybrid filling with molybdenum disulfide (MoS2) on sliding, erosive and abrasive wear were examined. Sliding tests were carried out with a ball‐on‐disc test apparatus, erosive wear tests were carried out with solid particle erosion and abrasive wear tests were carried out with a scratch test. It has been found that reinforcement agents improve sliding and abrasive wear resistance but worsen the erosion resistance. The hardness and contact angle of the samples were associated with their wear performances. Topographic and morphological analyzes of worn surfaces were performed using optical profilometer and scanning electron microscopy (SEM), respectively, and wear mechanisms were discussed.Highlights Filling materials (glass fiber, carbon particle and bronze particle) increase the adhesion and abrasion resistance of PTFE, while decreasing its erosion resistance. The effect of hybrid addition of MoS2 solid lubricant on wear performances depends on the type of filler. There is a correlation between surface properties (hardness and contact angle) and wear performances. Optical profilometer and scanning electron microscopy were used to examine wear mechanisms.

Effects of Ti/Nb Dual-Element Addition on the Microstructure and Properties of Tungsten Carbide-Reinforced Laser Cladding Coatings

Metal-ceramic composite coatings are produced on the surface of equipment components by laser cladding, improving the abrasive wear resistance of components and extending their service life. However, defects such as brittleness and cracks limit the wide application of metal-ceramic clad coatings in the field of construction machinery. In the present study, a dual-element (Ti/Nb) alloying method is innovatively adopted to regulate the microstructure and mechanical properties of tungsten carbide (WC)-reinforced clad coatings. Experimental results show that with the introduction of Ti/Nb, novel reinforcements are in-situ synthesized in the cladding coatings with two different kinds of morphologies: one is a core-shell carbide with the core of pure TiC and a shell of (Ti,Nb,W)C multiple carbide; the other is a (Ti,Nb,W)C multiple carbide. With 8 wt.% Ti/Nb addition, the newly formed multiple carbides with the appropriate content are well-dispersed and distributed in the clad coating, which effectively transfers load, inhibits the initiation and expansion of micro-cracks, and resists the wear damage of hard abrasive particles, solving the technical problems of the simultaneous improvement of toughness and abrasive wear resistance of metal-ceramic laser cladding coatings.

Microstructure, cracking susceptibility and abrasive wear resistance of core-shell ceramic particles reinforced laser cladding coatings

In this study, the typical core-shell ceramic particles were synthesized in-situ in the Fe-based composite coating using the laser cladding technology. The core-shell ceramic particles were composed of a pure TiC core and a (Ti,Nb,W)C multiple carbide shell, exhibiting fine cubic morphologies with particle sizes ranging from 0.5 μm to 1.0 μm rather than coarse dendritic morphologies. These core-shell ceramic particles were uniformly distributed in the entire coating with no obvious gradient distribution from the upper to the bottom. With the formation of the core-shell ceramic particles, the clad coating showed a more stable microhardness distribution along the depth direction and a lower cracking susceptibility than the original coating, and its average microhardness value (about 410 HV0.5) was only about 64 % of that of the original coating (about 640 HV0.5). Besides, the introduction of the core-shell ceramic particles caused the clad coating to possess the excellent abrasive wear resistance, which was approximately 10 times higher than that of the original coating. This significant improvement was attributed to the outstanding dispersion strengthening effect provided by the core-shell ceramic particles.