Abrasive Wear Resistance Research Articles

Evaluation of abrasive wear resistance of self-fluxing Ni-base coatings by scratch testing

"Abrasion wear is one of the most dominant types of wear in many applications, causing over 50% of all wear failures [1]. The abrasive wear phenomenon could be classified regarding several aspects: a) the position of the abrasive particles: two-body abrasion if they are fixed, or three-body abrasion if they are free to slide and/or roll, b) the stresses involved: gouging abrasion, high-stress abrasion (grinding) and low-stress abrasion (scratching), c) the surface appearance: ploughing, cutting, fatigue and fracture (cracking). In this study was approached the possibility of abrasion wear resistance evaluation of selffluxing Ni-base coatings by scratch testing. Materials used in tests were: three self-fluxing Ni-base coatings deposited on low-alloyed steel substrate using flame spraying process (referred to as S1, S2 and S3). The wear of the samples and the friction coefficient were investigated with scratch tester and analyzed in correlation with their mechanical properties. "

Comparative analysis of abrasion wear resistance of ultra-high-molecular-weight polyethylene and basalt plastics on its basis

Comparative analysis of abrasion wear resistance of ultra-high-molecular-weight polyethylene and basalt plastics on its basis

Effect of ZrB2 additions on the thermal stability of polycrystalline diamond

This study investigates the effect of ZrB2 additions on the microstructure, thermal stability, and thermo-mechanical wear resistance of polycrystalline diamond. Following high-pressure high-temperature (HPHT) sintering, the ZrB2-PCD material binder phase consisted of cobalt-boride (Co2B and B6Co23) phases. In-situ PXRD and TEM vacuum annealing experiments observed that the onset of bulk graphitisation occurred above 1000 °C for the ZrB2-PCD material, compared to 850 °C for the STD-PCD material. The ZrB2-PCD tools showed excellent thermo-mechanical wear resistance, exhibiting increased durability and a steady wear scar progression during high-temperature dry-VTL testing. However, lowered abrasion wear resistance was observed for the ZrB2-PCD tools during low-temperature wet-VTL testing, probably due the reduced diamond contiguity in the ZrB2 additive sample. Further optimisation of the ZrB2 additive phase content, mixing methodology, or sintering conditions could be explored to improve the abrasive wear resistance of this novel PCD material.

Influence of Plasma Electrolytic Oxidation of Cast Al-Si Alloys on Their Phase Composition and Abrasive Wear Resistance

The microhardness and abrasive wear resistance of cast Al-Si alloys after plasma-electrolytic oxidation (PEO) in a weakly alkaline basic electrolyte (3 g/L KOH + 2 g/L Na2SiO3), as well as with the addition of H2O2, were determined. X-ray analysis showed that the PEO layer comprises two oxide phases, namely α-Al2O3 and γ-Al2O3, as well as sillimanite -Al2O3 · SiO2 and a small percentage of mullite -3 Al2O3 · 2SiO2. Silicon is present in the structure of the oxide layer, and its percentage is greater than that of the alloys in their initial state. It has been shown that the characteristics of PEO layers on AK9 and AK12 silumins synthesized in an electrolyte of basic composition increase (microhardness up to 900–1000 HV and abrasive wear resistance by 14–57 times). The formation of PEO layers in the base electrolyte with the addition of 3 g/L of hydrogen peroxide intensifies the synthesis process and promotes the formation of high-temperature oxide phases (in particular, corundum). The abrasive wear resistance of both silumins with PEO layers synthesized in such an electrolyte increases by 30–70%.

Comparative Analysis of Strength Fatigue Properties and Abrasive Wear Resistance for a New Composition of Polymer Concrete Coated with Metal Alloy Powders

The possibility of using powder spraying to improve the strength properties of polymer concrete products has been studied. Different compositions of polymer concrete mixtures have been compared and analyzed in order to find out the adhesive and cohesive properties of coatings. An analysis of the stress-strain state under static loads has been carried out. To improve the tribological properties and wear resistance of critical parts of metal-cutting machine tools, such as beds, it is proposed to spray polymer concrete surfaces using the gas-thermal method. Two types of powder mixtures for spraying have been compared, and the adhesive properties of the analyzed coatings have been considered. The finite element method was used for the calculation of the abrasion resistance of polymer concrete models according to the proposed modification of Ni-7Cr-3Fe + 60% WC coating composition, which showed that the use of gas-thermal coating for polymer concrete is justified. Based on a simulation of adhesive peeling strength, it can be concluded that the wear coefficient of the coated sample is quite large. Under the impact of amplitude loads applied during 5 × 106 loading cycles with a high degree of wear equal to 1.5, the sample showed high safety margins equal to 0.67. The presence of a sprayed layer prevents the concentration of internal stresses in the area of polymer concrete, taking over the resulting stresses under an external force caused by the mechanical properties of the materials, thereby increasing the service life of a manufactured part.

Laser Cladding of NiCrBSi/WC + W2C Composite Coatings

This article presents the results of a study on the laser cladding of metal matrix composite coatings using an experimental custom-made powder composed of NiCrBSi matrix with 65 wt.% reinforcing hard particles of eutectic WC + W2C. The chemical and phase composition of the powder was designed to ensure high hardness, abrasion wear resistance at moderate dynamic loads and corrosion resistance at high temperature of the coatings. The influence of the basic processing parameters of the laser cladding, especially energy input, on the quality and single bead geometry, the dilution, share of the massive carbides in the matrix, and the fraction share of reinforcing carbides particles on cross-section of the clads, as well as hardness profiles and abrasive wear resistance, were analysed and presented. The microstructure of test coatings, chemical and phase composition were analysed by optical and scanning electron microscopes (OM, SEM), EDS and XRD spectrometers. It was found that the differences in the wear resistance of the coatings produced at different energy inputs of laser cladding were directly related to the share of the massive carbides WC + W2C in the metal matrix NiCrBSi. The tribological characteristics of the coatings were also studied and described. The test results indicate that the coefficient of friction for carbides is slightly higher than for the metal matrix, and therefore the greater the share of carbides, the higher the value of the coefficient of friction of the coating.

Impact-abrasive wear resistance of high alumina ceramics and ZTA

In transport of raw materials abrasive wear resistance is a requirement, which can be met with alumina ceramics. At certain locations additional impact load occurs, exacerbating the wear loss. As literature on impact-abrasive wear of ceramics is scarce this topic will be researched in this work.We selected a variety of commercial alumina ceramics (90–96% Al2O3) and according to literature much more impact resistant – and substantially more expensive – Zirconia Toughened Alumina (ZTA, 20–25% Zr) used for wear resistant linings in impact dominated systems. We selected the Impeller-Tumbler test, an impact-abrasion test for wear evaluation of highly loaded ceramic edges. Two load regimes were evaluated for the abrasive, either corundum particles for severe load or steel balls for extreme load conditions. Correlation of wear results with the fracture toughness (K1C) and Vickers hardness of the materials is intended – material parameters used as measure for brittle failure of ceramics and wear resistance, respectively.The various ceramic materials showed very different wear behaviour under the impact-abrasive load. The 90% Al2O3 was least wear resistant under both load conditions. Interestingly large differences between the 92% types were found at extreme load conditions. The increase of alumina content to 95–96% showed remarkable benefits in both wear regimes. Best wear resistance against severe load was achieved by 25% ZTA, while it is comparable to the 95–96% high alumina types at extreme load.

Macroscopic and nanoscale investigation of the enhanced wear properties of medium-Mn steel processed via room-temperature quenching and partitioning

High-manganese austenitic and high hardness martensitic steels are widely used in wear-related applications. However, their abrasive wear performance is unsatisfactory because of the insufficient twinning induced plasticity effect of the former and the weak strain hardening and low crack resistance during wear of the latter. Here, novel wear-resistant steels were developed via alloy design and simple room-temperature quenching and partitioning (RT-Q&P) of medium Mn steels (0.3C–10Mn and 0.3C–10Mn-0.25V). Their microstructure and sliding abrasive wear behavior were compared to those of conventional Hardox400 and Hadfield steels. The two medium-Mn steels had better wear properties than conventional wear-resistant steels. Moreover, the V-containing steel with a multiphase microstructure of tempered martensite, retained austenite, and nano-vanadium carbide precipitates, possessed 2.98 and 3.45 times higher abrasive wear resistance than the Hardox400 and Hadfield steels, respectively. Besides the stimulated transformation-induced-plasticity effect in RT-Q&P steels, the enhanced abrasive wear resistance of V-containing steel was attributed to microstructural refinement and improved strain hardening during wear imparted by V element. The main wear mechanism of RT-Q&P wear-resistant steels was cutting, while it was grooves and pits for Hadfield steel, and peeling pits and delamination for Hardox400 steel. This study can guide the design of structural materials with excellent wear resistance through multiphase microstructural and nano-precipitate regulation to overcome the wear challenges of components.

Effect of stacking sequence on abrasive wear behavior of abaca natural fiber reinforced polymer composites hybridized with glass fiber

This paper aims to investigate the tribological behavior of Abaca/Glass fiber reinforced epoxy hybrid composite. Different stacking sequences of Abaca(A) and Glass(G) fiber (AAAA, AGAG, AGGA, GAAG) are reinforced with epoxy polymer for fabrication of hybrid composite structure. Dry sliding abrasive wear characteristics of developed composites is analyzed by pin-on-disc (ASTM G99) test rig. The experiment is operated with different sliding velocities (1, 2, 3 m/s), applied load (10, 20, 30 N) and sliding distance of 2000 m. The experimental result indicates abrasive wear resistance is drastically enhanced with the abaca and glass fiber reinforcement in epoxy composite. Furthermore, least wear is found for AGGA hybrid composite. Morphology of worn surfaces were investigated by SEM analysis that indicates formation of micro crater, micro grooves and micro cracks.

Comparative studies of the three-body abrasion wear resistance of hardfacing Fe-Cr-C-B-Ti alloy

In this research, the mechanical and tribological properties of two deposited metal of Fe-C-Cr-B-Ti alloying systems. In this study, comparative tests of the deposited metal hardfacing by two self-shielded flux-cored wires electrode were carried out: with an exothermic additive (110Cr4Cu5Ti1MnVB) and without an exothermic additive (140Cr15TiSi1MnVB). Abrasive wear resistance was evaluated using a slightly modified procedure on a standardized tribological machine for abrasive wear, according to the limits established by the ASTM G65. The results of studies of the efficiency of introduction of an exothermic addition CuO-Al system into the core filler of a flux-cored wire electrode were presented.

Evaluation of the possibility of improving the durability of tools made of X153CrMoV12 steel used in the extrusion of a clay band in ceramic roof tile production

Abstract The article presents the results of a complex comparative analysis of the abrasive wear resistance of tools made of X153CrMoV12 steel after different heat treatment variants. These investigations aimed to select the most durable material for application in tools forming a mass band in the production of ceramic roof tiles. The tests included the determination of resistance to abrasive wear in ball-on-disc tests, hardness measurements, and microstructure analysis, including the assessment of changes occurring in the subsurface area, as well as impact tests (at a working temperature for the tools of 50°C). The comprehensive test results showed that the best effects of increasing the resistance to abrasive wear can be obtained through a heat treatment that consists of hardening at 1020°C and then tempering at 200°C for about 2 hours. The next stage of research will be to compare the results obtained with another popular material for tools for the production of roof tiles - Hardox steel, which is characterized by high resistance to abrasive wear.

ABRASIVE WEAR RESISTANCE OF FE3AL AND STELLITE 6 COATINGS FOR THE PROTECTION OF VALVE SEATS SURFACES

The development of a technology that increases the service life of valve seats in CNG/LNG-powered vehicles requires the appropriate selection of material and the technology of its application. Commercially used valve seat materials show accelerated wear under operating conditions, especially in natural gas vehicle engines. The authors developed a new material concept and a new technological concept for the protection of the valve seat in CNG/LNG-powered vehicles. This article aims to present the first stage of tribological research. Two materials were used in the research: Stellite 6 alloy and Fe3Al intermetal. A commonly used material for valve seats of combustion engines is Stellite 6. The Fe3Al is the new proposed material coating for the protection of the valve seats of internal combustion engines. This article compares the abrasive wear resistance of these materials. The abrasion tests were performed on a T-11 pin-on-disc tester, and the counter-sample was steel S235JR. The test conditions were similar to those prevailing during the operation of the valves in the head of the internal combustion engine, without the influence of temperature. The obtained results indicate that the Fe3Al intermetal is characterized by a lower coefficient of friction and lower wear intensity than Stellite 6. The results confirm that the Fe3Al phase is a prospective material to be used as a protective material on the valve seat of vehicles.

Use of Ion Beam Enhanced Deposition (IBED) Titanium Nitride for Knee Arthroplasty Implants.

For much of recent history, the metal-bearing surface in total knee arthroplasty has not changed much, with cobalt-chromium being the most widely-used material. However, due to the presence of nickel in its composition, much research has been done to develop alternative metal-bearing surfaces for patients with metal sensitivity. Titanium nitride coatings have shown improved performance and resistance to abrasive wear when compared to their counterparts, thus making this material an ideal alternative to current implant technology. Rigorous testing was undertaken to analyze the mechanical properties of titanium nitride for use as a coating in orthopedic implants, such as scratch adhesion, hardness, modulus, and wear rates with specialized machinery, including a Tribometer®, Nano Indenter® G200 (KLA Corporation, Milpitas, California), and scratch system. Across all properties tested-abrasive wear resistance, wear resistance, cohesive and adhesive failure load, hardness, and modulus-IBED TiN coatings were shown to be dominant to both uncoated CoCr and uncoated Ti-6Al-4V in a significant manner. The use of IBED TiN coatings offers a way to improve the performance of mechanical components, such as orthopedic implants made from Ti-6Al-4V materials. IBED TiN coatings can enable the use of Ti-6Al-4V as an alternative to CoCr for articulating orthopedic implant devices, such as knee arthroplasty.

A Newly Designed High-Strength Tool Steel with High Wear and Corrosion Resistance

In this study, a newly developed high-strength cast Fe81Cr15V3C1 (wt%) steel with a high resistance against dry abrasion and chloride-induced pitting corrosion is presented. The alloy was synthesized through a special casting process that yielded high solidification rates. The resulting fine, multiphase microstructure is composed of martensite, retained austenite and a network of complex carbides. This led to a very high compressive strength (>3800 MPa) and tensile strength (>1200 MPa) in the as-cast state. Furthermore, a significantly higher abrasive wear resistance in comparison to the conventional X90CrMoV18 tool steel was determined for the novel alloy under very harsh wear conditions (SiC, α-Al2O3). Regarding the tooling application, corrosion tests were conducted in a 3.5 wt.% NaCl solution. Potentiodynamic polarization curves demonstrated a similar behavior during the long-term testing of Fe81Cr15V3C1 and the X90CrMoV18 reference tool steel, though both steels revealed a different nature of corrosion degradation. The novel steel is less susceptible to local degradation, especially pitting, due to the formation of several phases that led to the development of a less dangerous form of destruction: galvanic corrosion. In conclusion, this novel cast steel offers a cost- and resource-efficient alternative to conventionally wrought cold-work steels, which are usually required for high-performance tools under highly abrasive as well as corrosive conditions.

Optimum abrasive wear resistance for epoxy composites reinforced with polyethylene (PET) waste using Taguchi design and neural network

The current work presents a study of the tribological properties of composite materials designed based on polyethylene terephthalate (PET), which has an important role in the structures of machines, represented by tribological couplings made of composite polymers. The paper examined the effect of two factors, namely recycled waste heating time (HT) and weight percentage (wt. %), on the improvement of the abrasive wear resistance of micro-filler-reinforced epoxy composites. The current research aims to develop epoxy composites by improving abrasive wear resistance while ensuring low cost and weight. Improving wear resistance due to the use of epoxy composites to connect joints that operate under conditions without lubrication in various industrial fields will increase their operational life. The signal-to-noise ratio was analyzed to find out the effect of test parameters HT and wt. % on the wear rate of epoxy composites. Using MINITAB 19 software, regression equations were obtained for each variable to compare it with the Artificial Neural Network (ANN) results. Predictive models based on the regression equation and artificial neural network were developed to predict the wear rate of epoxy composites, and to determine which model is more efficient, their results were compared and the most appropriate model with the low error was determined. The results of the current research showed that the wear resistance of epoxy composites reinforced with RCCF improved by 41 % when increasing wt. % and HT, and also showed that the ANN model is more suitable than the regression model for predicting the wear rate of epoxy composites

Effect of strength and toughness of ceramic particles on impact abrasive wear resistance of iron matrix composites

The wear resistance of ceramic particle reinforced metal matrix composites is closely related to the properties of ceramic particles. In this study, three kinds of ceramic particle (with 30 % volume fraction) reinforced iron matrix composites (Al2O3/Fe45, ZTA(Zirconia toughened alumina ceramic particles)/Fe45 and ZrO2/Fe45) were prepared by powder metallurgy method. The mechanical properties, impact abrasive wear resistance and impact abrasive wear mechanism of the composites were studied, and the phase transformation of ceramic particles in the composites was analyzed. The results show that the elastic modulus and hardness of ZTA/Fe45 composite are between Al2O3/Fe45 and ZrO2/Fe45, which are 248.5 GPa and 13.3 GPa, respectively. The ZTA/Fe45 composites exhibit a better impact wear resistance than the other two composites. The impact abrasive wear resistance of the three kinds of composites is positively correlated with the product value of fracture toughness and hardness (H·KIC) of ceramic particles. The wear mechanism of the Fe45 matrix of the composite is micro-furrow and plastic deformation. The brittle fracture and spalling of Al2O3 ceramic particles occur after impact abrasive wear, forming spalling pits and accelerating the wear of Al2O3/Fe45 composites. ZrO2 ceramic particles lead to easy removal from the Fe45 matrix due to lower hardness after impact abrasive wear. ZTA ceramic particles protruded from the surface of the Fe45 matrix after impact abrasive wear. On the surface of ZTA particle, the irregular protuberant steps morphology are formed by SiO2 abrasive impact and tangential wear. The ZTA and ZrO2 ceramic particles in the worn surfaces of the composites undergo t-ZrO2 to m-ZrO2 phase transformation during the impact wear, and the t→m phase transformation content is related to the impact energy. The amount of phase transition increases with the increase of impact energy, When the impact energy is higher than 2J, the amount of phase transition tends to be stable. Under the same impact energy, the amount of t→m phase transition in ZrO2 particles is much lower than that in ZTA. The t→m phase transformation increases the toughness of ZTA particle，improving the impact abrasive wear resistance of ZTA/Fe45 composite.

Changes in Abrasion Resistance of Cast Cr-Ni Steel as a Result of the Formation of Niobium Carbides in Alloy Matrix

Cast austenitic chromium-nickel steel is commonly used for the manufacture of machine parts and components, which are exposed to the attack of corrosive media and abrasive wear during operation. The most commonly used grades include GX2CrNi18-9 and X10CrNi18-8 as well as GX2CrNiMo17-12-2 and X6CrNiMoNb17-12-2. To improve the abrasion resistance of cast chromium-nickel steel, primary niobium carbides were produced in the metallurgical process by increasing the carbon content and adding Fe-Nb. The microstructure of the obtained test castings consisted of an austenitic matrix and primary niobium carbides evenly distributed in this matrix. The measured hardness of the samples after heat treatment ranged from 215 to 240 HV and was higher by about 60 units than the hardness of the reference cast GX10CrNi18-9 steel, which had a hardness of about 180 HV. Compared to the reference cast steel, the abrasive wear resistance of the tested cast chromium-nickel steel (measured in Miller test) with contents of 4.4 and 5.4 wt% Nb increased only slightly, i.e., by 5% for the lower niobium content and 11% for the higher niobium content. Compared to ordinary cast GX10CrNi18-9 steel, the addition of 9.2 wt% Nb reduced the abrasive wear by almost 2.5 times.

Surface roughness analysis in finishing end milling of Hardox® 450 steel using multilayer graphene-based nanofluid

Hardox® 450 is a structural steel commonly used in the mining and agricultural sectors due to its hardness and toughness combined with high abrasion wear resistance. It is widely known that good surface quality minimizes the occurrence of cracks generating higher fatigue resistance. However, the characteristics of this steel make it difficult to cut, resulting in greater complexity in the choice of process parameters. Additionally, the general industry concern for clean machining encourages the use of lubricooling conditions with less environmental impact. In order to address these difficulties, the paper aims to investigate the performance of multilayer graphene-based nanofluid applied in reduced quantity (NF-RQL) on surface roughness generated by finishing end milling of Hardox® 450 when compared to dry and flood machining. The cutting parameters at three levels were combined, randomized and analyzed via Box–Behnken design. The experimental results showed that the lowest roughness on average values was obtained with NF-RQL (Ra = 0.207 μm), followed by flood machining (Ra = 0.326 μm). The Abbott–Firestone and amplitude probability distribution statistical analysis indicated a greater uniformity of peaks and valleys in the roughness profile obtained by NF-RQL milling than in the other lubricooling environments. All prediction models demonstrated an excellent ability to estimate the roughness values (R-squared > 85%). After the multivariate optimization, NF-RQL and flood conditions generated similar average roughness values (respectively, 0.106 μm and 0.115 μm). However, the material removal rate with NF-RQL (2315 mm3/min) is about 83% higher than flood (1266 mm3/min), justifying its better performance.

The Effect of Heat Treatment on the Structural-Phase State and Abrasive Wear Resistance of a Hard-Anodized Layer on Aluminum Alloy 1011

The aim of this study was to evaluate the effect of heat treatment on the phase composition, hardness, and abrasion wear resistance of hard-anodized layers (HAL) on 1011 aluminum alloy. X-ray diffraction analysis revealed the Al2O3·3H2O phase in the structure of HAL synthesized for 1 h. While in the heat-treated HAL, aluminum oxide phases of the α-Al2O3(amorphous) and γ-Al2O3(amorphous) types were found. Treatment at 400 °C for 1 h increased the HAL microhardness from 400 to 650 HV, and its abrasive wear resistance with fixed abrasive by up to 2.6 times. The ranking of various ways of hardening aluminum alloys relative to the D16 alloy showed that the abrasive wear resistance of heat-treated HAL is 20 times higher. Plasma electrolyte oxidation increased the abrasive wear resistance of the D16 alloy by 70–90 times, and its coating with high-speed oxygen fuel by 75–85 times. However, both methods are complex, energy-consuming, and require fine grinding of parts. Despite the lower wear resistance of HAL, their synthesis is cheaper and does not require the fine-tuning of parts. Moreover, despite the low hardness of HAL at present, hard anodizing is already commercially used to harden engine pistons, clamshell rotators, and pulleys.

Development of WC-NiCrMo hardmetals

The demand for improved components with a wide range of properties is a reality in today's hardmetal market. Furthermore, supply shortages of raw materials such as W and especially Co resulted in rapid price fluctuations. Combined with stricter environmental legislation and health protection, these facts prompt the demand for alternative or modified binders. Therefore, in this work, WC-NiCrMo composites were developed as a potential alternative to conventional WC-Co hardmetals. To evaluate this new hardmetal composite, prototypes of submicrometric WC with approximately 15 vol% of NiCrMo binder were produced by conventional powder metallurgy route. Thermodynamic assessment, wettability testing and constant heating rate dilatometry were performed to design an adequate sintering route. A detailed characterization of the mechanical properties (Young's modulus, Vickers hardness and fracture toughness), together with corrosion resistance assessment (OCP, polarization curves, EIS) and abrasive wear (ball-cratering) resistance evaluation were undertaken. Good wettability of molten NiCrMo binder on WC surface was observed, and highly dense compacts could be successfully attained by gas pressure sintering. The new WC-NiCrMo composite has lower hardness but higher corrosion resistance and better wear resistance than the conventional WC-Co hardmetals.