Abrasive Research Articles

Application of Multifunctional Wellbore Cleaning Fluid in the Removal of Residual Drilling Fluids in Ultra-Deep Wells: Research Progress and Prospects

Developing ultra-deep wells presents a significant challenge in current petroleum exploration and production. Ensuring the cleanliness of the wellbore is a crucial aspect of safeguarding the development process. Removing contaminants from residual drilling fluids is vital to ensure unobstructed production pathways in ultra-deep wells, thereby achieving secure operational environments. This paper analyzes the primary residual components of drilling fluids in post-drilling operations of ultra-deep wells. It also explores the synergistic damaging mechanisms of residual drilling fluids on casing-ion corrosion and abrasive wear. Moreover, we summarize the technical challenges involved in the flushing and treatment of ultra-deep wellbores. Drawing from global developments in flushing fluids for ultra-deep wellbores, this study investigates the performance and on-site applicability of various flushing fluids. The findings indicate that the flushing of ultra-deep wellbores necessitates the development of fluid systems tailored to different well conditions and residual components. Adaptable flushing fluids exhibit suitability across diverse operational scenarios. Furthermore, understanding the mechanisms of flushing fluids provides novel perspectives for their future development. Presently, research on the mechanisms of flushing fluids predominantly relies on experimental observations and theoretical simulations. This study analyzes the future directions of flushing fluid research by summarizing and synthesizing existing technical challenges. In conclusion, as discussed in this study, the tailored technology for flushing wellbores lays a fundamental groundwork for large-scale flushing and treatment of ultra-deep wells, thus offering a foundational contribution to the field.

THE EROSIVE WEAR OF GRAPHENE OXIDE REINFORCEDEPOXY POWDER COATINGS

Powder coatings are organic coatings that protect the metal substrate against corrosion and wear, and playa decorative role. The doping of paints with nanoparticles is intended to create a barrier to corrosive andchemical agents and to increase abrasion resistance. This work tested the erosion resistance of epoxy powdercoating with graphene oxide flakes and polyethylene wax covered with a layer of micro diamonds. Twomethods of testing resistance to abrasive wear were used, in which the conditions are similar to operatingconditions: solid particle impingement (sandblasting) and barrel finisher with ceramic shapes. Mass loss dueto erosion in a sandblaster using glass beads with a diameter of 200 μm for the paint with graphene was muchlower than for the reference sample. The mass loss of the samples was tested after 15, 30, and 60 seconds ofabrasive jet operation. The surface texture was analyzed during the process and after the test. The test in thebarrel finisher was carried out twice for different times: for the first series weight loss was measured after 30,90, and 210 minutes, for the second Vickers hardness at 40 g load after 90 and 210 minutes. The tests showedthat the epoxy coating with the addition of graphene oxide has a much higher resistance to erosion under theinfluence of an abrasive stream than the reference paint, and a similar resistance to erosion in a containersmoother. It was found that the paints showed a higher Vickers hardness after the wear test.

Corrosion and wear performance and mechanism study of ZrB2/AA6016

Abstract This study involved the fabrication of aluminum matrix composites reinforced with ZrB2/AA6016 particles using the KBF4-Al-K2ZrF6 reaction system， the composites were then subjected to T6 heat treatment. An investigation was conducted to examine the impact of varying friction speeds on the corrosion and wear characteristics of ZrB2/AA6016. An investigation was conducted to study the frictional wear behavior of ZrB2/AA6016 in the presence of 3.5wt. % NaCl, both before and after T6 heat treatment. The study also aimed to understand the underlying mechanism of this behavior. The results indicate that the T6 heat treatment mitigates the impact of thermal stresses and strains caused by thermal mismatch, hence enhancing the material's wear resistance. The coefficient of friction (COF) for heat-treated ZrB2/AA6016 is lower than that for unheated-treated ZrB2/AA6016. As friction increases, the pace at which the material wears down tends to decrease. At a friction wear velocity of 50 mm/s, the wear rate of the material is minimized both before and after heat treatment, measuring 0.23×10-2mm3/Nm and 0.22×10-2mm3/Nm, respectively. Through the utilization of XRD, SEM, EBSD, TEM, and XPS analytical techniques, it has been determined that the ZrB2 particles exhibit strong bonding with the Al matrix. Additionally, the particle diameters range from 50~150nm. Following the T6 heat treatment, the grain size measured 40.53μm, while the proportion of large-angle grain boundaries was found to be 66.4%. The accumulation of Cl- resulted in the formation of localized corrosion pits on the surface undergoing wear, hence hastening the deterioration of the material. The primary causes of wear failure are corrosive wear, abrasive wear, and oxidative wear.

Enhanced Tribological Performance of UHMWPE Composites Reinforced With Wollastonite: Biocompatibility and Wear Behavior

Abstract Ultra-high molecular weight polyethylene (UHMWPE) is often limited by poor tribological properties in artificial joints, leading to high wear-rates compared to metals and ceramics. This study explores the use of wollastonite, a natural mineral, as a filler to enhance the tribological performance of UHMWPE composites. X-ray diffraction (XRD) analysis revealed that wollastonite content and particle size inversely affected the crystallinity of the composite due to heterogeneous nucleation and stress concentration. The incorporation of wollastonite significantly improved the tribological performance, with wear-rate reductions of 71%, 69.81%, and 50.73% under dry friction, normal saline (NS) lubricant, and new-born calf serum (NBCS) lubricant conditions, respectively. The wear mechanisms in the composite were predominantly slight fatigue and abrasive wear, contrasting with the extrusion deformation and severe fatigue wear observed in neat UHMWPE. Additionally, simulated body fluid (SBF) immersion tests demonstrated the composite's ability to form a surface apatite-like deposition. These findings suggest that wollastonite reinforcement effectively enhances both mechanical and tribological properties of UHMWPE.

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.

Influence of ZrB2 Nanoparticles on Microstructure and Mechanical Properties of Ni-Co Coating

To improve the service life of continuous casting crystallizer, the NiCo-ZrB2 coating was prepared using nanocomposite plating technology. Uniformly dispersed nano-ZrB2 particles significantly enhanced the hardness and wear resistance of the coating. Upon testing, the hardness of the coating exceeded 700 HV, with a friction coefficient below 0.2, which was superior to those of pure NiCo or other nanocomposite NiCo coatings reported previously. Microscopic analysis revealed that the addition of dispersants and ultrasonic vibration treatment had facilitated the homogeneous distribution of nano-ZrB2 within the matrix, thereby promoting the formation of numerous nano-twins. Due to dispersion strengthening, fine grain strengthening, and twinning strengthening, the wear behavior of the coating changed from fatigue wear to abrasive wear, and the wear volume was significantly reduced by 82%. The above findings could potentially extend the service life of the coating, reduce the cost of steel loss per ton, and have broad application prospects in other surface protection fields.

Understanding Electric Current Effects on Tribological Behaviors of Instantaneous Current-Carrying Pair With Recurrence Plot

Abstract Armature–rail instantaneous current-carrying friction in electromagnetic launchers refers to a sliding electric-mechanical impact friction and transition-induced arc erosion on a millisecond time scale. To reveal the electric current (50–300 A) effects on friction behavior and wear mechanism, the instantaneous current-carrying friction tests were performed with Al 1060 and Brass H62. Given the short nonlinear friction-induced signals, the friction behavior, including the time-domain information and system state, was comprehensively analyzed via frictional sound pressure (FSP), recurrence plot (RP), and recurrence quantification analysis (RQA). The wear topography was observed and characterized by the multifractal spectrum. Recurrence analyses demonstrate that as the current increases, the nonstationarity of the system state weakens, and the complexity and unpredictability enhance. Higher currents reduce the FSP amplitude, i.e., enhance the interfacial lubrication effect, but intensify electrical wear and surface roughness. This signifies a wear mechanism transition from abrasive wear and slight adhesive wear to arc ablation, fatigue wear, and severe adhesive wear. The widening spectrum width implies that the irregularity and fluctuation of the topography are enhanced with the current. RP patterns and RQA quantifiers correlate with the wear damage state. The results provide a reference for antiwear design and online degradation tracking of the rail.

Impact of tool nose size on the performance and wear behavior of carbide tool when boring 1Cr17Ni2 martensitic stainless-steel parts

Purpose This study aims to examine the cutting performance of a coated carbide tool during the boring of 1Cr17Ni2 martensitic stainless steel, with a focus on how the tool’s structural parameters, particularly the nose radius, affect the wear patterns, wear volume and lifetime of the cutting tool, and related mechanisms. Design/methodology/approach A full factorial boring experiment with three factors at two levels was conducted to analyze systematically the impact of cutting parameters on the tool wear behavior. The evolution of tool wear over the machining time was recorded, and the influences of the cutting parameters and nose radius on wear behavior of the tool were examined. Findings The results show that higher cutting parameters lead to significant wear or plastic deformation at the tool nose. When the cutting depth is less than the nose radius, the tool wear tends to be minimized. Larger nose radius tools have weaker chip-breaking but greater strength and wear resistance. Higher cutting parameters reduce wear for the tools with larger nose radius, maintaining their integrity. Wear mechanisms are primarily abrasive, adhesive and diffusion wear. Furthermore, the full-factorial analysis of variance revealed that for the tool with rε = 0.4 mm and 0.8 mm, the factors contributing the most to tool wear were cutting speed (38.76%) and cutting depth (86.43%), respectively. Originality/value This study is of great significance for selection of cutting tools and cutting parameters for boring 1Cr17Ni2 martensitic stainless-steel parts. Peer review The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-07-2024-0266/

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.

Effect of efficient structural tuning on the microstructure, corrosion resistance, and wear performance of AlCoCrFeNi/AT13 composite coatings

This study developed a rapid structure control technique for AlCoCrFeNi/AT13 (Al₂O₃–13 % TiO₂) composite coatings using plasma spraying and dual powder feeding. Four coatings were fabricated: pure HEA, HEA-D (dispersed), HEA-S1 (multilayer with outer HEA), and HEA-S2 (multilayer with outer AT13). The introduction of AT13 altered the internal stress distribution and enhanced corrosion resistance by lowering the electrochemical reaction rate. In layered coatings (HEA-S1, HEA-S2), the AT13 interlayer barrier reduced corrosion tendency. Additionally, pure HEA coatings exhibited adhesive wear. While HEA-D coatings experienced abrasive wear as AT13 particles improved plastic deformation and interface shearing. HEA-S1 reduced strain and wear via an internal AT13 layer. HEA-S2 achieved superior abrasion resistance through an outer AT13 layer, exhibiting typical abrasive wear mechanisms.

Formation of requirements for impact resistance and wear resistance of grinding balls

The article presents the results of a study of the operation processes of steel grinding balls in semi-autogenous grinding mills (SAG). It was determined that the balls experience both abrasive and impact loads. The properties of steel grinding balls with the same production technology are determined by the chemical composition and the formed microstructure over the entire cross-section of the ball. Balls made using 3 different technologies were studied. The balls of sets 1 and 2 show high hardness values at the surface, sufficient to ensure good resistance to wear during operation, and a sharp decrease in hardness at a distance of ~(15–20) mm from the surface as the volume of pearlite structures increases. At the same time, the balls of the 1st and 2nd sets showed low values of impact strength and insufficient resistance to impact. The lowest hardness values from the surface to the center were observed for set 3. Also, the highest mass loss during the abrasive wear test was recorded for set 3, which is explained by the lowest hardness values. The balls of set 3 showed higher values of impact strength and no splitting during the ball-on-ball test, which is explained by the soft ferrite-pearlite structure both on the surface and across the cross section of the ball, due to the reduced carbon content and the presence of nickel in the chemical composition. At the same time, the balls from set 3 showed the worst result in terms of abrasive wear. In the course of the conducted research, it was established that for successful operation in SAG, steel grinding balls must have a surface with high hardness due to the martensitic structure and a viscous core with a ferrite-pearlite structure. A promising direction in the development of technology for the production of steel grinding balls will be to obtain a steel ball microstructure that decreases uniformly from the surface to the center, which will allow maintaining high wear resistance and increasing the resistance to ball splitting

Effects of Al variations on the microstructure and mechanical properties of laser-cladding AlxNbMo0.5Ti1.5Ta0.5Cr0.5 refractory high-entropy alloy coatings

Lightweight refractory high-entropy alloy coatings (RHEAcs) of AlXNbMo0.5Ti1.5Ta0.5Cr0.5 (where x = 0, 0.1, 0.2, and 0.3) were fabricated on 316L stainless steel surface by pre-placed powder laser cladding (LC) technology. The incorporation of Al element significantly enhanced the forming quality of coatings, resulting in nearly defect-free coatings with a thickness of 1.2–1.4 mm. Microstructural analysis revealed that the coatings were primarily composed of body-centered cubic (BCC) solid solution and C15-Laves phase. Due to the influence of a single brittle BCC phase, the Al-free coating exhibited high strength and brittleness, leading to numerous defects caused by thermal stress. The introduction of Al element refined the microstructure and facilitated the formation of Laves phases at grain boundaries, thereby alleviating stress to a certain extent. Consequently, the microhardness of the RHEAcs was significantly higher than that of the substrate, with the Al-free coating achieving the highest microhardness of 1250 HV, which was 5.89 times that of the substrate. Wear resistance results indicated that, prior to annealing, RHEAcs with varying Al content outperformed 316L stainless steel. Post-annealing, the coatings exhibited significantly lower friction coefficients compared with the annealed 316L substrate. The Al-free coating showed significant accumulation of abrasive particles, leading to severe abrasive and oxidative wear. Conversely, post-annealing oxidation induced the formation of dense and directional oxide accumulation, resulting in a notable improvement in wear resistance. Finally, the underlying strengthening mechanisms have been proposed and analyzed.

Tribological Properties of 7A04 Aluminum Alloy Enhanced by Ceramic Coating

The 7A04 Al alloy is a commonly used lightweight metal material; however, its low wear resistance limits its application. In this study, the wear resistance of this alloy was improved by preparing micro-arc oxidation (MAO) coatings, MAO/MoS2 composite coatings, and hard-anodized (HA) coatings on its surface. The friction and wear behaviors of these three coatings with diamond-like coated (DLC) rings under oil lubrication conditions were investigated using a ring–block friction tester. The wear rates of the coatings on the block surfaces were determined using laser confocal microscopy, and the wear trajectories of the coatings were examined using scanning electron microscopy. The results indicated that, among the three coatings, the MAO/MoS2 coating had the lowest coefficient of friction of 0.059, whereas the HA coating had the lowest wear rate of 1.47 × 10−6 mm/Nm. The MAO/MoS2 coatings exhibited excellent antifriction properties compared to the other coatings, whereas the HA coatings exhibited excellent anti-wear properties. The porous structure of the MAO coatings stored lubricant and replenished the lubrication film under oil lubrication. Meanwhile, the introduced MoS2 enhanced the densification of the coating and functioned as a solid lubricant. The HA coating exhibited good wear resistance owing to the dense structure of the amorphous-phase aluminum oxide. The mechanisms of abrasive and adhesive wear of the coatings under oil lubrication conditions and the optimization of the tribological properties by the solid–liquid synergistic lubrication effect were investigated. This study provides an effective method for the surface modification of Al alloys with potential applications in the aerospace and automotive industries.

Investigate the impact wear failure behavior of CoMoCr engine valve and valve seat pairs under harsh conditions

The wear of sealing face is one of the main reasons for the failure of engine valve and valve seat pair. Changes in engine combustion load, running time, temperature, and other operating conditions can affect the wear of valve-valve seat pair. In this work, the CoMoCr alloy cladding valves and valve seat were used as the pair, to investigate the influencing mechanism of combustion load and valve lift on wear. Three groups of tests under different combinations of combustion loads and valve lifts were completed on self-designed testing rig. The results demonstrate that the increase of combustion load and valve lift exacerbate the wear of the valve and valve seat, and valve lift has a more significant effect on wear than combustion load. The increased combustion load worsens the microslip process and intensifies the abrasive wear process. Whereas valve lift enhances the impact process, causing the dense tribofilm on the material surface to delaminate due to fatigue. Destruction of the tribofilm prevented effective protection of the underlying material, which increased wear process.

Wear properties of Al6061/SiC + B4C + TiC hybrid composites produced by vacuum infiltration method

Abstract In the study, hybrid metal matrix composite (HMMC) structures were produced by vacuum infiltration method (VIM) using Al6061 alloy and varying amounts of SiC, B4C, and TiC ceramic powder pairs. Age-hardening processes were applied to these HMMCs. After heat treatment, wear behavior was examined under different loads using the pin-on-disc test method. All Al6061 hybrid composites exhibited better wear performance than unreinforced Al6061. In the wear tests of composite samples, the lowest volume loss and therefore the highest wear resistance were obtained in Al6061 3 wt.% B4C + SiC composites under 5 N force. The lowest wear resistance due to the highest volume loss was determined in Al6061/1 wt.% TiC + B4C composites under 15 N force. Abrasive and adhesive wear characteristics were observed in field emission scanning electron microscopy(FESEM) images of worn surfaces. Additionally, wear debris, smearing, and deep grove formations were determined on the surface. In the EDS analysis performed on the worn surface, O and Fe elements were found in addition to the elements that are likely to be in the structure (such as Al, B, C, Ti, Si, and Mg). The wear tests caused the formation of oxide layers on the sample surfaces.

Achieving considerable wear resistance in new Ti-based high-entropy alloys through microstructural hardening by adding Nb

In this study, (CoCrNiMn)78Ti22−xNbx eutectic high-entropy alloys were successfully synthesised via an arc melting process under vacuum, and the phase structure, microstructure, mechanical properties and dry sliding tribological behaviour of the alloys were systematically investigated. The XRD results for the (CoCrNiMn)78Ti22−xNbx eutectic high-entropy alloys are almost in agreement with the JMatPro phase diagram simulations, and the volume fraction of the Laves phase increased with increasing Nb content. OM and SEM images revealed that the microstructure was composed of dendrites (BCC A2) and interdendrites (BCC B2 +Laves) and changed from a hypoeutectic to a eutectic to a BCC B2 +Laves dual-phase structure, with the average grain size decreasing from 6.715 µm to 6.391 µm. Ti promoted the growth of the layered Laves phase and provided the alloy with base hardness and wear resistance. The hardness of the alloy combination of 21 % Ti and 1 % Nb reached the maximum value of 707.04 HV, whereas the average coefficient of friction (COF) and wear rate reached the lowest values of 0.49 and 1.668 × 10−4 mm3/N·m, respectively. With increasing load, the wear mechanism was mixed fatigue, delamination wear, and abrasive wear accompanied by oxidation, and the possibility of three-body wear paths between compacted tribolayers cannot be excluded. The debris was mostly in the form of microclusters, and the particle size range was concentrated between 1 −2 µm; meanwhile, the shape of the debris tended to develop from lamellar to spherical with increasing hardness.

Effect of Solution Aging Heat Treatment on Tribological Properties of Selective Laser Melted WC/18Ni300 Composite

Different contents of WC particle‐reinforced 18Ni300 composites are prepared by selective laser melting method, and the tribological properties are comparatively studied before and after solution aging heat treatment. The results show that a part of WC particles are dissolved, and no obvious pore defects appear. With the increase of WC content, the microstructure gradually transforms from cellular and fine columnar α‐Fe martensite to γ‐Fe austenite. After solution aging heat treatment, the phase is transformed into acicular martensite. The grain size significantly decreases, and the Vickers hardness increases. The grain size decreases and the hardness increases with increasing WC contents. For the as‐built composite, the friction coefficient first decreases and then increases, and the wear rate first increases and then decreases with the increase of WC content. With WC content increasing, the wear rate first decreases and then increases. After heat treatment, the tribological properties are improved. The groove of the specimens before heat treatment is deep with large delaminated craters, and the wear mechanism is dominated by adhesive and abrasive wear. The grooves become shallower, and the adhesive trace becomes lighter after heat treatment. The wear mechanism is mainly adhesive wear and abrasive wear, accompanying with oxidative wear.

Manufacturing Aluminum-Based Nanocomposites via Stir-Squeeze Casting Combined with Ultrasonication

This study successfully produced aluminum nanocomposites using a stir-squeeze casting process, both with and without ultrasonication (US) assistance. The matrix material utilized was scrap automobile wheel aluminum alloy (A356), with 1% SiC nano particles, averaging a size of 40 nm, serving as the reinforcement material. A comparison was made by also producing A356 aluminum casts with and without the use of US. The produced casts underwent thorough chemical and mechanical characterization, including optical and scanning microscopy, porosity measurement, hardness measurement, compression and tensile testing, as well as wear testing. Additionally, energy-dispersive X-ray spectroscopy (EDS) and X-ray diffraction (XRD) analyses were conducted to assess compositions and confirm the presence of SiC nano particles in the aluminum matrix. Porosity levels were slightly higher in the nanocomposite samples compared to pure matrix samples, attributed to the tendency of pore formation due to improper distribution of ceramic particles, resulting in clustering and agglomeration. However, significant reduction in porosity was observed with the application of ultrasonication, effectively breaking up clusters and agglomerations of reinforcement particles. Regarding mechanical properties, the A356+SiC sample with US exhibited the highest hardness (70.8 HRB), tensile strength (163.25 MPa), and compressive strength (387.2 MPa), along with the lowest abrasive wear loss (0.0017 g) among all types of casts produced in this study.

Comparative analysis on high temperature tribological behaviour of additive manufactured and cast AlSi10Mg alloy

Abstract In recent years, additive manufacturing (AM) of AlSi10Mg, a material widely used in the aerospace and automotive sectors, has gained considerable interest for its ability to produce intricate shapes with improved mechanical properties. This proposed study aims to experimentally assess the high-temperature tribological performance of as-printed AlSi10Mg and compare it with traditionally cast AlSi10Mg to determine its suitability for high-temperature tribological applications. Samples of AlSi10Mg were manufactured via powder bed fusion, followed by tribological testing at elevated temperatures (30 °C, 100 °C, 200 °C, and 300 °C). The performance of both printed and cast AlSi10Mg pins was compared against an EN31 disc. The microstructure, worn surface, and wear debris of both printed and cast AlSi10Mg were examined using XRD and SEM with EDX analyses. As the load and temperature increase, both printed and cast AlSi10Mg materials demonstrate an increase in wear rate and friction coefficient. The wear rate of printed AlSi10Mg decreased by 60% compared to cast AlSi10Mg at higher temperatures. There is a consistent trend in the coefficient of friction between printed and cast AlSi10Mg samples at low temperatures and loads. Abrasive wear predominantly occurs in both printed and cast AlSi10Mg samples at 30 °C within a load range of 10 to 20 N, while adhesive wear predominates in the same samples at temperatures ranging from 100 °C to 300 °C with an applied load of 30 N. At low temperatures, smaller wear debris is observed, whereas at high temperatures and under a load of 30 N, larger wear debris is observed for both cast and printed AlSi10Mg samples.

The Effect of DLC Surface Coatings on Microabrasive Wear of Ti-22Nb-6Zr Obtained by Powder Metallurgy

Titanium alloys have a high cost of production and exhibit low resistance to abrasive wear. The objective of this work was to carry out diamond-like carbon (DLC) coating, with dissimilar thicknesses, on Ti-22Nb-6Zr titanium alloys produced by powder metallurgy, and to evaluate its microabrasive wear resistance. The samples were compacted, cold pressed, and sintered, producing substrates for coating. The DLC coatings were carried out by PECVD (plasma-enhanced chemical vapor deposition). Free sphere microabrasive wear tests were performed using alumina (Al2O3) abrasive suspension. The DLC-coated samples were characterized by scanning electron microscopy (SEM), Vickers microhardness, coatings adhesion tests, confocal laser microscopy, atomic force microscopy (AFM), and Raman spectroscopy. The coatings did not show peeling-off or delamination in adhesion tests. The PECVD deposition was effective, producing sp2 and sp3 mixed carbon compounds characteristic of diamond-like carbon. The coatings provided good structural quality, homogeneity in surface roughness, excellent coating-to-substrate adhesion, and good tribological performance in microabrasive wear tests. The low wear coefficients obtained in this work demonstrate the excellent potential of DLC coatings to improve the tribological behavior of biocompatible titanium alloy parts (Ti-22Nb-6Zr) produced with a low modulus of elasticity (closer to the bone) and with near net shape, given by powder metallurgy processing.