Abrasive Wear Experiments Research Articles

Synergistic regulation of microstructure, properties, and abrasive wear mechanism of a medium carbon dual phase steel for plowshares

In this study, a new medium carbon dual phase (DP) steel for plowshares is prepared. The quenching and partitioning process of the medium carbon steel is designed and optimised using the constrained carbon equilibrium model. The optimised process parameters are quenching temperature of 880 °C, quenching bath temperature of 190 °C and partitioning temperature of 350 °C. The microstructure of the acicular martensite matrix with 13% retained austenite was prepared, so that the good mechanical properties of tensile strength of 2007 MPa, yield strength of 1689 MPa, elongation of 11% and impact energy of 12 J are obtained. The multi-scale characterisation and abrasive wear experiments are carried out to investigate its microstructural evolution and wear mechanism under simulated working conditions. The results show that the coordinated deformation of retained austenite and martensite, as well as the trip effect, endows it with ultra-high strength and good plasticity. The recurring process of formation and spalling of the hardened layer is the main wear pattern of this medium carbon DP steel. The synergism of twinning formation and (Ti, Mo)C precipitation enhances wear resistance of this medium carbon DP steel.

Effect of groove textures on wear of friction pair between groove side and scraper under different factor combinations

Three-body wear is the primary wear mechanism in friction pair between groove side and scraper. This study quantitatively investigates the effect of groove textures on three-body wear under different factor combinations through abrasive wear experiments. The results indicate that groove textures significantly reduce wear of samples. The wear reduction rate of sample reaches 41% under the optimal factor combination. Width, depth, and tilt angle of groove textures significantly influence wear loss. Among these factors, width exhibits a negative effect on the change of wear loss, while depth and tilt angle show positive effects. Additionally, there are interactive effects on the change of wear loss between width and depth, as well as width and tilt angle. The effect process of groove textures to three-body wear was qualitatively analyzed by discrete element method (DEM) simulation. Combined with wear morphologies, the wear-resistant mechanism of groove textures was explored. The results indicate that groove textures can mitigate the severity of three-body abrasive wear, reduce the contact area between particles and samples, alter particles movement and enhance wear resistance. Meanwhile, groove textures can serve as a guiding mechanism to modify particles movement and direction and transform the sliding motion of coal particles into rolling motion, converting the continuous “face-face” contact of three-body wear into intermittent “point-face” and “line-face” contacts. This study provides novel study ideas and theoretical foundations for wear-resistant designs in mining machinery and three-body wear equipment.

Evaluation of Mechanical Properties of Al6061 Composite by Stir Casting Method

Aluminium alloy-based metallic matrix composites (MMC) have recently gained popularity in various aerospace and automotive applications. Aluminium has been utilized as a matrix material due to its high mechanical qualities, superior formability, and diverse industrial applications. The Al6061 alloy system becomes harder, stronger in tension, and more wear-resistant when TiB₂-SiC-Rh is added as reinforcement. Al6061–TiB₂-SiC-Rh composites were created in this study using a liquid metallurgical method, with TiB₂-SiC-Rh added in percentages ranging from 2% to 8% by weight in increments of 2%. The cast matrix alloy and its composites were treated with solutionizing at 500°C for 1 hour before being quenched in different media like air, water, and oil. After quenching, the samples were aged both artificially and naturally. Microstructural analysis was conducted to understand the relationship between structure and mechanical properties. Mechanical characteristics, including microhardness and abrasive wear experiments, were performed on matrix Al6061 and Al6061-TiB₂-SiC-Rh composites before and after heat treatment. Under the same heat treatment conditions, the Al6061-TiB₂-SiC-Rh composites exhibited improved microhardness, tensile strength, and reduced wear compared with the Al matrix alloy.

Coupled abrasion Erosion-Oxidation wear from particles in Concentrating solar thermal power facilities

Solid particles represent an attractive heat transfer and energy storage media for next generation solar thermal power facilities for their ability to operate at high temperatures without concerns for freezing or corrosion. A potential outstanding issue that still remains for particles as heat transfer media is the wear on components operating with particles flowing (sliding) in, along, or over them. Prior work has shown that even at the low velocities (∼1 cm/s to ∼ 1 m/s) expected in solar thermal facilities, material wear will still occur, and the lifetime and performance of components undergoing wear needs to be well understood. Abrasion erosion occurs when particles come into contact with containment materials at extremely shallow angles, and is likely to be seen in heat exchangers, storage bins, and flow control mechanisms. Additionally, because of the open nature of most of these systems to air, oxidation of metals is also of concern. Here, we show how critical the coupled erosion-oxidation mechanism is to understanding particle/material durability and therefore need for greater in-depth analysis. Abrasive wear experiments are conducted on metals such as SS316 (L and H grades), Inconel 740H, Haynes 230 with different particles (HSP 40/70, Wedload 430, and CarboMax HD) for different operating conditions. Results clearly indicate that oxide spallation and removal is critical to the overall wear seen at high temperatures.

Microstructure evolution, mechanical and abrasive wear properties of NiCrSiB-SiC composite coatings prepared on 16Mn low-carbon steel by Ni-based alloy catalyzed SiC decomposition

In this study, NiCrSiB-SiC composite coatings were prepared on 16Mn low-carbon steel by vacuum cladding technology using SiC and NiCrSiB mixed powders as raw materials for enhancing their wear resistance. The effects of different content of SiC particles on the microstructure evolution, mechanical and abrasive wear properties of the coatings were investigated. The results showed that SiC particles in all the NiCrSiB-SiC composite coatings with different SiC contents were completely decomposed into C and Si under the catalysis of Ni-based alloy. The out-diffused Si into the coating mainly led to the formation of the Ni3Si eutectic phase, while the out-diffused C introduced M7C3, M3C2, M2(C, B) and other hard phases. Besides, C also diffused to the substrate, leading to a carburizing effect, which remarkably enhanced the mechanical properties of the substrate. In the NiCrSiB-SiC composite coatings with high SiC content, the decomposition of SiC led to the remaining graphite phase. However, once the concentration of SiC was over high, excess graphite would deteriorate the compactness and adhesion of the coating, weakening its wear performance. The nanoindentation and abrasive wear experiments revealed that the composite coating with 5 wt% SiC particles had lower elastic modulus (E), higher hardness (H), H/E, and H3/E2, and its wear volume was only 1/10 of that of the substrate, indicating the best mechanical and wear properties. The excellent wear performance can be attributed to the combination of the in-situ formed carbides and borides hard reinforcing phases and the tough coating matrix composed of Fe and Si dissolved γ-Ni and Ni3Si eutectic phase.

Influence of Counter-Face Grit Size and Lubricant on the Abrasive Wear Behaviour of Thermoplastic Polymers Reinforced with Glass Fibres

Thermoplastic composite materials are widely used for aerospace, automobile and structural applications due to their good combination of high strength to weight ratio and specific modulus. Combined with the ease of melt processing, good resistance to corrosion, low friction, and noise damping are attributes which make them a popular choice in a wide range of emerging applications. Random, short-fibre, E-glass fibre reinforced Polyamide 6 (PA6) composites were manufactured by injection moulding in three different fibre volume fractions (25%, 33% and 50%) and the samples were scanned using micro-CT. The tribological properties of PA6 and glass fibre reinforced PA6 were investigated in the abrasive wear mode by using a pin-on-disc test setup. The tests were done at an abrading distance of 257 m and applied load of 10 N. The abrasive wear experiments were performed against three abrasive grit size papers (220, 500 and 1000 grit), to ascertain the wear response of the studied materials with respect to these adverse running conditions. Moreover, the mechanical properties of PA6 and PA6 composites were examined using tensile testing and compression testing. The surface roughness of the worn surfaces was analysed using a 3D digital profilometer. The worn surface topographies were scanned using field emission scanning electron microscopy. It was observed that the optimum fibre loading that was associated with the highest wear resistance was 33% volume fraction of glass fibres, and the wear performance deteriorated with higher fibre loadings. The increase in the grit size showed a significant reduction to the wear rates of all compositions. The results confirmed that the wear performance of polyamide composites is highly dependent on the tribological system under which it is being tested.Graphical

Gradient-distributed ZTAp-VCp/Fe45 as new anti-wear composite material and its bonding properties during composite casting

Abstract In this article, gradient-distributed VCp-ZTAp/Fe45 composites were prepared by vacuum sintering, and three-body abrasive wear experiments were carried out to investigate its anti-wear performance. The composite casting of VCp-ZTAp/Fe45 was investigated by using the finite element method and experiments, and the bonding between the Fe45 substrate and 35SiMnCrMoNi steel was fully investigated. Results show the in situ formation of VCp in the VCp-ZTAp/Fe45 composite matrix during vacuum sintering. The anti-wear property of the VCp-ZTAp/Fe45 composite is ca. 7 times that of Hardox450 and NM450 and ca. 8 times of 30SiMn. There forms a solid metallurgical bonding between the Fe45 matrix of VCp-ZTAp/Fe45 and 35SiMnCrMoNi steel, with a ca. 80 μm thickness of the bonding area during the composite casting.

Study on microstructure and abrasive wear properties of in-situ TiC reinforced high chromium cast iron matrix composite

In this paper, the TiC particle-reinforced high chromium cast iron matrix composite was prepared in situ by the method of injection infiltration, and the effect of adding different volume fractions of moderators on the size of the reinforcing particles, the volume fraction of the reinforcing particles and the abrasive wear of the composite was systematically studied. Performance impact. The research results show that the TiC particles obtained by the in situ method are uniformly distributed in the matrix of high chromium cast iron, and the interface between the particles and the matrix is clean. And as the volume fraction of the moderator increases, the size of the obtained TiC particles becomes smaller and more uniform, and the volume fraction of the reinforcing particles also gradually decreases with the increase of the volume fraction of the moderator. And the introduction of TiC has increased the hardness of the material by up to 69.036%. Abrasive wear experiments show that the introduction of the moderator makes the reinforcing particles smaller, which further improves the wear resistance of the composite material, and the composite material with 20% moderator content has the best wear resistance, compared to The wear resistance of the metal matrix material is increased by 1.8 times.

Novel monitoring method for material removal rate considering quantitative wear of abrasive belts based on LightGBM learning algorithm

Wear is an inevitable problem in abrasive belt grinding, and the material removal rate decreases with continuous wear of the abrasive belt. This indicates that the grinding control force is affected by two dynamic factors, namely the actual material removal and abrasive belt wear state. To obtain an accurate force-control model to achieve uniform material removal, a new method for online monitoring of abrasive belt material removal rates and their corresponding wear statuses is proposed herein using only the grinding sound signals. By performing material removal rate and abrasive belt wear experiments, the grinding sound signals during processing are obtained. The wear states of the abrasive belt are quantified using the newly defined gray-mean values of the topographical images of the belt into different levels. The grinding sound signals are quantitatively described via the statistical features of their sound wavelet signals. The statistical features related to material removal rates or belt wear states are selected on the basis of the Pearson correlation coefficients. The prediction models for material removal rate and wear levels of the abrasive based on the selected features are then established using the LightGBM learning algorithm. Experimental datasets are used to train and validate the established model. The test results show that the evaluation parameters of the prediction model of the material removal rate are all within 5%. Further, the accuracy of the wear levels of the abrasive belt can exceed 91%. Compared with other prediction models, the new LightGBM models exhibit superiority in terms of time factor without loss of accuracy of the model. It is thus proved that the proposed method can provide a good basis for monitoring the material removal rate and belt wear in the abrasive belt grinding process.

Investigation of abrasive wear in contact load-dominated slurry flows using a Toroid Wear Tester

Friction loss in slurry pipelines transporting coarse (settling) particles are governed by two mechanisms: Coulombic and kinematic friction. The Coulombic (sliding bed) friction component produces a highly abrasive condition that results in significant wear at the pipe invert and produces asymmetric thinning of the pipe wall. In this paper, an experimental investigation was carried out to study abrasive wear under Coulombic friction-dominated slurry flow conditions. Experiments were conducted in a laboratory-scale apparatus known as the Toroid Wear Tester (TWT) using narrowly-sized coarse particles (0.125–4 mm) suspended in three different carrier fluids (μf: 1–5.12 mPas, ρf: 998–1103 kg/m3). The friction loss attributable to the presence of the coarse particles was obtained from torque measurements made during each test. Visualization experiments were used to establish contact load-dominated (sliding bed) slurry flow conditions based on the ratio of flow velocity to the particle terminal settling velocity i.e. V/v∞. Abrasive wear experiments were then conducted with the TWT operating under full contact load conditions. It was found that the measured wear rates correlated with the magnitude of the Coulombic shear stress. The most important outcome of this study is the demonstrated potential to predict actual slurry pipeline wear rates from TWT experiments.

Adhesive and abrasive wear behavior of Kenaf long fiber reinforced epoxy composites

Polymers are widely used as replacement of convention metal components for various applications of engineering. In order to improve mechanical properties of polymers, fiber is introduced as reinforcing phase. In this work epoxy was used as polymer whereas Kenaf long fiber was used as reinforcement. This paper presents wear properties of alkali treated long Kenaf bast fiber reinforced epoxy composites. The weight percentage of reinforcement was increased from 10 to 40%. Hand layup technique was used to fabricate the composite plate. The results showed that wear strength is increased with increase in reinforcement. Both adhesive wear and abrasive wear behavior of Kenaf long fibers reinforced epoxy polymer composites were discussed. The adhesive wear experiment was carried out using pin on disc machine at different normal load and sliding velocities whereas abrasive wear experiment was conducted at different abrasive size particles using Olsen wearometer. Adhesive wear was conducted perpendicular to the direction of fibers and abrasive wear was conducted along the direction of fibers. From the experimental results, the 30% wt. fiber loading has best wear resistance both in adhesive and abrasive wear compared to rest of the composites.

Microstructure and Wear Resistance of WC and High Chromium Cast Iron Hardfacing Layers

The WC and high chromium cast iron (HCCI) welded layers were prepared on Q235 low carbon steel by hardfacing technique in order to improve high-temperature performance. The microstructure and mechanical properties of the welded layer were investigated. It was found that Fe3W3C is the major strengthening phase of the WC welded layer. Furthermore, a high-temperature three-body abrasive wear experiment was designed and conducted on the welded layers. The results show that the wear resistance of the WC welded layer was much better than that of the HCCI welded layer at both room and high temperatures. During the high-temperature abrasive wear process, the Fe3W3C phase can effectively strengthen the matrix and hence, contribute to improved wear resistance.

Rapid Wear Modelling in a Slurry Pump Using Soft 3D Impeller Material

Slurry transport systems are often limited in run length by the life of the pump internals, especially the impeller. The present work investigated abrasive wear of the impeller of a Hayward Gordon XR2(7) Torus Recessed Impeller slurry pump in a flow loop. The stock stainless steel impeller was replaced by a set of plastic test impellers with the same nominal geometry, fabricated by additive manufacturing (3D printing). A parametric set of abrasive wear experiments was conducted at five pump rotational speeds and three solid concentrations of garnet slurry in a pipe flow loop. Pump performance tests were conducted using impellers with progressive wear conditions, to investigate how a worn impeller affects hydraulic power delivery. A parabolic fit was imposed to describe the relationship between head and flow rate, and an empirical model was proposed to predict the pump head with damaged impellers. When the rotational speed is high, the damaged impeller has a larger effect on the pump’s performance than when the rotational speed is low. The head difference between the undamaged impeller and a 7.62%-mass-loss damaged impeller was 1.5 m at 1750 rpm rotational speed, however, for 850 rpm, the head difference was 1 m. Implications for pump diagnostics in other types of systems are discussed. This experiment gives a method for rapidly assessing wear locations, and provides a tool to predict wear rates on harder materials if scaling parameters are available. This first attempt at a scaling law is not reliable enough to accurately predict the wear rate for specific conditions, but shows the relative wear as a function of pertinent parameters.

Investigation of tribological behaviour of 88WC-12Co coating

High velocity oxy-fuel (HVOF) is a coating technique of thermal spray process usually employed for protecting the substrate, where high velocity is used instead of high temperature for coating the substrate. In this paper, the wear behaviour of tungsten carbide-cobalt (88WC-12Co) coating was studied experimentally. The coating of 0.3 mm was deposited by HVOF technique on SS202 substrate. The dry abrasive wear experiments were carried out using pin-on-disc test rig at fixed sliding velocity 0.603 m/s, and 20, 40, 60 N load for 1000 m distance. The weight loss was measured at each 250 m distance. For the preparation of abrasive surface 80 grit SiC (silicon carbide) emery paper was used. Results show that at initial stage wear rate of coated substrate was high which reduces with increase in sliding distance and linear increment in coefficient of friction with increase in load.

Analysis of the Wear-Resistance Characteristics of Bionic Ridge Structures

HighlightsBionic technology can be applied to resolve agricultural engineering problems.Pangolin Squama and Chlamys Farreri shells possess excellent wear-resistance.Bionic ridges can improve sample wear-resistance.Abstract. Consistent soil contact rapidly wears the soil-engaging components of agricultural machinery, such as ploughs and subsoilers. A bionic method was applied to their structural design to improve component wear resistance. Some animal organs possess excellent wear-resistant structures which can provide design inspiration for improving the wear-resistance of agricultural mechanical parts. Previous research found that many ridges exist on Pangolin squama and Chlamys Farreri shell surfaces. Those ridges cause Pangolin squama and Chlamys Farreri shells to exhibit excellent wear-resistance. Therefore, these ridge structures were applied to the design of experimental subsoiler samples (bionic samples) to enhance their wear-resistance. An abrasive wear tester was utilized to conduct abrasive wear experiments under special experimental conditions. These experimental conditions involved sliding speed, soil particle size, moisture content, and space between the ridges. Finally, nine experiments were conducted that subjected the bionic and flat surface samples to different experimental conditions, and their respective mass-loss quantities were measured. Results show that bionic sample mass loss was less than that of the flat surface samples under the same experimental conditions; bionic sample wear-resistance improved by 77%, 73.8%, 66.9%, 45.4%, 58.9%, 65.5%, 33.1%, 66.4%, and 42.6% when compared with flat surface samples under the same experimental conditions. Orthogonal test results reveal that the soil particle size most significantly affected sample wear-resistance, followed by the space between bionic ridges and the sliding speed. One reason that bionic samples exhibited excellent wear-resistance is that the soil particles underwent a “guiding effect” and a “rolling effect” over the bionic ridge surface, thereby reducing the “micro-plowing” that soil particles generated when moving over the contact surface. Mutual interference among soil particles also reduced wear. Part of the soil particles rushing over the bionic sample surface rebounded back; the rebounded soil particles collided with incoming soil particles, then the speed and kinetic energy of all of the particles decreased and sample surface abrasion declined. Moreover, “vortexes” generated by sample surface air and ridges lead to an “air cushion” effect which can lessen the number of sample surface soil particles, and bionic ridge sample abrasions can be significantly reduced. Abrasion experiment results analysis indicates that bionic ridges distributed on subsoiler sample surfaces can significantly improve wear-resistance. The bionic design method provides a new approach for increasing the wear-resistance of the soil-engaging components of agricultural machinery. Keywords: Abrasive wear, Bionic ridge, Optimal design, Wear-resistance.

Abrasive wear behaviour of cast Al–Si–Mn alloys

In this paper, the effect of manganese (wt%) and size of the Al2O3 abrasive grains of abrasive wear behaviours of Al–Si–(0.16–0.76%) Mn alloy was examined. Abrasive wear experiments were conducted against abrasive Al2O3 paper grains with diameters in the variety of 38–250 µm, under the normal load range of 10, 20 and 30 N and the sliding velocity of 0.1 m s−1. Wear measurements have shown that the wear rate of the material is dependent on the manganese content and the abrasive grain size. The best wear resistance is in the content of 0.73 Mn, which is associated with increased toughness and strength. The Al–Si casting alloy which had 0.73% Mn content exhibited lower wear rate than the Al–Si–0.16/0.22/0.23% Mn alloys after scoured on fine abrasive Al2O3 grains (<65 µm). Wear experiments achieved on Al2O3 grains having sizes greater than 65 µm revealed that, the cast Al–Si– alloy which had 0.73% Mn content had lower wear rate than the cast Al–Si–0.16/0.22/0.23% Mn alloys.

Effect of Experimental Parameters on Wear Response of Thermally Sprayed Carbide Based Coatings

Friction and abrasive wear response of WC-12 Co and Cr3C2-25 NiCr coatings was studied. Abrasive wear experiments were conducted with SiC abrasive particles with varying load and sliding speeds. The results were analyzed using SEM, XRD and XPS observations of worn surfaces, wear debris and worn out abrasive paper. Friction coefficient diminished with rise in sliding speed and increased for increase in load while wear rates decreased for increasing sliding speed for both coatings. WC-12 Co coating had better wear resistance than Cr3C2-25 NiCr coating while Cr3C2-25 NiCr coating displayed lower friction coefficient. The variation in wear rate and friction response of coatings was due to combined effects of adhesion, abrasion and tribo oxidation effects. The composition of tribo films was strongly influenced by load and sliding velocity and altered friction and wear response of the coatings.

Experimental comparison of abrasive and erosive wear characteristics of four wear-resistant steels

In the current research, the wear behavior of four steel wear resistant plates was investigated. In order to compare the wear-related characteristics of the candidate steels, tests of hardness, slurry erosion and two-body abrasive wear experiments were conducted. In addition, the microstructural evolutions were analyzed using optical microscopy. To identify the changes in samples’ characteristics along the depth, the aforementioned tests were conducted at different depths of the plates. The microstructural evolutions regarding the changes in the phases, including their types, their shapes and their sizes, were studied. To study the erosion behavior, an experimental rig was developed that allows samples to move inside a slurry environment. Regarding the abrasive wear, the pin-on-disk method was used in which the sample plays the role of a pin moving on a circular abrasive grinding disk. The tests were carried out under different amounts of the normal force that pushes the sample on the disk. Finally, the samples were compared regarding their microstructures, hardness, erosive and abrasive behavior. The results showed that the steel that exhibited the highest hardness did not necessarily show the highest wear resistance. Furthermore, it was observed that the steel that had the highest erosive resistance did not show the abrasive resistance accordingly.

Effect of Centrifugal Speed in Abrasive Wear Behavior of Al-Si5Cu3/SiC Functionally Graded Composite Fabricated by Centrifugal Casting

Centrifugal casting was adopted for fabricating AlSi5Cu3/10 wt% SiC functionally graded metal matrix composite under three different centrifugal speeds of 800, 1000 and 1200 rpm, and hollow cylindrical components (φout 150 × φin 132 × 150 mm) were obtained. Microstructures of outer and inner periphery of all composites were observed through optical microscope and micro hardness of outer, intermediate and inner region of composite was tested using Vicker’s hardness tester. Results revealed that outer region of the composites centrifuged at all speeds have particle rich region with higher hardness. Abrasive wear experiments were conducted only on surface of particle rich region based on Taguchi’s technique by varying parameters such as centrifugal speed of casting process, rotating speed and applied load of abrasive wear tester. Analysis of variance results revealed that, centrifugal speed had highest significance on wear rate. Abraded surfaces were examined using scanning electron microscope and the maximum wear resistance was observed on particle rich zone of composite centrifuged at 1200 rpm.

Abrasive wear behaviour of aluminium hybrid nanocomposites produced by ultrasonication assisted casting method

In this investigation, the abrasive wear resistance of Al/ (B4C+SiC) hybrid nanocomposites was tested against hard SiC abrasive sheets and compared to those of unreinforced Al alloy. Three loadings of nano-SiC (0.5, 1.0, and 1.5 Wt. %) and one loading of nano-B4C (0.5 Wt. %) were mixed with an aluminium alloy to produce the aluminium hybrid nanocomposites using an ultrasonication assisted casting method. Scanning electron microscopy showed a uniform distribution of nanoparticles in the Al alloy. Transmission electron microscopy indicated an increase in the dislocation density of nanocomposites compared to monolithic Al. The abrasive wear experiments were conducted on a Pin-on-Disc tribometer using pins of 9 mm diameter and 15 mm height under dry sliding conditions at room temperature. The wear rate in terms of wear volume per unit weight was calculated for both unreinforced alloy and hybrid nanocomposites. It was observed that Al hybrid nanocomposites showed superior wear resistance properties compared to the unreinforced sample. The nanocomposite with 1.5 Wt.% nano-SiC and 0.5 Wt.% nano-B4C possessed better wear resistance properties compared to the other composites tested in this work. The worn out surface of the Al alloy and its hybrid nanocomposites imply that the wear mechanism is through plowing action on the surface by SiC abrading particulates. The nanocomposite with 1.5 Wt.% SiC and 0.5 Wt.% B4C showed 88.32 % increase in wear resistance compared to the monolithic Al. This combination of material can be selected for abrasive wear resistance applications.