Abrasive Wear Testing Machine Research Articles

Wear Characteristics of Hybrid Polymer Composite Manufactured by Hand Layup Technique Using Fuzzy Logic Systems

Synthetic fiber reinforced composites have already been proved to be stronger and more durable. The composites are being globally used in all the possible fields like automobiles, aircraft and marine industry. The present work is an investigation on the wear behaviour of the hybrid polymer composites. In this experimental work, the carbon fibres are reinforced with vinyl ester, g-C3N4 and Si3N4 were used to obtain hybrid composite by hand layup technique. The experiments were designed according to Taguchi (L27) orthogonal array. Experiments are carried out using slurry abrasive wear testing machine to inspect the wear rate. Further, a fuzzy logic model is adopted for the estimation of sliding wear in hybrid composites by the experimental data. Results showed that estimated fuzzy logic outputs are compared to experimental results, which is very much satisfied with a mean error estimation of 0.27%, so that the fuzzy logic model can be efficiently used to compute the wear performance.

Development of Temperature-controlled and Humidity-controlled three-body Abrasive Wear Testing Machine based on MLD-10 Dynamic Abrasive Wear Testing Machine

In order to simulate engineering machinery (such as mining machinery, feed pellet machine, building machinery and so on), which existence of different degrees of high temperature and humid corrosion three-body abrasive wear behavior in the laboratory environment. In view of the current three-body abrasive wear testing machine cannot simultaneously take into account the composite conditions characteristics of the three-body abrasive wear behaviour, high temperature and humidity, and make the optimization design, based on the MLD-10 dynamic abrasive wear tester. It includes corrosion and wear groove, fluid medium, temperature measuring and controlling device, stirring device, etc. A three-body abrasive wear testing Machine that can control temperature and humidity. Subsequently, the simulated working condition test of the ring die of feed pellet machine were carried out. The test results show that the wear appearance of the test sample is basically consistent with that of the real ring die of feed pellet machine. It indicates that the developed testing machine can simulate the high temperature and humid three-body abrasive wear behavior, and has good reliability and applicability.

Effect of B Content on Microstructure and Wear Resistance of Fe-3Ti-4C Hardfacing Alloys Produced by Plasma-Transferred Arc Welding

The Fe-3Ti-xB-4C (x = 1.71, 3.42, 5.10, 6.85 wt. %) hardfacing alloys are deposited on the surface of a low-carbon steel by plasma transferred arc (PTA) weld-surfacing process. Microstructure, hardness and wear resistance have been investigated using scanning electron microscopy (SEM), X-ray diffraction (XRD), Rockwell hardness tester and abrasive wear testing machine, respectively. The results show that the microstructure in all alloys is composed of austenite, martensite, Fe23(C,B)6, Ti(C,B) and Fe2B. The volume fraction of eutectic borides and Ti(C,B) carbides increases with increasing B content. Many brittle bulk Fe2B phase arises when the boron content increases to 6.85%, which causes the formation of microcracks in the hardfacing layer. The microhardness of the hardfacing alloys is significantly improved with the B addition, however, the wear resistance of hardfacing alloys increases firstly and then decreases with increasing of B content. The hardfacing alloy with the 5.10% B content has the best wear resistance, which is attributed to high volume fraction of eutectic borides and fine Ti(C,B) particles distributed in the austenite and lath martensite matrix with high hardness and toughness. The formation of brittle bulk Fe2B particles in the hardfacing alloy with the 6.85% B leads to the fracture and spalling of hard phases during wear, thus, reducing the wear resistance.

Microstructural Evolution and Wear Behavior Involving the K-Carbides Precipitation of a Fe-25Mn-6.6Al-1.3C Austenitic Steel

In this paper, the microstructural evolution and mechanical properties of the as-cast Fe-25Mn-7Al-1.3C austenitic steel after different heat treatment were investigated. After solution treatment and subsequent aging treatment, the κ-carbides with perovskite structure were found to precipitate coherently within the austenite matrix, which improved the initial hardness and mechanical strength. The experimental steel exhibited an optimal comprehensive performance after being solution treated at 1050 °C for 1 h and then aged at 550 oC for 2 h. The tensile strength was 751 MPa, the yield strength was 581 MPa, the elongation was 48%, the hardness was 252 HB, and the Charpy V-notch impact toughness was 168 J, respectively. The impact wear test was carried out on MLD-10 abrasive wear testing machine, and the worn out surfaces under different heat treatment were characterized by scanning electron microscopy (SEM). The results indicated that the abrasion resistance of the steel under the additional aging treatment was better than that of the as-solutionized steel. The optimal abrasion resistance was obtained after being soluted at 1050 °C for 1 h and then aged at 550 oC for 2 h. However, with the aging time increasing, the coarse κ-carbides precipitating around the grain boundaries would deteriorate toughness, which lead to increase of the abrasive wear volume loss. Besides, obvious micro-cracking and relatively larger peeling pit were observed.

Effect of impact energy on wear behavior of high chromium white iron produced by liquid die forging

Impact abrasive wear behavior of high chromium white iron (HCWI) produced by liquid die forging process were investigated. the wear tests were performed with the MLD-10 abrasive wear testing machine, using SiO2 abrasive and with four impact energies of 1.5 J, 2.5 J, 3.5 J and 4.5 J for 120 min. The results indicated that the cumulative volume loss of HCWI sample increases with the growth of impact energy, and exhibits best wear resistance under low impact condition. For given impact energy, the volume loss increases with the increasing of wear time, which shown an approximately liner tendency. The macro-morphologies, SEM images of worn surface and cross-sectional images of wear samples were observed by optical microscope and SEM, and the wear mechanism and characteristics were analyzed. Results shown that the wear characteristics is mainly based on the shallow ploughing and accompanied by plastic deformation under lower impact energy, while the fatigue peeling and embedded abrasive become the most significant characteristics when the impact energy is higher.

Wear Resistance of the Multilayer TiN/Ti(B,N) Coating Deposited on Cold Work Tool Steels

Abstract This paper investigates the abrasion and erosion wear resistance of the multilayer coating within the system Ti-B-N applied to samples made of two hardened and tempered tool steels: Böhler grades K390 MC and X155CrVMo12-1. The multilayer coating consists from the thin interlayer TiN deposited directly on steel substrate and the Ti(B,N) coating, with continuous variation of stoichiometric ratio of boron and nitrogen through the thickness of the coating. Near the TiN interlayer Ti(B,N) coating has only a small content of boron while at the surface the layer TiB2 has been obtained. The multilayer TiN/Ti(B,N) coating was produced by the direct current plasma-assisted chemical vapor deposition (dc PACVD) in an industrial furnace with a hot wall. Tests of abrasive wear resistance were performed using an abrasive wear testing machine constructed according to ASTM G65-15, Standard Test Method for Measuring Abrasion Using the Dry Sand/Rubber Wheel Apparatus. The weight loss of samples was measured after a total wear path of 358 m. The test of erosion resistance was carried out by exposing the samples to impact erosion of fine sand particles and by determining the weight loss after 60 min of wear. Worn surfaces were analyzed by scanning electron microscopy (SEM). The results show a significant improvement in the abrasion and the erosion wear resistance of the TiN/Ti(B,N) coating applied to both tool steel samples with compared with the noncoated samples.

Effects of carbides on abrasive wear properties and failure behaviours of high speed steels with different alloy element content

High speed steels (HSSs) are effective materials applied in aggressive environments where abrasion resistances are required because they have hard carbides and relatively ductile matrix to bind carbides. But there are many kinds of carbides in HSSs, which lead to different effect on wear properties of HSSs. In this paper, three kinds of casting HSSs with VC, M6C or M2C type carbide were prepared respectively through the reasonable design of alloy elements, and then the effects of carbide type on wear behaviours were researched under different abrasive particle size and load using abrasive wear testing machine. The microstructures and failure behaviours of HSSs were analyzed by electron microscopy. The results showed the abrasive particle size and load had obvious effect on wear weight loss of high speed steel (HSS), but the carbide type decided the relative wear resistance of HSS. As the abrasive particle size or load increased, the wear weight loss of any HSS increased obviously. For the fine abrasive wear, the HSS with M6C had higher relative wear resistance than HSS with M2C. But the contrary was the case for the coarse abrasive wear. For any abrasive particle size and load, the HSS with VC had more excellent wear resistance than HSS with M6C or M2C type carbide. The relative wear resistance of HSS with VC was three times higher than that of HSS with M6C or M2C. The excellent wear resistance of HSS with VC was mainly attributed to VC characteristics, such as high hardness and good morphology, which can resist micro-cutting of abrasive particles efficiently.

Abrasive Wear Behaviors of Light-weight Austenitic Fe-24Mn-7Al-1C Steel and Mn13Cr2 Steel

The impact abrasive wear behaviors of light-weight austenitic Fe-24Mn-7Al-1C steel with increasing impact wear conditions were studied by comparing with the modified Had field (Mn13Cr2) steel. Wear tests were performed with the MLD-10 abrasive wear testing machine. Main parameters such as impact energy, impacting frequency and wear time were evaluated. To explore the abrasive wear behaviors under different impact energies, the parameters including mass loss, wear resistance and hardness were evaluated in detail. The microstructures of the steels were further analyzed using optical microscopy (OM), scanning electron microscopy (SEM), transmission electron microscopy (TEM) and X-ray diffraction (XRD). Results showed that the light-weight austenitic Fe-24Mn-7Al-1C steel had a better wear resistance than Mn13Cr2 steel under the impact energy tested. The wear resistance of light-weight austenitic Fe-24Mn-7Al-1C steel was about 1. 09 — 1. 17 times as high as that of Mn13Cr2 steel under low and medium impact energy (0. 5 —2.0 J) conditions, and l. 41 times under high impact energy (4. 0 J) condition. In Mn13Cr2 steel, the evolution of dislocation substructure with increasing impact energy showed typical stacking fault, interaction of twins and dislocations, as well as mechanical twins. The high work-hardening rate in Fe-24Mn-7Al-1C steel was caused by Taylor lattice and high density of dislocation tangles.

Surface failure behavior of 70Mn martensite steel under abrasive impact wear

The aims of this paper are to reveal the surface failure behavior of 70Mn martensite steel under abrasive impact wear by impart wear tests. The wear tests were performed with the MLD-10 abrasive wear testing machine, using SiO2 abrasive with three different impact loads for 30000 cycles. Worn surfaces and white-etching layers (WEL) were analyzed by scanning electron microscopy, x-ray diffraction and transmission electron microscopy, and the abrasive impact wear mechanism was analyzed. Strain-hardening effects beneath the contact surfaces were researched by Micro-hardness profiles. Results indicated that the main formation mechanism of white-etching layers (WEL) in test steel were the formation of twin martensite and accumulation of dislocations attributing to plastic deformation during impact wear tests. The thickness and hardness of WEL were both increased with test load, which led to an increased brittleness of WEL. Under the effects of impact load, the micro-cracks initiated at subsurface and extended to surface, eventually led to delamination and fracture. Therefore, the delamination and fracture resulting from plastic deformation fatigue were the primary surface failure mechanism of the steel at abrasive impact wear.

Study on TaC Reinforced Iron Matrix Surface Gradient Composites Produced <i>In Situ</i>

Tantalum carbide (TaC) gradient composites were fabricated via in-situ fabrication method from the tantalum plate and gray cast iron. The morphology, phase constituents, micro-hardness, and relative abrasion resistance of the composites were analyzed by scanning electron microscopy (SEM), X-ray diffraction (XRD), micro-hardness tester and abrasive wear testing machine. The surface layer, which was ~160μm thick, was dense ceramic layer composed by ~90% submicron TaC particulates. The highest micro-hardness value of the dense ceramic layer was 13.84 GPa. In the sub-layer, the gradient distribution of TaC particulates reflected in the volume fraction decreased from 90% to 0%. While the micro-hardness value decreased from 10.81 GPa to 4.10 GPa. The metallurgical combination of the interface between the composites and matrix was perfect. The wear resistance of TaC reinforced iron matrix surface gradient composites increased significantly.

Mitigation of the Wear Failure of Ti-6Al-4V Dental Biomedical Implant by Isothermal Treatment

Ti-6Al-4V alloy has been in use as dental implants till date because of its favorable mechanical properties. However, it wears off over a period of time in the oral cavity. Bearing this problem in mind, this research aims at mitigating the wear failure of Ti-6Al-4V dental implant via isothermal treatment. The as-received Ti-6Al-4V was cut and machined into 30 mm × 25 mm × 3 mm for abrasive wear samples. The samples were solution heat-treated at 960 °C accompanied by the aging process at 480 °C for varying soaking times of 2, 4, 6, and 8 h. The samples for wear analysis were subjected to abrasive wear using a three-body abrasive wear test machine with varying loads of 5 and 15 N, and silica sand was used as the abrasive medium. From the result, the wear rate of the heat-treated titanium alloy increased with the applied load, and the samples aged for 8 h showed 99 and 98% wear resistance at 5 and 15 N, respectively. In the present study, it was established that isothermal aging can be employed to enhance the wear resistance of Ti-6Al-4V alloy for use in biomedical applications.

Hardness and Wear Characteristics of Hybrid Aluminium Metal Matrix Composites Produced by Stir Casting Technique

Aluminum alloys are widely used in aerospace and automobile industries due to their low density and good mechanical properties, better corrosion resistance, wear resistance and low thermal coefficient of expansion as compared to conventional metals and alloys. These materials have excellent mechanical properties and cost of production is comparatively low. Because of these qualities they form a very strong contender in variety of applications. In this work, attempts were made to produce aluminium hybrid metal matrix composite (LM 25+ Activated Carbon+ Mica) by stir casting method and compare the properties with conventional composites (LM25+ Activated Carbon) and (LM25+Mica). The specimens were tested for hardness using Brinnel Hardness Tester and wear properties using Abrasive belt wear testing machine. The contributions of the reinforcement on the wear process and the wear loss have been investigated. Study of wear debris and worn surfaces was carried out using Light Optical Microscope (LOM).

Fe–0.4 wt.%C–6.5 wt.%Cr hardfacing coating: Microstructures and wear resistance with La2O3 additive

Flux-cored wires with different La2O3 additives were developed. The microstructures of the hardfacing coatings were observed by optical microscopy (OM) and field emission scanning electron microscope (FESEM). The phase structures were determined by X-ray diffraction (XRD). The hardness, wear resistance and friction coefficient of the hardfacing coatings were measured by Rockwell hardness tester, unilateral abrasive belt wear testing machine and CETR reciprocating wear testing machine, respectively. At last, the worn morphologies of the hardfacing coatings were observed by FESEM.The results indicate that, the microstructures of the hardfacing coatings consist of needle-like martensite, high alloy matensite and retained austenite. With the increase of La2O3 additive, the high alloy matensite dissolves in the matrix gradually and the amount of retained austenite is not changed basically after it is increased firstly. When La2O3 addition is 0.70wt.%, the grain size of the hardfacing coating is the smallest, which is 18μm and the average hardness is the highest. Unidirectional abrasive belt wear test shows that the high alloy martensite can be as wear-resistance phase during the wear process of the hardfacing coatings. When the La2O3 addition is 0.35wt.%, the unidirectional wear resistance of the hardfacing coating is the highest. Reciprocating wear test shows that with the increase of the La2O3 additives, the friction coefficient is decreased and the reciprocating wear resistance is increased. When La2O3 addition is 0.70wt.% the reciprocating wear resistance is the highest.

Research on the Friction and Wear Properties of the NBR under Dry Sliding and Water Lubrication

The wear mechanisms of different graphite contents of NBR by 45# steel under dry sliding and water lubrication were investigated. On MPV-600 computer-controlled abrasive wear testing machine, the coefficients of friction were measured continuously. Results showed that under dry sliding condition, the rubber wear loss is big, the coefficient of friction is higher, the temperature of the friction surface is rise obviously. Wear loss and friction coefficient of NBR decrease with the increase of graphite contents; With the increase of graphite contents wear loss and the friction coefficient decreases, and is mainly due to the graphite lubrication performance and increase the stiffness of the rubber contact area. At low content of graphite, adhesive wear of NBR is showed, in the high content of graphite, abrasive wear is showed. Water lubrication condition, wear surface level off, the wear loss is very small, and the lubrication and cooling effect of water makes the friction coefficient decrease. Graphite content is higher, the wear loss and coefficient of friction is smaller.

Research on the Properties of Grind-Hardening and Abrasion of 42CrMo Steel in Agricultural Diesel Engine Crankshaft

In order to improve the strength and wear-resistance of agricultural diesel engine crankshaft, the grinding-hardening experiment of crankshaft material 42CrMo steel was carried out on MM7132 surface grinder. Microstructure of the specimens was observed with SSX-550 scanning electron microscope (SEM) and the abrasion experiment was carried out on ML -100 abrasive wear testing machine. The results showed that the maximum mircrohardness of 42CrMo steel after grind hardening was 850HV and the maximum depth of grind hardening layer was 1.25mm. The hardened layer was fully occupied by lath martensite; a little of martensite and much tempered sorbite appeared in the transitional region. The wear-resistance of the specimens after grind hardening was improved by three times.

Wear Experiment of Alfalfa Lawn Mower Wheel for Soil-Environment Resources Based on Wear Resistance of Materials

In order to study the wear between machine wheel and soil-environment resources during alfalfa mowing, the gray iron and loess were chosen as sample materials to research the abrasive wear behavior at different speed and load condition by abrasive wear testing machine. The scanning electron microscopy was used to observe the wear surface morphology. The results showed that, peripheral speed and load had significant effects on wear resistance of materials. When the peripheral speed in 1m/s~2.5m/s and the load in constant, wear quantity decreased gradually with the peripheral speed increased. When the load in 40N~110N and peripheral speed in constant, the wear mass loss increased as the load increased. After that, the wear volume dropped gradually as the load increased. The main wear form is peeled off and micro cutting. The research results would provide references for improving the wear resistance of the wheel

Fe–24wt.%Cr–4.1wt.%C hardfacing alloy: Microstructure and carbide refinement mechanisms with ceria additive

The microstructure and carbide refinement mechanisms of Fe–24 wt.%Cr–4.1 wt.%C hardfacing alloys with 0 wt.%, 0.5 wt.%, 1.0 wt.%, 2 wt.%, and 4 wt.% ceria additives have been systematically investigated in this work. Optical microscopy, field emission scanning electron microscopy with energy dispersive spectrometer, and X-ray diffraction were collectively used to study the microstructure, the phase components, and the chemical formation of inclusion formed in the welding process. Wear-resistance of the alloys was comparatively studied using an abrasive wear testing machine. The structure analysis results show that the Fe–Cr–C hardfacing alloy mainly consists of martensite, retained austenite, MC carbide and M7C3 carbide. With increasing ceria additive contents, the average size of the primary M7C3 carbide decreases and reaches a most refined state in the alloy with 2 wt.% ceria additives. Comparative wear tests data shows that the wear resistance of the hardfacing alloys with ceria additives is better than that without ceria additive. In a good agreement with the carbide refinement results, the wear resistance of the alloy reaches an optimum level in the sample with 2 wt.% ceria additive. The main RE inclusion type identified with in-situ XRD analysis is RE inclusion Ce2O2S. Thermodynamics calculation confirms that this type of RE inclusion could precipitate prior to M7C3 carbides, and act as a heterogeneous nucleus for M7C3 in the welding process, which effectively provides a mechanism for significant refinement of the M7C3 carbide and improves its wear resistance.

Research on Wear Behavior of NBR by 45 Steel in Crude Oil Medium

NBR is the essential material selected for the stator of progressing cavity pump which is used for oil extraction. The premature failure of NBR is the primary cause for shortening working life of the pump. Wear behavior of NBR and its mechanism by 45 steel were studied in crude oil medium using a MPV-600-type compute-controlled abrasive wear test machine. Through the friction test found at constant low load, and at constant temperature, the friction coefficient is along with the rotational speed increased first and then decreased and then increased; At constant low speed, and at constant temperature, friction coefficient decreases as the force increases; The friction coefficient increases with rising temperature first and then drops; The main wear mechanism of the rubber in crude oil is wet abrasive wear. The test results on the rational selection of working parameters to improve rubber metal friction pair of whole life have practical significance.

The Forecast for the Abrasive Wear of Metal Materials Aginst Plant Abrasive Based on the Grey Markov Model

Metal materials wear loss against plant abrasive of different wear process was obtained by simulation test on the abrasive wear testing machine. On the basis of it, the GM (1, 1) model is established by using grey theory. Then the state of experiment data is divided using markov chain, the state transition matrix is constructed, finally the grey markovian model is established and wear prediction of metal materials against plant abrasive is gained. The results indicate that wear prediction based on the grey markovian model is more precise than the GM (1, 1), model, relative error being only 1.13%

Study on Ware Resistance of Laser Hardening Rolling Mill Liner

In order to change the traditional status that rolling mill liner can not be manufactured with a single material, laser transformation hardening was carried out by HL-1500 cross-flow CO2 laser processing machine on 45 steel surface. developed a non-composite liner instead of the original. The microstructure and properties were researched by means of scanning electron microscopy, X-ray diffractometer, microhardness tester and abrasive wear testing machine. The result indicate that, the microstructure of laser transformation hardening layer fine and homogeneous, mainly composed of Fe, Fe3C, Fe-Cr and Cr3C2, the hardness and the relative wear resistance are about 3 times and 2.7 times as that of the substrate respectively; which can reached the technical requirements liner needed.