Adhesive Wear Research Articles

Microstructure, hardness, and tribological properties of CoCrFeNiX (X = Mo, Ti, W) high entropy alloy coating by red-blue composite laser cladding on copper alloy

In this study, the problem of high reflectivity of copper alloy surface to traditional infrared laser beam was overcome by red-blue composite laser cladding technology. The problem of cracks and other defects caused by the large difference in thermal expansion coefficient between copper substrate and high entropy alloy coating was overcome by electroplating Ni intermediate layer on the surface of copper alloy. A high-entropy alloy coating with tight bonding and no obvious defects was successfully prepared on the surface of copper alloy. The phase composition, microstructure evolution, hardness and tribological properties of high-entropy alloy coatings after adding different elements were studied. The experimental results show that all the CoCrFeNi coatings are FCC phase. After the addition of Mo, Ti and W elements, σ phase rich in Mo and Cr, TiCo2-type Laves phase and Fe7W6-type μ phase appeared in the high entropy alloy coating, respectively. The average microhardness of CoCrFeNiX (X = Mo, Ti, W) high entropy alloy coatings reached 730 HV0.2, 1090 HV0.2 and 378 HV0.2, respectively. The wear rates of CoCrFeNiMo, CoCrFeNiTi and CoCrFeNiW high-entropy alloy coatings were 47.17 %, 90.56 % and 22.64 % lower than those of CoCrFeNi coating, respectively. The wear scars were analyzed by SEM and EDS, and the friction and wear behavior mechanism of CoCrFeNiX (X = Mo, Ti, W) high-entropy alloy coating was investigated. It is mainly composed of abrasive wear, adhesive wear and oxidation wear. The research results provide practical guidance for the preparation of high-entropy alloy coatings on copper surface, and lay a theoretical foundation for laser cladding such high-entropy alloy materials and substrate materials.

Surface modifications to reduce wear in hot extrusion of copper

During hot extrusion of copper, the material tends to stick to the extrusion die due to strong adhesive forces between hot working steel and copper at high temperatures. In this context, surface modifications like nanocomposite coatings deposited by plasma enhanced chemical vapor deposition or boriding of nickel-based alloy 718 (DIN 2.4668) create hard and wear resistant thin solid films that offer high temperature stability. Ti–Si–B–C–N nanocomposite coatings consist of nanocrystalline grains embedded in a thin amorphous matrix. Due to this particular nanostructure, hardness values of up to 39.3 GPa were reached. Boriding of alloy 718 leads to formation of phases consisting of alloying elements like nickel, iron, and chromium and the diffusing element boron. The borides form a boriding zone that offers high hardness. Extrusion of Ø122 mm × 300 mm copper billets preheated to 850 °C was carried out and adhesive wear on tool's surfaces was analyzed. The comparison between hot working steel DIN 1.2367 without surface modification and with Ti–Si–B–C–N coating or borided alloy 718 showed remarkable differences between conventional tools made of hot working steels/alloy 718 and tools with surface modification. A strong decrease particle adhesion was observed.

Fretting wear behaviors of Cr-coated Zr–1Nb alloy cladding tube mated with Zr-4 alloy dimple under different tangential displacements

The fretting wear behaviors and wear mechanism of the Cr-coated Zr–1Nb alloy cladding tube mated with Zr-4 alloy dimple were investigated under different tangential displacements. With the increasing tangential displacement, the fretting running status changes from mixed fretting regime to gross slip regime, the friction coefficient increases first and then decreases, and the removed material volume, maximum wear depth, and wear coefficient of the Cr-coated Zr–1Nb alloy cladding tube increase. Fouvry's criteria were used to verify the correctness of the fretting running status. The primary wear mechanisms in the mixed fretting regime are adhesive wear and oxidative wear, while those in the gross slip regime are delamination wear and oxidative wear. The wear mechanism of the dimple is mainly delamination wear. Cr coating inhibits the wear of the cladding tube. After the coating is completely removed, the volume of material removed from the cladding tube increases dramatically, eventually exceeding the volume of material removed by dimple.

Friction and wear behavior of C implanted copper via ion beam-assisted bombardment

This work modified the surface of copper using physical vapor deposition and investigated the wear behavior of the modified copper at low load and sliding speed. The results of the study showed that the adhesion between the thin film prepared using the ion beam deposition technique and the substrate was insufficient, leading to an increased wear rate of copper after surface modification. However, when carbon particles were injected using ion beam-assisted bombardment, the friction properties of copper were significantly improved, with a decrease in wear rate from 1.6 × 10−4 to 8 × 10−6 mm3/N m and a 40% reduction in friction coefficient. This improvement can be attributed to the amorphous carbon layer on the copper surface, as well as the injection of carbon particles into the substrate, which enhanced the adhesion between the film and the substrate. Furthermore, a continuous copper oxide film formed during the friction and wear process, providing lubrication and protection to the substrate in conjunction with the amorphous carbon layer. Additionally, the primary wear mechanism of copper shifted from abrasive and adhesive wear to oxidation wear after ion beam-assisted bombardment with carbon injection. This study provides new insights and methods for material design and engineering applications by investigating the effects of ion beam-assisted bombardment technology on the wear resistance of copper materials.

The overlap rate influences the microstructure and properties of laser-cladded Fe-Ni-Ti composite coatings

The overlap rate has a significant impact on the quality and performance of laser cladding coatings. In order to prepare high wear-resistant laser cladding coatings. Single and multi-pass Fe-Ni-Ti composite coatings were prepared on the surface of 45 steel using a semiconductor laser. The microstructure and phase composition of the fusion layers were analyzed using metallographic microscopy, XRD diffraction, scanning electron microscopy, and energy dispersive spectrometry. Friction coefficients and microhardness of fusion layers with different overlap ratios were tested using a multifunctional surface performance tester and a microhardness tester. The wear performance of coatings with different overlap ratios was tested using a wear testing machine.The results indicate that when 6% Ti was simultaneously added to the Invar alloy matrix during the laser fusion of Fe-Ni-Ti alloy coatings, the phase composition of the fusion layer mainly consists of γ-[Fe, Ni] austenite, Fe3Ni2, α-Fe, and other metallic compounds. Simultaneously, in-situ formation of TiC reinforcement is dispersed in the matrix of γ-[Fe, Ni] solid solution. When the overlap ratio is 46%, the fusion layer exhibits a uniform, dense structure with fewer defects and higher coating hardness, resulting in improved wear resistance. At this point, the microhardness of the fusion layer is 450 HV, 1.5 times that of the substrate material and 2.2 times that of the base material. The friction coefficient on the coating surface is 0.412, with a percentage weight loss of 0.17%. The wear theory of the cladding layer is mainly adhesive wear, which also includes abrasive wear.

Investigation of friction and wear behavior of titanium alloy-diamond based on the morphology evolution of single abrasive clusters

This study investigates the wear mechanism of single diamond clusters during flexible scratching of titanium alloys. High-temperature rotary friction and wear tests were conducted using a flexible abrasive tool with bonded single diamond clusters. The study examined the impact of normal loads, rotation speeds, and temperatures on cutting ability and wear in titanium alloys. The percentage of abraded area in the annular cross-section was proposed as an index for evaluating diamond wear. The results indicate that the primary factors affecting diamond cluster wear are normal load and temperature, while friction speed has a relatively minor impact. At a 2 N load, the abrasive grains exhibited abrasive blunt wear without causing obvious damage to the titanium alloy surface. However, at a 4 N load and a temperature of 110 °C, adhesive wear became dominant, resulting in localized damage and oxidative wear on the diamonds. The annular cross-section abrasive wear profile revealed a nearly 30% increase in abrasive grain wear area as the normal load and temperature increased. This study aims to improve understanding of the abrasive grain wear at various stages and lays the foundations for grinding and polishing large-sized, high-precision parts.

Effects of aluminizing on the microstructure and wear resistance of AISI 321 steel

To enhance the surface properties, particularly hardness and wear resistance, of AISI 321 steel, an aluminizing coating was introduced through pack cementation treatment. Microstructure characterization and wear resistance tests were conducted to elucidate the intricate relationship between the microstructure and wear behaviors. A thorough analysis on the structure and compositions revealed the incorporation of FeAl(Cr) phases, aluminum oxides, titanium compounds and B2-NiAl phases in the coating, which resulted in a remarkable 192 % increase on the surface hardness, elevating it from 226 HV to an impressive 662 HV. In comparison to the uncoated 321 steel, the aluminized counterpart exhibited a pronounced reduction in coefficients of friction (COFs), wear volume losses, and wear rates. The wear mechanisms of both the uncoated 321 steel and aluminized steel were intricately analyzed. The uncoated 321 steel endured severe adhesive and oxidation wear, characterized by pronounced plastic deformation, the presence of wear debris and flaking oxides. In contrast, the aluminized steel predominantly underwent abrasive wear, showcasing a relatively smooth worn surface and dense continuous oxides. These findings not only reveal the significant enhancement of tribological properties by aluminized coatings, but also provide valuable insights into their fundamental behavior during wear.

Study on Fretting Wear Properties of GCr15 Steel Via Ultrasonic Surface Rolling Process

Abstract Ultrasonic surface rolling (USR) was applied to GCr15 steel with different static loads and passes to improve the friction and wear properties, and then the fretting wear mechanism of GCr15 steel after USR treatment was systematically investigated. The results showed that the specimens treated by the USR had lower surface roughness and significantly increased compressive residual stress and microhardness. Furthermore, severe plastic deformation occurred in the surface layer of the specimen, which refined the grains and increased the density of high- and low-angle grain boundaries. Besides, the results of the fretting test showed that the USR treated specimens had lower wear volume, dissipated energy, and steady-state friction coefficient. The fretting wear resistance increased with the static load and the number of passes. The fretting wear mechanism changed from abrasive wear and severe adhesive wear to slight fatigue wear and abrasive wear owing to the use of the USR treatment. Surface smoothing and hardening are responsible for the improvement in the fretting wear properties of GCr15 steel for USR treatment.

Wear behavior of ultrafine WC-Co cemented carbide end mills during milling of Inconel 718

Two innovative ultrafine cemented carbide end mills, denoted C1 and C2, were synthesized through spark plasma sintering, featuring compositions of WC-8Co-0.4VC-0.4Cr3C2 and WC-40(Ti,W)–8Co-0.4VC-0.4Cr3C2, respectively. Their wear behaviors were delved into during the precision machining of Inconel 718, and distinct disparities in wear evolution and tool longevity were unveiled. C1 exhibits exceptional wear resistance, surpassing C2 by a striking margin of 7.4–9.5, depending on the cutting speed employed. The sharp cutting edge of C1, characterized by a single hard phase of WC, minimal grain size, and high hardness, demonstrates excellent wear resistance and deformation resistance, thereby minimizing the onset of notch wear. In contrast, C2 experiences severe adhesive and diffusive wear phenomena, which culminate in substantial flank wear and cutting edge chipping. The addition of 40 wt% of (Ti,W)C exacerbates adhesion, flaking, and notch wear during machining. The prolonged and intensified adhesive wear witnessed in C2 leads to the deterioration of the tool surface and the formation of deep wear craters on the flank face. A comparison evaluation involving the prepared novel tools and commercially available end mills reveals that C1 boasts a longer tool life that outstrip those of its commercial counterparts by approximately 1.7–3.5 times under identical cutting conditions.

Microstructure and Wear Performance of High-Velocity Arc Sprayed FeMnCrNiBNbAl Coating

In this study, FeMnCrNiBNbAl wear-resistant coatings were prepared via high-velocity arc spraying technology on the surface of Q235 steel. The effects of spraying distance, voltage, and current on the coating performance were studied via the orthogonal experimental method with microhardness and porosity as evaluation indicators, and the process parameters were optimized. The order of primary and secondary factors affecting coating performance were: spraying distance, voltage, and current. The optimized process parameters are: spraying distance 200 mm, voltage 36 V, and current 240 A. The coating prepared using the optimized process parameters has an average microhardness of 756 HV0.1 and an average porosity of 1.03%. The coating mainly consists of α-Fe, Fe-Cr, Ni-Cr-Fe, Al2O3, and (Fe, Ni) solid solution. The coating friction coefficient was 0.5 while that of the substrate was 0.7. The depth and width of the wear marks of the coating were 6.32 µm and 555.41 µm, respectively, which are 66% and 32% lower in comparison with Q235 steel under the same test conditions. The wear forms of this coating were mainly fatigue peeling and adhesive wear.

Comparative study of the current-carrying property of different copper-impregnated carbon skateboards/contact wires

The pantograph-catenary system plays a crucial role in the current acquisition of Electric Multiple Unit. To obtain better carbon skateboard/contact wire matching properties, this study discusses the current-carrying properties of four different copper-impregnated carbon skateboards with chromium-zirconium-copper alloy contact wires at different currents. The test results demonstrate that the CI-D carbon skateboards are able to withstand higher currents with relatively stable electrical contact resistance and have a lower wear rate. According to tribological analysis, adhesive wear was the main wear mechanism of copper-impregnated carbon skateboards under the test conditions, which micro-analysis revealed as oxidized layers over a wide range of small areas. Small amounts of oxide particles and third-body abrasive debris cause abrasive wear on the carbon skateboard surface.

Thermal effects on wear behavior of additively manufactured NiTi shape memory alloys

NiTi alloys fabricated by laser powder bed fusion (LPBF) additive manufacturing technology not only address the compositional instability resulting from complex processes but also solve the challenges of difficult machining of intricate aerospace structures. However, there are very few reports on the wear behavior of LPBF-NiTi alloys. In the present work, the effects of microstructure and thermal treatment, including heat treatment and frictional heat, on the wear behavior of LPBF-NiTi alloy and 100Cr6 ball were analyzed through a series of tribological experiments with different sliding speeds. As the average sliding speed increases (0.079–0.216 m/s), the wear rate of the as-built and heat-treated samples tends to decrease in the range of 2.69 × 10−3–0.97 × 10−3mm3/m. Although the heat-treated LPBF-NiTi alloy is 46 % harder than the as-built alloy is, the latter has a higher toughness (505 MJ/m3) and greater transformation strain of SIM (0.097). This leads to a coupling effect of heat treatment and sliding speed on the wear resistance. In addition, the wear track morphologies under different sliding speeds are asymmetric due to the 24% greater acceleration at the far end from the motor and the 2.15 mm deviation between the maximum speed position and the geometric center of the track. The wear modes of the as-built and heat-treated samples included adhesive, abrasive and delamination wear. Moreover, the wear morphologies and dominant wear modes change with the frictionally caused heat release induced by the sliding speed.

Mechanical properties and wear behaviors of FeCoNiCrMnTix high-entropy alloys manufactured by vacuum arc melting

FeCoNiCrMnTix (x = 0, 2, 4, 6 wt%) high-entropy alloys (HEAs) were prepared using vacuum arc melting. The microstructure, mechanical and wear properties of the HEAs were investigated using XRD, OM, SEM, Vickers hardness, tensile tests and friction tests. The crystal structure of the FeCoNiCrMnTix HEAs consists of FCC and BCC, and the precipitation of the strengthening phase Ni3Ti inhibits the FCC to promote the formation of BCC. The dendrites (DR) of the FCC phase enriched with Fe, Co, and Cr. Ni, Mn, and Ti aggregated between the inter-dendrites (IR) of BCC phase. The addition of Ti to FeCoNiCrMn HEA decreased the grain size. FeCoNiCrMnTi6 reaches a maximum microhardness of approximately 293 HV higher than the equiatomic FeCoNiCrMn HEA (∼151 HV). The significant increase in hardness and wear resistance is attributed to solid solution strengthening, grain refinement, and precipitation hardening. With increasing Ti content, the yield strength of FeCoNiCrMnTix HEAs increased from 296 to 601 MPa and the average coefficient of friction (COF) gradually decreased. Tensile fracture is characterized by ductile and brittle fracture. The generated oxide layer protects the alloy matrix during friction, and the wear mechanism gradually transforms from adhesive wear to abrasive wear.

Microstructure and Wear Resistance of Grx-Ti-BN Composite Coating on TC4 by Argon Arc Cladding

The TC4 (Ti-6Al-4V) alloy has problems such as low material hardness, poor wear resistance, and abnormal sensitivity to adhesive wear and fretting wear. In this study, we used graphene-reinforced Ti/BN composite coatings prepared on the surface of the TC4 alloy by argon arc cladding technology. We explored the optimal content of graphene to improve its hardness and wear resistance. The physical phases and microstructures of the coatings were analyzed using an X-ray diffractometer, metallurgical microscope, and scanning electron microscope. Microhardness and wear properties of the cladding coating were measured by a Vickers hardness tester and a universal friction and wear tester. The incorporation of graphene resulted in a transformation of the reinforcing phase in the coating from TiN to Ti(N, C). The C element in the molten pool was substituted with the N element in an unending solid solution, resulting in the formation of Ti(N, C) through intermittent nucleation. As the amount of graphene in the molten pool increases, the concentration of carbon (C) also increases. This leads to the continuous growth of Ti(N, C) particles, resulting in a coarser coating structure and a decrease in coating performance. When the graphene content is 5 wt.%, the microstructure refinement of the coating is the most obvious, the microhardness is 900 HV0.2, which is 3 times higher than that of the matrix, and the wear rate is 4.9 × 10−5 mm3/(N·m), which is 4.9 times higher than that of the matrix. The wear mechanism of the coating is primarily abrasive wear with some slight adhesive wear.

Effects of multilayer structure on the high-speed dry-cutting performance of AlCrBN/AlCrN multilayer coatings

To investigate the effects of different structures on the cutting performance of AlCrBN/AlCrN multilayer coatings, AlCrBN/AlCrN coatings with different multilayer structures (single layer, 10 bilayers, and 20 bilayers corresponding to T1 coating, T10 coating, and T20 coating) were synthesized using multi-arc ion plating technology. Grazing incidence X-ray diffraction (GIXRD) and transmission electron microscopy (TEM) results showed that the coatings were mainly composed of fcc-(Cr, Al) N phases located on the (111) and (200) crystal planes. All coatings exhibited a good indentation adhesion to the substrates. The hardness of the T10 coating (32.6 GPa) and T20 coating (31.2 GPa) was significantly higher than that of the T1 coating (28.0 GPa). Annealing experiments show that no phase composition evolution was revealed at 800 °C. High-speed milling tests imply that the milling life of the T10 coating (13 m) and the T20 coating (10 m) was increased by 62.5% and 25.0% compared to the T1 coating (8 m), respectively. In high-speed dry turning tests, the T10 coated tool also showed the longest lifetime (16 mins), an improvement of 23.1% over T1 or T20 coated tools (13 mins). SEM analyses of wear coated tools indicated that a multilayer structure enhanced their resistance to abrasion and adhesion wear, and led to better cutting performance, probably because of their excellent mechanical properties and thermal stability.

High temperature tribological properties of TiAlSiN/NiCr multilayer coatings with different modulation periods

In this work, TiAlSiN/NiCr multilayer coatings with different modulation periods were deposited by cathodic-arc techniques, which combined filtered cathode vacuum arc (FCVA) and cathodic-arc ion plating (CAIP) techniques to deposit sublayers at different bias voltages. The nanoscale multilayer coating (TiAlSiN: 88 nm; NiCr: 9 nm) exhibited excellent oxidation resistance and thermal stability. Annealed coatings at 900 °C in air for 1 h, the thickness of the oxide layer of N32 coating is only 0.91 μm and the increase in coating thickness was only 9.01%, while the thickness of oxide layer of monolayer TiAlSiN coating is 3.02 μm and thickness increasing of 122.28%. Due to the existence of numerous interfaces, the N32 coating exhibited the lowest wear rate of 1.92 × 10−7 mm3N−1m−1 at 600 °C under abrasive wear and adhesive wear mechanisms. In parallel, a new AlNi intermetallic compound with excellent thermal stability was characterized by high-resolution transmission electron microscopy (HRTEM) at the coating interfaces. This compound is derived from different cathodic-arc techniques and bias voltages used to deposit coatings, which provides a reference for the structural design of coatings facing thermal environments.

Playing with Low Amounts of Expanded Graphite for Melt-Processed Polyamide and Copolyester Nanocomposites to Achieve Control of Mechanical, Tribological, Thermal and Dielectric Properties.

Polyamide 11 (PA11) and copolyester (TPC-E) were compounded through melt extrusion with low levels (below 10%) of expanded graphite (EG), aiming at the manufacturing of a thermally and electrically conductive composite resistant to friction and with acceptable mechanical properties. Thermal characterisation showed that the EG presence had no influence on the onset degradation temperature or melting temperature. While the specific density of the produced composite materials increased linearly with increasing levels of EG, the tensile modulus and flexural modulus showed a significant increase already at the introduction of 1 wt% EG. However, the elongation at break decreased significantly for higher loadings, which is typical for composite materials. We observed the increase in the dielectric and thermal conductivity, and the dissipated power displayed a much larger increase where high frequencies (e.g., 10 GHz) were taken into account. The tribological results showed significant changes at 4 wt% for the PA11 composite and 6 wt% for the TPC-E composite. Morphological analysis of the wear surfaces indicated that the main wear mechanism changed from abrasive wear to adhesive wear, which contributes to the enhanced wear resistance of the developed materials. Overall, we manufactured new composite materials with enhanced dielectric properties and superior wear resistance while maintaining good processability, specifically upon using 4-6 wt% of EG.

A novel wear-resistant and corrosion-resistant Mo2NiB2–Ni cermet coating prepared using fast hot pressing sintering

A new fast hot pressing (FHP) sintering method was used to prepare Mo2NiB2–Ni cermet coating to solve the problems of small scale and high energy consumption in the production. The synthetic phase and microstructure of the Mo2NiB2–Ni cermet coating were studied, and friction and wear as well as electrochemical corrosion performance were also tested. The results indicated that the Mo2NiB2–Ni cermet coating was composed of two phases, the Mo2NiB2 hard phase and the Ni metal-bonded phase. A metallurgical bond interface resembling interlocking teeth was formed between the Mo2NiB2–Ni cermet coating and the stainless steel substrate, thereby enhancing the bonding strength of the interface. Compared with the Mo2FeB2–Fe cermet coating, the Mo2NiB2–Ni cermet coating had certain wear resistance and excellent corrosion resistance. The high hardness of the Mo2NiB2 hard phase, the low mutual solubility between the Ni metal-bonded phase and the Si3N4 balls, and the generated mechanical mixing layer reduced the friction coefficient and the adhesive wear, which improved the wear resistance. The higher open circuit potential and the formation of the passivation film during the corrosion process enhanced the corrosion resistance of the Mo2NiB2–Ni cermet coating.

Friction and wear performances of 7075 aluminum alloy surface with V-shaped microtexture via numerical simulation and experimental characterizations

Purpose The purpose of this study is to design and process the optimal V-shaped microstructure for 7075 aluminum alloy and reveal its wear resistance mechanism and performance. Design/methodology/approach The hydrodynamic pressure lubrication models of the nontextured, V-shaped, circular and square microtextures are established. The corresponding oil film pressure distributions are explored. The friction and wear experiments are conducted on a rotating device. The effects of the microstructure shapes and sizes on the wear mechanisms are investigated via the friction coefficients and surface morphologies. Findings In comparison, the V-shaped microtexture has the largest oil film carrying capacity and the lowest friction coefficient. The wear mechanism of the V-shaped microtexture is dominated by abrasive and adhesive wear. The V-shaped microtexture has excellent wear resistance under a side length of 300 µm, an interval of 300 µm and a depth of 20 µm. Originality/value This study is conductive to the design of wear-resistant surfaces for friction components.

Assessment of polyethylene wear in dual mobility implant for Asians on various head-to-liner ratios: A finite-element analysis

Based on several references, Asians carry out several daily activities that are different from Westerners, which require a greater range of motion. Because of that, a dual mobility (DM) implant was created that was adapted to the activities of Asian people. One of the factors that might shorten the life of a hip implant is wear. Simulations of wear that are based on computation can guide product design to reduce the amount of adhesive and abrasive wear. Even though advanced modeling approaches have been established, a great deal of wear is still not understood, especially regarding the metal-on-polyethylene articulations found on DM cups. It is critical to examine the wear on the DM cup's head-to-liner ratio to determine the proper head diameter and liner thickness for this DM cup. In this work, wear was analyzed using finite-element analysis and compared between three different femoral head diameters matched with different thicknesses of the polyethylene liner on DM cups. Wear was analyzed throughout the regular walking cycle at each head-to-liner ratio. The findings of this study can be used to develop a dual-mobility artificial hip joint for Asians with the slightest wear.