Body Abrasive Wear Research Articles

On Three Body Abrasive Wear Resistance of Eggshell and Marble Powder Reinforced Hybrid Sustainable Polymer Composites

On Three Body Abrasive Wear Resistance of Eggshell and Marble Powder Reinforced Hybrid Sustainable Polymer Composites

Influence of MoS2 nano-filler additions on wear behavior of carbon fiber reinforced epoxy composites

In this research work, two body wear and three-body wear performance of carbon fabric reinforced HTR 212 epoxy resin(CF/Epoxy) composites are experimentally evaluated. Carbon fabric/epoxy resin composite panels with MoS2 nano-filler additions of 0.1, 0.2, 0.4 and 0.7 weight percentage are developed by Vacuum Assisted Resin Transfer Molding process. Two Body Wear test is conducted on the prepared specimen in accordance with ASTM G-99, whereas Three Body Abrasive wear test is conducted as per ASTM G-65. Experimental Tests are conducted for sliding and abrading distances in multiples of 250 m up to 1500 m. Results reveal that Carbon fabric/epoxy resin composites with 0.7 weight percent of MoS2 show 18% reduction in two body wear compared to a decrease of 35% in Three Body abrasive wear at 1500 m abrading distance. Scanning Electron Microscopy is used to study the surface morphology of the tested samples and to know the mode of damage at the surface.

Investigation of Three Body Abrasive Wear Behavior of Micro-Nano Sized Iron Ore Pieces on Bronze

In In this work, the three-body abrasive wear of bronze (C86200) in pig cart transmissions was examined. Micro-nano-sized ore particles were introduced to the lubricating media during the Ball-on-flat test to represent three-body abrasive wear. Load shear rate and lubricating medium were useful research inputs. Outputs included examining sample surfaces, mass loss, friction coefficient, and trace depth. Taguchi, ANOVA, and RSM were used to analyze experimental data. The most effective parameter for all outputs was the load value, with a rate of 55.76 percent, while the speed had the lowest influence on mass loss, at 9.74 percent. The regression model fits these results well.

Mechanical property analysis and dry sand three-body abrasive wear behaviour of AZ31/ZrO2 composites produced by stir casting

An experimental study of three body abrasive wear behaviour of AZ31/15 vol.% Zirconium dioxide (ZrO2) reinforced composites prepared by stir casting has been carried out. Microstructural analysis of the developed composites was carried out and found out that the microstructure of the composites revealed a uniform distribution of ZrO2 particles with refinement in the grain size of the matrix from 70 to 20 µm. The alterations in the microstructure led to an enhancement in both hardness (68–104 HV) and tensile strength (156–236 MPa) due to Orowan strengthening, quench hardening effect and better bonding. Response surface methodology was applied to formulate the three-body abrasive wear test characteristics such as load, speed, and time. Three body abrasive test results were utilized to generate surface graphs for different combinations of wear test parameters revealed an increase in specific wear rate. The specific wear rate was observed to increase with increase in speed up to a certain level and then started to decrease. The lowest possible specific wear rate was obtained for an optimized load of 20 N and a speed of 190 ms−1. Scanning electron microscopic examination of wear-tested samples showed higher specific wear rate at higher loads with predominantly abrasion type material removal. In conclusion, this study makes a substantial contribution to the field by elucidating the complex relationships among microstructure, mechanical properties, and the three-body abrasive wear behavior of AZ31/ZrO2 composites. The determination of optimal wear conditions and the insights gained into wear mechanisms provide valuable information for designing materials, implementing engineering solutions, and advancing the creation of wear-resistant components across a range of industries.

Effect of textured parameters on tribological properties of hydrodynamic journal bearing

PurposeThis study aims to improve the tribological properties of hydrodynamic journal bearing via surface texture, as well as the wear and antifriction mechanisms of textured bearing were represented. It provides a design direction for solving the tribological problem of rotor-bearing system.Design/methodology/approachIn this paper, the variation of surface texture parameters (e.g. texture diameter, d; area density, sp; and depth, hp) were analyzed based on finite difference method. The optimal surface texture parameters were obtained by designing orthogonal experiments, and the relationship between friction and wear properties and microstructure was studied via combining electron probe microanalyzer, scanning electron microscope, X-ray diffractometer and friction and wear testing machine.FindingsDimensionless film pressure P increased as the d increased, whereas P first increased and then decreased as the sp and hp increased, and the maximum P was got as sp = 15% and hp = 25 µm, respectively. The friction coefficient of textured surface with suitable parameters was effectively reduced and the textured surface with the best antifriction effect was 5#. Orthogonal experimental design analysis showed that the influence order of factors on friction coefficient was as follows: sp > sp × d > d > d × hp > hp > sp × hp and the friction coefficient first decreased and then increased as the sp, d and hp increased. In addition, the friction and wear mechanism of textured bearing were three body friction and abrasive wear as the matrix structure and hard phase were a single β phase and Mn5Si3, respectively. While the antifriction mechanism of textured surface was able to store abrasive particles and secondary hydrodynamic lubrication was formed.Originality/valueThe sample with reasonable texture parameter design can effectively reduce friction and wear of hydrodynamic journal bearing without reducing the service life, which can provide a reference for improving the lubrication performance and mechanical efficiency of rotor-bearing system.

Effect of abrasive grit grade on the abrasion wear behaviour of long banana-jute fibers reinforced hybrid epoxy composites

The effect of abrasive grit geometry on two-body abrasion wear behavior of long banana and jute fiber reinforced epoxy composites has been investigated. Epoxy (EP), Epoxy/4 wt% Banana fiber (BF)/4 wt%Jute fiber (JF) (EP8), Epoxy/8 wt%BF/8 wt%JF (EP16), Epoxy/12 wt%BF/12 wt% JF (EP24), and Epoxy/16 wt% BF/16 wt%JF (EP32) were the composite materials systems used for the investigation. These composites were processed and fabricated using hand—lay-up technique. The two body abrasion wear test was carried out in accordance with ASTM G99 under the influence of different SiC grit particles (180, 320, 400, and 600 SiC grit). The test was conducted at a room temperature under the abrasion load of 10 N and abrasion speed of 1 m s−1 over a distance of 100 m. The findings of the experiments revealed that wear response of composites depends on pressure, geometry of abrasion particles and their composition. The wear volume loss and specific wear rate decreases with increase in the rank of grit grade. Further, 16 wt% of fibers in composites exhibits the superior abrasion wear resistance. But the higher volume fraction of natural fibers in composites impaired the abrasion wear resistance. Higher rank of grit number was associated with the lesser wear volume loss because of the change in wear mechanism from abrasion to adhesion. In comparison to epoxy based composites, EP16 composite shows superior wear resistance. SEM images were used to examine the worn surfaces.

Three body abrasion wear resistance of cenosphere particle‐reinforced syntactic foams developed using molding method

AbstractThis study aims to investigate the factors that affect the abrasion of cenosphere‐reinforced syntactic foams and assess their three‐body wear behavior using Taguchi's design of experiments (L16 Orthogonal array). Cenospheres were dispersed into an epoxy matrix to create syntactic foam samples. The findings show that the syntactic foams' rate of wear was influenced by the cenosphere concentration. Reduced wear rate was obtained with a greater cenosphere concentration. Duration and applied force both had an impact on how quickly the syntactic foams wore out. This research can help in the creation of wear‐resistant composite materials for a variety of applications by illuminating the variables influencing the abrasion of cenosphere‐reinforced syntactic foams. The findings demonstrate that sp. rate of wear is minimum (0.124 × 10−8 m3/Nm) at the factor combination of 60% loading of filler, 40 N of applied load and duration of 15 min which can be indicated as A4B4C2. This is 10.56 times better than the combination A1B4C4 which exhibits an sp. wear rate of 1.31 × 10−8 m3/Nm. These lightweight syntactic foams have the potential to be used as tribo‐materials in friction applications, such as composite brake pads.

Comparative study on three body abrasive wear behaviour of natural compliant thermoplastic composite under dry and lubricated conditions

This experimental study investigates the three-body abrasive wear behavior of jute/natural rubber flexible green composite under both dry and lubricated conditions. The composite material is prepared using a layering and compression method. A three-body abrasion tester is used to conduct the wear testing under various loads. The use of a lubricant further enhances the wear resistance of the composite, reducing the wear rate and friction coefficient. Mass loss of Jute/Rubber/Jute, Jute/Rubber/Rubber/Jute and Jute/Rubber/Jute/Rubber/Jute in lubricated wear condition is 44.44%, 15.87% and 29.96% less compared to dry wear condition. Wear mechanisms of the composite material are analyzed using scanning electron microscopy (SEM), revealing the presence of fiber breakage, and adhesive wear. Overall, this study provides valuable insights into the abrasive wear behavior of jute/natural rubber flexible green composite and its potential applications in various industrial sectors.

Effect of heat treatment on microstructure and tribological performance of PH 13-8Mo stainless steel fabricated via wire arc additive manufacturing

The scratch and reciprocating sliding wear response of a PH 13-8Mo stainless steel fabricated by wire arc additive manufacturing (WAAM) are investigated after different cycles of post-printing heat treatments and correlated with the microstructure and mechanical properties. The performed heat treatment cycles comprised of solutionizing for 1 h at 1050 °C followed by an aging cycle for 4 h at 400 °C, 500 °C, and 600 °C. The optimum aging temperature was found to be at 500 °C under which hardness, scratch, and wear resistance were maximum and the coefficient of friction was minimum due to removal of determinantal δ-ferrite phase from the as-printed microstructure and the attained precipitation hardening through the formation of coherent nano-scale β-NiAl precipitates. The employed heat treatment was effective in eliminating the anisotropic scratch and wear response in the as-printed part arising from its anisotropic microstructure. The overall wear micro-mechanisms were similar for as-printed and heat-treated conditions with ploughing during scratch test, and adhesive, oxidative, and three body abrasive wear mechanism during the reciprocating sliding wear test. The results showed that WAAM-produced PH 13-8Mo parts have great potential to be an alternative to their wrought counterparts for wear resistance demanding applications.

Structural and wear assessment of H11 die steel as a function of tempering temperature

H11 steel is widely used in helicopter landing gears and dies for extrusion and forging. The property of H11 steel can be enhanced by several types of heat treatments for a long life span and improved design accuracy. In the present work, an attempt is made to study the effect of the tempering cycle on the two-body abrasive wear behavior. The structural characterization of hardened and tempered specimens was carried out using scanning electron microscopy (SEM) and X-ray diffraction (XRD). Two body abrasive wear tests were carried out using silicon carbide abrasive with a systematic and simultaneous variation of test parameters. The different tempering temperatures used in the present investigation are 200 °C, 400 °C and 600 °C. The result showed that the wear mechanism like (ploughing and micro-cutting) in each condition was dominated by the types of phases present in the material and their morphology. The wear debris was flaky and ductile. There was the presence of a small amount of SiC particles from the abrasive wear paper in wear debris for high load (40 N) wear tests. The wear debris particles were relatively finer in as-quenched condition and low tempering temperature (200 °C), while those were large for samples tempered at 400, 600 °C and fully annealed condition. The wear debris analysis through micrographs and iron oxide particles were not detected in XRD patterns.

Mechanical and Three Body Abrasive Wear Behaviour of Nano-Filler Filled, Chopped Glass Fiber Filled Hybrid Composites

Polymer matrix composites are developed for tribological applications due to the possibility of optimizing the properties with the addition of special filler materials as reinforcement. Filler filled polymer matrix composite systems are used in many automotive parts and components like brake pads or clutches which require high coefficient of friction coupled with low wear. However, in most cases it is the primary concern to develop polymer composites that posses low friction and low wear properties under dry sliding conditions against smooth metallic counterparts e.g., gears or bearings, chute liners and coal handling equipments in power plants, gear pumps handling industrial fluids, agricultural machine components. Polymer composites operate in applications where fluid and grease lubricants fail, and have superior tribological performance to traditional polymer composites. Particulate fillers or fibres or solid lubricants have been a part of notable reductions in the wear rate of the polymer matrix at very low loading, and there exists a wide scope on the development of polymer composites on the tribological behaviour. The incorporation of fillers in polymer could provide a synergism in terms of improving mechanical properties and wear performance, which has not been adequately explored so far. The research on nano fillers such as nano clay, Glass fiber and Titanium di-oxide (TiO2) in epoxy system is scarcely reported and further they focus on a few specific issues only. The present study was focused on investigating Mechanical - Tensile, Hardness, and three body abrasive wear characteristics of thermosetting based Epoxy composites and the effect of incorporation of nano clay, TiO2 nanoparticles and chopped glass fiber on microstructure, hardness, friction and abrasive wear are determined and analyzed. The main aim was to investigate the effect of applied load, sliding distance /abrading distance, sliding speed and percentage of filler. The surface morphology of the worn out surfaces were examined using SEM, to get a better understanding of the wear mechanisms.

Friction and wear properties of core-shell (CI is a core & GO is a shell) particles based magnetorheological fluid under steel on steel point contacts

This work is concerned with the experimental investigation of tribological and rheological properties of core–shell (carbonyl iron is the core and graphene oxide is the shell) particle-based MR fluid. Carbonyl iron (CI) particles were encapsulated with graphene oxide (GO) by a simple wet stirring process. The surface morphology, structural properties, and magnetic properties of graphene oxide encapsulated CI particles were analyzed by Field Emission Spectroscopy (FE-SEM), Raman Spectroscopy, and Vibrational Sample Magnetometer (VSM). The rheological properties of prepared samples were examined on a modular compact rheometer. The CI@GO particle-based MR fluid exhibited lower yield stress compared to bare CI particle-based MR fluid. Tribological tests of developed MR fluid were conducted on a universal tribometer with and without the presence of a magnetic field to ascertain the friction and wear behaviour. Experimental results revealed that the tribological properties are significantly improved by using CI@GO-based MR fluid in comparison to bare CI-based MR fluid and dry sliding conditions. Further, the wear analysis of worn surfaces was observed on FE-SEM, Energy-Dispersive X-ray Spectroscopy (EDS), and 3D-profilometer before and after each test. Three body abrasion wear mechanism was observed with some ploughing and groove formation.

Experimental investigation on the two body abrasive wear of AA6061-SiC-Gr nano and hybrid nanocomposites

Aluminium based hybrid nanocomposites can be employed in many applications owing to their desirable traits. Depending on the constituents of the hybrid metal matrix composites, they must be tested for their wear performance since there is a high chance that these materials will experience rapid wear. Determining the tribological behaviour of AA6061/ 2 wt. % SiCp nanocomposite and AA6061/2wt. % SiCp/2 wt. % graphite hybrid nanocomposite is the prime objective of this study. With AA6061 as the metal matrix and nano sized silicon carbide, graphite particles as primary and secondary reinforcements respectively, all the composite samples have been fabricated using ultrasonic assisted stir casting. Evaluation of the wear behaviour of the aforementioned materials is done using the two body abrasive wear tests conducted on a pin-on-disc apparatus. Wear coefficients and friction coefficients have been computed and were also analyzed with respect to various parameters. Additionally, wear mechanisms involved were deciphered and subsequently, wear maps have been developed for all the samples. The sample consisting 2 wt. % SiC and 2 wt. % graphite was found to have excellent wear resistance among all. Additionally, coefficient of friction was the lowest for the aforementioned sample itself.

Effect of Temperature and Sliding Velocity on the Dry Sliding Wear Mechanisms of Boron Modified Ti-6Al-4V Alloys

The dry sliding wear behavior of as-cast pristine and boron-modified Ti-6Al-4V (Ti64) alloys (having 0.3 and 0.55 wt% B) is investigated using pin-on-disc experiments with the pin being Ti64 alloy and the EN31 steel disc. Experiments are performed at sliding speeds (s) of 1, 2, and 4 m/s and temperatures 300 and 573 K. A mixed response in wear behavior is observed. At the lowest sliding speed, all three alloys (except 0.55B alloy at 300 K) exhibit similar wear rates, with abrasive wear being the dominant wear mechanism. At 2 m/s, temperature and s increase, and adhesive wear takes over along with delamination wear. Here, the 0.55B sample shows the highest wear rate due to the debonding of more TiB particles, which increases three body abrasion wear. With further increase in s to 4 m/s, delamination and oxidation wear are observed for all the samples. XRD evaluation shows traces of TiO2 and Fe2O3, which imply the formation of MML in samples tested at s = 4 m/s, which is also validated through subsurface microstructure analysis. It is found that MML having more TiB particles has more stability, because of which 0.3B samples show higher wear rate.

An experimental study on two body abrasive wear behavior of natural fiber reinforced hybrid polymer matrix composites using Taguchi analysis

In earlier days the synthetic fibre composite material was considerably used for the secondary structures of automobile and aircrafts. But by knowing the performance at critical and elevated conditions natural fiber reinforced polymer matrix composites have been receiving considerable attention as the attribute for synthetic fiber reinforced composites for its functional efficiency, tailorable properties and strength to weight ratio. In the present study, abrasive wear behavior of natural fibre reinforced hybrid polymer matrix composite was carried out using pin-on-disc wear testing rig for abaca, basalt and hybrid abaca- basalt fibre reinforced epoxy using L9 orthogonal array. The tests were carried out on silicon carbide paper with a grit size of 320 µm with varying parameters of Load, Speed, and Time. From the obtained results, it is concluded that the optimal parameters for minimum weight loss is observed at load 10 N, speed 200 rpm and time of 10 min for basalt fibre reinforced epoxy composite and the maximum weight loss is observed for abaca fibre reinforced epoxy composite at load 30 N, 300 rpm and time of 20 min. The results also reveal that the material composition is the most influencing factor affecting the weight loss of the specimen followed by load, time and speed for the adopted testing conditions.

Three-Body Abrasive Wear Behavior of WC-10Cr3C2-12Ni Coating for Ball Mill Liner Application.

Carbide coatings are frequently used to improve the wear resistance of industrial components in various wear environments. In this research, aiming at the service characteristics of easy wear and short service life of ball mill liners, WC–10Cr3C2–12Ni coatings were prepared by supersonic flame spraying technology (HVOF). The reciprocating sliding tests were conducted under four different WC particle size conditions, and the differences in the tribological behavior of the coatings and three–body abrasive wear mechanism were obtained. The findings reveal that the average nanohardness of the WC–Cr3C2–Ni coating is nearly five times greater than that of the steel substance. The COF of tribo-pairs decreases and then increases as the particle size increases. In the case of no particles, the surface of the coating is slightly worn, with fatigue and oxidative wear being the primary wear mechanisms. Small particles (1.5 μm and 4 μm) are crushed and coated on the coating surface, in which the extremely fine particles are plasticized to form friction layers that have a protective effect on the coatings. The protective effect of the particles disappears as the particle size increases and is replaced by a powerful chiseling effect on the coatings, resulting in serious material loss. The particle size has a direct relationship with coating wear.

THE EFFECT OF HEAT TREATMENT AND SURFACE ANODIZATION ON FRICTION AND WEAR COEFFICIENT OF ALUMINIUM 2024 USING PIN ON DISK METHOD

The use of aluminum alloys as a material for engineering components that rub against each other is increasing, so it is important to know the friction characteristics of these aluminum alloys. In this study, Aluminum 2024 was given heat treatment with variation in aging time and anodization. Then, the wear and friction coefficient tests were carried out using a pin tool on the disc. The effect of aging time and surface anodization on wear tests are carried out to determine the amount of wear and the coefficient of friction test is carried out to determine the coefficient of friction of the material when it rubs against a pin made of AISI 52100 Steel. The coefficient of friction test is carried out by adding lubrication as a parameter. The test results showed that the aluminum material given heat treatment had better resistance than that which was not heat treated. This is because the heat treatment creates precipitates that can increase the aluminum's hardness and wear resistance. Whereas for anodized specimens, the alumina layer can act as an abrasive grain when given a high enough friction and load continuously, so the wear testing mode changes from dry sliding wear to three body abrasive wear and decreased wear resistance. From the friction coefficient test results, the aging time affects the hardness of the aluminum alloy, which leads to the value of the coefficient of friction. The harder the sample surface, the smaller the coefficient of friction obtained. Furthermore, applying lubricant to the sample will also decrease the value of the friction coefficient of the sample. Lubricating oil will provide a more significant reduction in friction coefficient than air. Finally, the anodizing surface on the sample will act as a lubricant reservoir when it occurs.

Tribological characterization of sustainable Jute-Epoxy-Rubber crumb hybrid composite

The present work deals with three body abrasive behavior of Jute-Epoxy-Rubber crumb hybrid composites at different rubber crumb loading (0%, 5% and 10%). Three body abrasive wear tests are performed to determine the specific wear rate for different combination of proposed composites in terms of filler percentage, abrasive distance, and load. Results indicate that addition of rubber crumb as filler in the proposed composite results in enhanced resistance to abrasion. Statistical method, Taguchi’s L9 orthogonal array is used to find the most influential factor affecting the abrasive behavior of the proposed composites. The outcome of the statistical approach revealed that the filler is the most influential factor influencing abrasion of the proposed composites. Experimental results are compared with the predicted results and it was found that they agree well with each other. The SEM micrographs studies reveal the dynamics of three body abrasive wear and underlying micro mechanisms that serve as determinant for wear performance of such composites.

Study on the three body abrasive wear behaviour of EN8-steel before and after coating of wear resistance material

The effects of aluminum, zirconium, and fly-ash mixture additions on three-body abrasive wear behaviour of EN8- steel have been systematically investigated using a threebody abrasive machine and SiO<sub>2</sub> as abrasive.The coating material is preferred by using 49% aluminum and 49% zirconium is mixed by using 2% fly-ash, the fly ash works as a binder between aluminum and zirconium. Investigate the worn surface of EN8-steel specimen before and after coating of Al<sub>2</sub>O<sub>3</sub>, ZrSiO<sub>4</sub> and fly-ash mixture. The Al<sub>2</sub>O<sub>3</sub>, ZrSiO<sub>4</sub> and fly-ash coated working specimen will give less wear rate in grams compared to working specimen without coating. It clearly shows that using Al<sub>2</sub>O<sub>3</sub> and ZrSiO<sub>4</sub> will reduce the wear rate and increase life of EN8 steel.

Microstructure and sliding wear behavior of HVOF sprayed Al(1−x)CoCrFeNiTix high-entropy alloy coatings

Al(1−x)CoCrFeNiTix high-entropy alloy (HEA) coatings were prepared by HVOF technology with atomic ratio of 0 ∼ 0.25 (x = 0, 0.125, 0.25). The microstructure, phase composition and sliding wear behavior of the coatings were studied. The results show that the Al(1−x)CoCrFeNiTix HEA coatings have compact structure. The coatings include B2 phase and A2 phase. Besides, the coatings have good sliding wear resistance. The wear failure mechanism of the AlCoCrFeNi coating is mainly three body abrasive wear, oxidative wear and fatigue wear. With the increase of replacement Ti, the degree of abrasive wear decreases gradually and the wear resistance and the effect of oxidation wear increases.