Abrasive Wear Characteristics Research Articles

Influence of metallic Cr addition on the phase structure and mechanical properties of plasma-sprayed Ti–Si–C coatings

The Ti–Si–C coatings with metallic Cr addition were plasma-sprayed using the Ti–Si–C–Cr powder aggregates with different molar ratios. The influence of metallic Cr addition on the phase structure and mechanical properties of the coating were studied. The outcomes illustrate that Ti–Si–C–Cr coatings contained binary TiC and Ti5Si3, ternary Ti3SiC2 phase, metallic Cr, and small amounts of residual Si and graphite phases. The fracture toughness of the 3Ti–Si–2C-1.0Cr coating had an ~35% improvement compared to that of the 3Ti–Si–2C coating, while its micro-hardness only had ~4% decrease. The wear loss of 3Ti–Si–2C-0.2Cr coating was only ~39% of that observed for the 3Ti–Si–2C coating, indicating that the addition of metallic Cr improved the wear resistance. The coating worn surfaces primarily showed the characteristics of adhesive and abrasive wear.

Investigation of three-body abrasive wear characteristics of white ark shell powder

Abstract In this work, white ark shell powder (a natural sea waste) was investigated for its abrasive character using dry abrasion tester with two other commercially available materials i.e., American Foundrymen’s Society (AFS) quartz sand and cashew nut shell liquid (CNSL) friction powder. A total of 54 experiments were performed on dry abrasion tester using these powdered materials against a grey cast iron (GCI) specimen at two different wheel speeds of 100 r.p.m. and 200 r.p.m. with varying wheel revolutions from 250 to 750 under the loads of 38 N, 51 N and 64 N. The particle size was kept in the range of 50–70B.S.S. mesh. It was observed that the volume loss of GCI specimen increased with increase in load and wheel revolutions at both the wheel speeds. The increase in wheel speed from 100 r.p.m. to 200 r.p.m. also influenced the volume loss significantly. The wear volume loss at all the combinations of wheel revolutions and wheel speed for the tested abrasives in decreasing order was observed as: AFS quartz > CNSL powder > white ark shell powder. The lower volume loss of counter surface against white ark shell powder suggests its use in such applications where low wear rate is required.

A comparative analysis of the abrasion wear characteristics of industrial wastes filled glass/polyester composites based on the design of experiment and neural network

AbstractThis article presents the abrasion wear behaviour of different industrial wastes filled glass/polyester composites. Two types of fillers such as fly ash and granite dust are chosen with different weight proportions along with polyester and glass fiber for fabricating the composite using hand layup route. Abrasion wear properties of the developed composites are studied in the dry sand abrasion wear test rig as per the ASTM‐G‐65 standard. The experiments were conducted based on Taguchi design. Between the two fillers, granite filled composite showed better abrasion resistance property as compared with fly ash. Normal load and filler content are found to be the most influential factor for the abrasion loss of the composites followed by abrading distance and sliding velocity. The results are predicted using neural network and also compared with the experimental and regression model data. Abraded surfaces are examined by the SEM to ascertain the different wear mechanisms responsible for abrasion loss of material.

Abrasive wear characteristics and microstructure of Fe-based overlaid ploughshares in different field conditions

In the present research, two different Fe-based claddings, namely SZ (Fe–Cr, Fe–33.37Cr–3.83C) and ZK (Fe–Mo, Fe–8.18Mo–4.5Cr–0.65C) were overlaid on EN-42 steel substrate by Manual Metal Arc Welding (MMAW) process with an aim to enhance the abrasive wear characteristics of the steel. The microstructural and abrasive wear behavior of overlaid samples was investigated in comparison with bare steel (EN-42) in actual field conditions at two different moisture levels (0–3% and 14–17%). Optical microscopy, scanning electron microscope (SEM), X-ray diffraction (XRD), and hardness testing were performed to characterize the microstructural and mechanical properties of bare and overlaid steel samples. The effect of moisture content on abrasive wear resistance of tillage tools and tillage quality has also been evaluated. The results revealed that the variables such as carbide shape, size, distribution, and matrix structure of hardfacing influence the wear resistance of hardfacings. The SZ alloy showed higher abrasive wear resistance than ZK alloy due to the formation of M23C6 and M7C3 carbides in the hardfaced layer. The moisture content of the soil also affected the abrasive wear resistance of the substrate and different hardfacings materials, which in turn influence the tillage efficiency of the tool. The wear rate of bare and overlaid ploughshares is almost 3 times higher in dry field conditions (0-3% moisture) as compared to moist conditions (14–17%). The wear resistance indices (WRI) for SZ and ZK overlaying were found to be 1.85 and 1.48 respectively for low moisture conditions, and 1.9 and 1.54 for the moist condition.

A Comparison of Adhesive Wear with Three-Body Abrasive Wear Characteristics of Graphitic White Irons Designed for Metal-to-Metal Wear Systems

Frictional heat-induced severe adhesive wear has been limiting the lifetime of metal-to-metal wear systems for many years. Five graphitic white irons were previously designed and produced to introduce flake graphite into white iron, with the goal to expedite heat dissipation and reduce the frictional heat effect. This paper focused on the graphite addition effect on adhesive wear resistance for graphitic white irons and its comparison with abrasive wear. Adhesive wear resistance was assessed with a block on ring apparatus in accordance with ASTM G77. An empirical model was formulated to quantitatively evaluate graphite additions’ effect on the adhesive wear resistance. The model indicated that 1 vol.% graphite addition had the same effect as a hardness increase of 2.66 HRC, which was a 14% higher contribution than previously observed for three-body abrasive wear of the same alloys studied following ASTM G65. The improved wear resistance was related to an increased thermal diffusivity of the composite microstructure, and the surface lubricating effect of graphite.

Enhanced corrosion and tribocorrosion behavior of Ti6Al4V alloy by auto–sealed micro-arc oxidation layers

Surface modification of titanium alloys are being considered to justify their use as articulating surfaces. This study examined the corrosion and tribocorrosion behavior of Ti6Al4V specimens whose surfaces were modified using micro-arc oxidation (MAO) at −3 o C and + 20 °C. After MAO, the porous oxide layers containing Ca and P that are incorporated from the electrolyte, were fabricated on the surface. Many of the pores were sealed by the deposition of erupted materials on the surface of −3 °C MAO layers, resulted in a reduced surface fraction of open-porosities. Corrosion studies revealed nearly 80 mV positive shifting of corrosion potential and more than 50% decrease in the passive current density of auto-sealed layers. In contrast to the sudden potential drop of the untreated Ti6Al4V alloy, the MAO layers showed no significant decrease during the tribocorrosion. The presence of a relatively smooth surface with some parallel scratches were the main characteristics of mild abrasive wear as the dominant wear mechanism of the −3 °C MAO layers.

Research of Electrolyte Plasma Treatment Impact on Wear Resistance and Roughness of 18HN3MA-SH Steel

This work provides the results of research of the wear resistance of the surface of samples of low carbon structural of 18HN3MA-SH steel, subjected to electrolytic-plasma treatment by nitriding and carbonitriding. The effect of the structure on the surface wear resistance of steel is shown. Changes in abrasive wear and dry friction characteristics were studied depending on temperature and processing time. The results of studies of tribological tests show that after electrolytic-plasma nitriding, the wear resistance of steel 18HN3MA-SH increases by 1.5–2 times compared with the initial state. The observed effects can be explained by the flowing surface modification - the formation of a modified surface layer with the formation of hardening phases. The nature of changes in the surface roughness Ra of steel samples after cementation, carbonitriding and nitriding was studied.

Abrasive wear behavior of WC nanoparticle reinforced magnesium metal matrix composites

In this study, abrasive wear characteristics of AZ31-WC nanocomposites with varying weight percentage of nanoparticles (0, 0.5, 1, 1.5 & 2) are examined. AZ31-WC nanocomposites have been fabricated by ultrasonic vibration assisted stir casting method. Optical microscopy and scanning electron microscopy are employed to perform characterizations of cast composites. Density and micro hardness of nanocomposites are also investigated. Effect of abrasive grit size and sliding distance on abrasive wear behavior and friction behavior of nanocomposites are evaluated using pin-on-disc tribotester. Worn surfaces are studied with the help of 3D optical surface plotter, SEM and EDAX to find dominant wear mechanism at several experimental conditions. Microscopic observations disclose that distribution of WC nanoparticles is uniform throughout the matrix. Density and micro hardness increase with increasing percentage of WC nanoparticles. Moreover, significant improvement in wear resistance and friction behavior is observed by incorporation of WC nanoparticles. Wear resistance of Mg-2WC nanocomposite is improved around 56% than base alloy when tested with 400 grit SiC paper and 50 mm track diameter. Higher grit size abrasive paper exhibits less wear in composites. 3D Surface plots of worn surfaces show that, surface roughness is decreased with increasing wt% of WC. Surface roughness of worn surface of Mg-2WC nanocomposite tested with 800 grit, 50 mm track diameter has 35.06% less surface roughness than Mg-2WC nanocomposite tested with 400 grit, 50 mm track diameter. Investigation of worn surfaces discloses dominant mechanisms as abrasion, adhesion and delamination at several experimental conditions.

Effects of groove-textured surface combined with Sn–Ag–Cu lubricant on friction-induced vibration and noise of GCr15 bearing steel

Taking GCr15 steel as the research object, the groove-textured surfaces (GTSs) and the composite antifriction surfaces (CASs) with the grooves and Sn–Ag–Cu were prepared. Experimental researches on the tribological performance, friction-induced vibration and noise of SS (smooth surface), GTSs and CASs were conducted. The results showed that SS exhibited the obviously abrasive wear characteristics, thus the uneven surface was obtained, leading to the high-frequency scream. The fluctuation of friction force caused by the grooves on GTSs could suppress the high-frequency scream but cause the low-frequency chatter. The cooperate effect of grooves and Sn–Ag–Cu increased the fluctuation amplitude of friction force, hence CASs profile with obvious wrinkles was formed, suppressing the friction-induced vibration and noise.

Experimental investigation and optimization of abrasive wear characteristics of polypropylene nanocomposites

The applications of the polymer nanocomposites are increasing to a greater extent in several sectors. In this investigation, the matrix selected was Polypropylene (PP) and reinforcing filler was Cloisite 30B (C3B) with Elvaloy-AC-3427 (EAC) as a compatibilizer. Twin screw extruder was used for manufacturing of PP/C3B/EAC nanocomposites. C3B was added at the range of 1, 2, 3, 5 wt% to PP matrix. The manufactured composites was analysed for mechanical and thermal characterization. The tribological characteristics of manufactured nanocomposites were studied using abrasive wear tests. The input parameters considered for the abrasive wear tests were (i) load, (ii) C3B and (iii) sliding distance. The output parameters for the abrasive wear tests were weight loss, Coefficient of Friction (COF) and Specific Wear Rate (SWR). Grey relational analysis and grey fuzzy were done for the optimisation of abrasive wear characteristics. Analysis of Variance (ANOVA) was used for analysing the effect of input parameters over the output factors. Finally, the abraded wear samples of PP/C3B/EAC nanocomposites samples were examined microscopically.

Abrasive wear characteristics of bio-based jatropha oil cake incorporated basalt fiber reinforced epoxy composites

In this work, abrasive wear performance of basalt fabric reinforced - epoxy (BTE) composite and jatropha oil cake filled basalt fabric epoxy (JPH) composite have been investigated. The composition analysis of jatropha cake was observed through SEM. The two-body abrasive wear tests of the composites were carried out by using pin on disc machine. The abrasive wear behavior has been performed at dissimilar loads namely 5 N &10 N, and at different abrading distances. Jatropha filled composite shows better abrasive wear performance as compared to BTE composite. The specific wear rate declines with growing load and abrading distances. The wear mechanisms of the abraded specimens have been examined by using optical microscopy and scanning electron microscopy.

Abrasive wear characteristics of complex carbides overlay (CCO) in comparison to low-alloy boron steels

The aim of present study was to evaluate the abrasive wear resistance of complex carbide overlay plates in comparison to low alloy boron steels of different hardness grades. These materials are typical in mining, trasportation and crushing aplications worldwide. The abrasive wear resistance was evaluated by weight loss using a dry sand-rubber wheel laboratory abrasion test that exposed the materials to slidding abrasion. All tests were performed under dry conditions at room temperature. In order to evaluate the tribological response of the different steels and their wear mechanisms, post-characterization of the worn surfaces was performed by SEM/EDX. To better understand the wear process, microstructural SEM/EDX and microhardness analyses were performed as well. The results showed that abrasive wear performance was determined by a combination of high hardness and toughness (fracture strain). The dry sand-rubber wheel using quartz sand with 1100 HV causes severe damage in low alloy boron steels plates due to transition between cutting and plastic deformation. By applying the described methodology it was possible to establish performance comparisons and wear behavior due to individual material features according field applications.

Microstructure and property of Ni/WC/La2O3 coatings by ultrasonic vibration-assisted laser cladding treatment

Ultrasonic vibration was introduced during laser cladding Ni-60%WC-0.8%La2O3 coatings in this study. The microstructure, elemental distribution, and properties of the cladding coatings, as well as the morphology of WC particles were also investigated. Results showed that with WC ceramic particles, the columnar dendrites that formed at the bottom of the cladding coating without ultrasonic vibration were dissolved, crystallized, and aggregated. As ultrasonic vibration was introduced, the dendrites in the cladding coating were disrupted, and the grains were refined. WC particles concentrated at the bottom of the cladding coatings at an ultrasonic power of 600, 700, and 900 W, resulting in obvious degradation in surface hardness and wear resistance. However, when an ultrasonic power of 800 W was applied, improved hardness and wear resistance, which are attributed to the strengthening of precipitated carbides, refined microstructure, and homogenous distribution of WC particles in the cladding coatings, were observed . For laser cladding coatings without ultrasonic vibration, typical characteristics of abrasive and fatigue wear could be found on the wear tracks after a ring-on-disk (ROD) wear test, and flaking pits appeared along the sliding direction. For the composite coatings prepared with different ultrasonic vibration power, typical abrasive wear occurred on the surfaces of the coatings under 600, 700, and 900 W during ROD wear tests, with additional shallow and mild ploughing for that under 800 W.

Abrasive wear characteristics of 40Mn2 steel in simulated condition of sprocket wheel in crawler bulldozer walking system

The abrasive wear characteristics of 40Mn2 steel be studied in this paper. The rubber wheel abrasive wear tester be used for simulating the sprocket wheel working-conditions. The relationship between worn surface residual stress and wear rate was studied. Wear surface morphology and mechanism worn surface micro-structures are also shown in results. In addition, there are XRD pattern of the experimental abrasives, to better reveal the abrasive wear mechanisms. The results indicates that the larger the applied load and sliding speed is, the greater the wear rate will be. The content of hard phase in abrasive determine the wear rate. The main wear mechanisms of soil and coal in working-conditions are scratching and spalling, respectively. Spalling, chipping, scratching and pitting are the main wear mechanisms in sand working-condition. There are same trend of the wear rate and the worn surface residual stress with the wear time increasing. Intergranular carbides can decrease the wear resistance to some extent.

Influence of Artificial Aging on Mechanical Properties and High Stress Abrasive Wear Behaviour of Al–Mg–Si Alloy

The present study evaluated hardness, tensile properties and two-body abrasive wear behaviour of Al–Mg–Si alloy specimens artificially aged at 448 K for different durations ranging from 0.5 to 504 h. In addition to the measurements of Vickers hardness and tensile properties, wear tests of differently aged alloys were conducted against SiC abrasive paper of 220 grit size under normal load of 9.81 N with the help of a pin-on-disc tribometer. Abrasive wear characteristics were assessed in terms of measurements of specific wear rate and roughness of the abraded surfaces. These were substantiated via examinations of worn surfaces, collected wear debris and subsurfaces of worn specimens to comprehend the micro-mechanisms of abrasion. The abrasive wear performance varied significantly with the duration of artificial aging and the lowest specific wear rate as well as roughness of the abraded surfaces corresponded to the peak-aged condition. An attempt was also made to correlate mechanical properties and tribological performance. It was found that the specific wear rate exhibited direct linear relation with the strain hardening exponent, and inverse linear relationships with hardness, yield strength and strength coefficient. Microplowing, microcutting and microcracking were identified as mechanisms of abrasion; the extents of these processes were found to be governed by the state of aging that determined the mechanical properties.

Three body type abrasive wear characteristics of multi-component white cast irons

Abrasive wear can occur on tooth and suspension parts such as construction machinery power shovels and bulldozers. In order to reach high safety and low cost, it is important to develop wear resistant material and estimate of life service during abrasion.The amount of alloy element dissolved in the matrix is changed by the type of carbide and microstructure due to the addition content of alloy. However, it is important to consider the relationship the actual wear situation with environment reproducible testing machine.In the present study, nickel (Ni) which will encourage the carbides formation by suppressed the solid solution of the carbide-forming elements into the matrix was added into the traditional Fe-2C-5Cr-5Mo-5W-5 Nb-5Co system multi-component white cast iron. The effect of Ni on the three type of abrasive wear characteristics of this new material was investigated. A rubber wheel type abrasion tester was used for the abrasion tester. Test piece was pressed against the circumferential portion of the rubber wheel rotating at 100 ± 1 rpm with a load of 196 N. Silica sand of 170–220 µm was supplied at a rate of about 4.2 g/s from the popper between them, an abrasion test was conducted for 5 min.As a results, in both 0Co and 5Co type specimens, the specimens added with 3% Ni showed good three body type abrasive wear characteristics. In particular, the hardness of 3Ni-5Co showed a high value of 790 HV, showing the most excellent three type abrasive wear characteristics. With or without addition of Co, there was no difference in wear loss for 0Ni and 5Ni specimens. This is because there was no significant difference in hardness between 620 and 690 HV. Thereby, it can be concluded, the wear loss tended to decrease with increasing hardness of specimens.

Two body abrasive wear characteristics of Al7068/Si3N4/BN hybrid composite

The present study emphasises the mechanical and tribological characteristics of stir cast Al7068/Si3N4/BN hybrid metal matrix composite. The composites were prepared at various weight percentages of Si3N4 and BN and their mechanical properties were evaluated. The composite with maximum tensile strength of 238.7 MPa was obtained for 10% Si3N4 and 5%BN. The abrasive wear test was conducted to evaluate wear rate of composites using pin-on-disc apparatus by varying abrasive grit size, load, sliding velocity and sliding distance. The Taguchi L27 orthogonal array was used to design the experiments and analyse the effect of process parameters. The ANOVA test revealed that the wear rate is highly influenced by mass fraction of Si3N4 and grit size of abrasives. The worn out surface of wear test specimen was analysed using SEM to understand the mechanism of wear.

Performance Study on Modified UHMWPE Composites Water Lubricated Bearing Material

Ultrahigh Molecular Weight polyethylene (UHMWPE) is modified by adding Polyimide (PI) and the performance of composite marerial is studied. The density as well as the Shore hardess of the modified UHMWPE composite increases with the percentage of PI. The average water absorption rate is less than 0.03%. the composites reaches steady-state creep after 287h’s compression. Electrical insulation capacity of the composite material with 1% PI is about equivalent to that of Thordon material and then the composite material with 5% PI composite materials and the performance of Tenmat material is poor. An experiment in artificial seawater is conduct as the test contact mode is the pin/disc contact, in which the pin sample is modified UHMWPE composite material, the results show that the friction coefficient of the modified UHMWPE composite is the smallest, the wear height of the UHMWPE/PI polymer is smaller than that of the other seven groups, and the PI content of composite is 1% and the wear height is the smallest, wear weight of tin bronze sn10-2 in pair of UHMWPE/PI polymer composites and Thordon and Tenma is in the same stage. As the PI weight percent increases, the depth and width of furrow cutting increase, and there are obvious characteristics of large PI particles shedding, and there are holes on the worn surface. There are obivous cracks on the worn surface of the Thordon material, and the characteristics of abrasive wear is shown in Tenmat material.

Abrasive Wear Characteristics of Multi-Component White Cast Iron and Effect of C Content

Abrasive Wear Characteristics of Multi-Component White Cast Iron and Effect of C Content

Effect of Nanofillers on Abrasion Resistance of Carbon Fiber Reinforced Phenolic Friction Composites

The present study focuses on the development of polymeric friction composites with short carbon fiber, micron and nano-sized fillers, additives with varying weight% in phenol formaldehyde (PF) matrix using hot compression moulding process. The composites prepared with fillers viz. Molybdenum disulfide or Molykote (MK) and multi walled carbon nanotubes (MWCNTs) in carbon fiber reinforced PF matrix is designated as Set-I composites. Inclusion of graphite and nano-clay in carbon fiber reinforced PF matrix is designated as Set-II composites. The prepared composites are tested in Dry sand rubber wheel abrasion wear test rig, following ASTM standards for evaluating the abrasive wear behaviour. From the routine experiments, it was observed that the presence of combined micro and nanofillers i.e. 11.5 wt% MK + 0.5 wt% MWCNTs of Set-I, has shown superior abrasion resistance among the study group. The test results of the Set-I and Set-II composites are analyzed using Taguchi experimental design followed by analysis of variance (ANOVA) to understand the contributions of wear control factors affecting the abrasive wear characteristics. Further, worn surface of selected samples is analyzed using scanning electron micrographs.