Dry Abrasive Wear Research Articles

Deposition of Amorphous Hardening Coatings by Electrospark Treatment in a Mixture of Crystalline Granules

This article is devoted to the formation of amorphous coatings on the steel 35 surface by electrospark treatment in a mixture of crystalline granules. It is revealed by the energy dispersive X-ray spectroscopy (EDS) that formed coatings contain W, Mo, Co, and Ni in various ratios. The weight of granules of various compositions decreases by 11–16 wt % for 6-h treatment due to electric erosion. The mass transfer coefficient varies in a range from 33 to 54%. X-ray structural analysis showed the prevalence of an amorphous phase (81–99%) in the structure of deposited layers. Annealing of coatings at a temperature above 1150°C leads to the crystallization of the amorphous phase into boron carbide of the M23(C, B)6 type, as well as into α-Fe. The coatings have an increased hardness of 10–15 GPa, while their wear resistance in the dry sliding wear mode under loads of 10 and 50 N is higher than for steel 35 by a factor of 3.3 and 1.6. The coating friction coefficient is lower than for steel 35 by 13–30% and was 0.27–0.31. The wear resistance of coatings in a dry abrasive wear mode is higher by a factor of 3–5 when compared with uncoated steel 35. The best characteristics are inherent without nickel and worst are inherent without cobalt. Thus, it is established that tungsten and cobalt increase the wear resistance of iron-based amorphous alloys, while nickel and molybdenum tend to worsen their tribotechnical behavior.

Physicomechanical and Taguchi optimized abrasive wear behaviour of KOH/KMnO4/NaHCO3 treated Himalayan Agave fiber reinforced polyester composite

This manuscript investigates the effect of various chemical treatments (potassium hydroxide, potassium permanganate and eco-friendly sodium bicarbonate) of Himalayan agave fibers (HAF) of size 7 mm on its physical, mechanical (tensile, flexural, impact, hardness and water absorption) and abrasive wear performance of HAF/polyester composites. The fibers were chemically treated at different concentration of 5, 10 and 15% of these chemicals for 24 h and reinforced at 10 wt% of fiber loading into polyester resin. Sodium bicarbonate fiber treated composite showed maximum tensile strength (145 MPa), flexural strength (214.5 MPa), impact strength (3.65 J cm−2), and hardness (30.33 Hv) with least water absorption as compared to other chemically treated HAF reinforced polyester composites. The optimum concentration of KOH and KMnO4 treatment were arrived at 10 and 15% concentration respectively with both exhibiting comparable results. The dry abrasive specific wear rate of composites was studied at three different factors i.e. chemical concentration (5–15 wt%), normal load (10–30 N), and speed (50–150 RPM) using Taguchi technique L9 orthogonal array. The sodium bicarbonate composite treated HAF based composites exhibited least specific abrasive wear rate. The scanning electron microscope (SEM) analysis of worn surfaces revealed the fiber breakage, debonding, debris, crack surface and micro-ploughing as the prominent wear mechanism.

Abrasive wear behavior of austempered ductile iron with niobium additions

Carbidic Austempered Ductile Iron (CADI) microstructures containing eutectic carbides can be produced by the addition of carbide stabilizing elements, such as chromium. Carbides formed from the addition of Cr are eutectic of M3C type. The presence of such hard phases can enhance the abrasion wear resistance of ductile iron. A new CADI can be produced by the addition of Nb. Niobium carbide particles are formed in the beginning of solidification and remain stable once they are insoluble in solid iron matrix. The dry sand abrasive wear resistance of ductile irons alloyed with 1.0, 1.8, and 2.4 wt% Nb were tested in both “as-cast” and “heat treated” conditions using standard ASTM G65. Results were compared to abrasive wear data obtained on ductile iron alloyed with 1 wt% Cr, CADI (1 wt% Cr), and the basic composition of iron without carbide stabilizing elements. In the “as-cast” condition, the addition of Nb did not lead to a reduction in wear, while CADI with Nb is a promising substitute for CADI with Cr addition, because both materials showed very similar values of abrasion resistance. Micro-ploughing and micro-cutting mechanisms were observed on the worn surfaces of ductile irons. Abrasive wear resistance of these alloys was correlated with the volume fraction of carbides.

Dry sliding and abrasive wear behaviour of Al-7075 reinforced with alumina and boron nitride particulates

Abstract Present research examination focuses on the surface morphology; mechanical properties and wear conduct of Al-7075 metal matrix composites reinforced with alumina and hexagonal boron nitride fillers. Particulate reinforced Al-7075 metal matrix composites were manufactured following the two step stir casting method with differing the weight percentage (2.5 and 5) of reinforcement. Uniform dispersion of alumina and hexagonal boron nitride in pure alloy was verified by optical microstructure. The fabricated samples were subjected to abrasion using dry sand rubber wheel abrasive wear test rig by varying the abrading distance and the applied normal load. Silica sand of particle size 350–400 µm was used as abrasive medium. Mechanical and dry sliding wear test results indicated that both alumina and hexagonal boron nitride fillers show improved mechanical properties and wear resistance. From the abrasive wear test results, it was recognized that the wear resistance of composites is increased by increasing the weight percentage of reinforcements and the reinforced composite gave better resistance against abrasion than the control sample (Al-7075). Further, it was adjudicated that 5 wt% micro hexagonal boron nitride reinforced Al-7075 composite prompts predominant abrasion resistance. Finally, it was presumed that hexagonal boron nitride and alumina fillers gracefully and successfully improved morphological, mechanical, and also the wear properties of Al-7075 alloy for various engineered load-bearing applications.

Deposition of amorphous hardening coatings by electrospark treatment in a crystalline granule mixture

The article focuses on the preparation of amorphous coatings on the Steel 1035 surface by electric spark treat the coating composition control by changing the granule mixture composition was studied. EDS analysis showed that the coatings obtained contain W, Mo, Co and Ni in different ratios. The weight of granules having different compositions decreased by 11–16 wt.% in 6 hours of treatment as a result of electric erosion. The mass transfer coefficient varied from 33 to 54 %. X-ray diffraction analysis showed the predominance of the amorphous phase in the composition of layers deposited. Annealing of the coatings at 1150 °C led to amorphous phase crystallization into M23(C,B)6 type borocarbide and α-Fe. The coatings had an increased microhardness of 10–15 GPa, and their wear resistance under dry sliding wear conditions at 10 and 50 N loads was 3,3 and 1,6 times higher, respectively, than in Steel 1035. The highest values at both loads were shown by samples without nickel, while samples without tungsten featured the lowest values. The coatings had a friction coefficient within 0,27–0,31 that is lower than for Steel 1035 by 13–30 %. Wear resistance of the coatings under dry abrasive wear conditions at the 25 N load was 3 to 5 times higher as compared to uncoated Steel 1035. Samples without nickel demonstrated the best performance, while samples without cobalt had the worst indicators. Thus, it was shown that tungsten and cobalt increase wear resistance of iron-based amorphous alloys, while nickel and molybdenum tend to worsen their tribotechnical behavior.

Tribological investigation of MgO/Al2O3 ceramic composite with the inclusion of nano CuO in dry abrasive wear test

This paper aims to investigate the tribological influence of nano sized (∼50 nm) copper oxide (CuO) into the magnesium (MgO) based alumina (Al2O3) ceramic composite in a hard-abrasive sliding condition. Sliding wear test was performed to find the frictional and wear behavior of the specimens against abrasive silicon carbide (SiC) interface by means of a rotary pin-on-disk tribometer. Nano CuO added specimen significantly diminished both friction coefficient and wear rate by ∼42.94% and ∼38.30%, respectively as compared to base MgO/Al2O3 specimen. Mending effect of nano CuO by providing a smooth layer was expected to be the main lubricating mechanism against rough abrasive wear surface. Delamination and two body abrasion were the predominant wear mechanism which was investigated using field emission scanning electron microscopy (FESEM) coupled with energy dispersive x-ray spectroscopy (EDS). Different phases of the compounds were identified by x-ray diffraction (XRD) analysis.

Characterization and corrosion resistance of boride layers on carbon steel

Boriding treatment was carried out at 850, 900, 950, 1000 and 1050 °C for 2, 4 and 8 h on carbon steel. The effect of some treatment parameters such as the chemical composition of the mixture, boriding temperature and time were investigated. X-ray diffraction (XRD), scanning electron microscopy (SEM) and microhardness tests were used to describe the formed boride layers. Some properties of boride layers have been studied such as corrosion and wear resistance. The obtained results confirm that the corrosion resistance of boride carbon steel was improved compared to no-boriding steel. The dry abrasive wear resistance of boride alloy samples is about 5 times greater than that of non-boride ones.

The response of two-wheeler tires to three-body wear phenomena by experimental simulation of off-road terrains

The operation of two wheelers frequently encounters off-road terrain comprising loose particles of sand and soil, which setup three-body abrasive wear phenomena affecting the tire life. To evaluate the response of two-wheeler tires on such terrains, the dry abrasive wear behavior of two-wheeler tires was experimentally determined using a three-body wear test apparatus. Three different mixtures of sand and granite dust of varying grit size, 100, 200, and 300 µm, were employed to represent the abrasive cluster, typical of the varying roughness on off-road terrains. Taguchi’s L27 (33) orthogonal array was applied to analyze the specific wear rate as a response to three parameters—load, speed, and road roughness—separately for front and rear two-wheeler tires. Variation of hardness and wear pattern observation for the front and rear tires were carried out to oversee the surface deterioration. A numerical model based on abrasive grit-tire surface interaction was developed for comparison with the experimental results.

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.

Al–7Si–5Cu/Al2O3–ZrO2 Laminated Composites with Excellent and Anisotropic Wear Resistance

The authors prepare nacre‐mimetic Al−7Si−5Cu/Al2O3−ZrO2 composites with alternately arranged soft‐hard phases and different ceramic compositions using freeze casting and gas‐pressure infiltration techniques and investigate their dry abrasive wear resistance. These composites exhibit excellent and anisotropic wear resistance when worn along different directions. The wear rates of the composite with Al2O3:ZrO2 = 1:9 against 400‐grit, 240‐grit, and 100‐grit SiC sandpapers are approx. 1/78, 1/37, and 1/27 of those of the Al−7Si−5Cu alloy. The underlying mechanisms for the excellent wear resistance of these nacre‐mimetic composites are ascribed to the “self‐sharpen” effect in the early running‐in period and the formation of friction films in the later wear period. Moreover, the anisotropic wear resistance is interpreted by the different stress states that the interface is subjected to.

COMPARISON OF EFFECTIVENESS OF CARBON NANO- AND MICROFIBERS FOR FORMATION OF PHYSICAL-MECHANICAL AND TRIBOLOTECHNICAL PARAMETERS OF POLYMER COMPOSITES BASED ON HIGH MOLECULAR WEIGHT MATRIX

The mechanical and tribo-technical parameters of composite materials of mixtures on the bases of super- molecular polyethylene (SMPE) at conditions of dry friction and abrasive wear were studied for comparative estimation of solid- grease properties of nano and micro fibers of carbon. It was shown that wear resistance of polymer compositions of SMPE+0.5 weight% the percent of C(nano) increases by a factor 6.6 and for SMPE+5 weight% the percent of C(micro) increases by a factor 2.5 at conditions of dry friction of slip. At conditions of abrasive wear the resistance of composites mentioned above increases by a factor about 2 for both types of fillers. The role of nano and micro fibers of carbon is discussed as solid grease in tribo- conjugated polymer compositions based on SMPE for application at various conditions of operation.

Evaluation of Mechanical and Tribological Properties of Glass/Carbon Fiber Reinforced Polymer Hybrid Composite

Polymer matrix composites used in different industrial applications due to their enhanced mechanical properties and lightweight. However, these materials are subjected to friction and wear situations in some industrial and automobile applications. Therefore, there is a need to investigate the wear properties of polymer matrix composite materials. This article emphasizes the dry abrasive wear behavior of a hybrid glass/carbon ([GCGGC]S) composite. The mechanical and wear properties of the composite was evaluated and compared with maiden glass and carbon fiber reinforced polymer composite. Design of experiment of Box-Behnken type was adopted to perform the experiments. Response surface methodology (RSM) was employed to optimize the experimental parameters to minimize the specific wear rate of the composites. A second order mathematical model was developed. The model has predicted the optimum input parameters for minimum specific wear rate of 18.847×10-3 mm3/Nm for the hybrid ([GCGGC]S) composite. Furthermore, the model predicted specific wear rate value was validated with experimental one and found a close agreement between them.

Quaternary Zn-Ni-MoO2-NbO2 intermetallic composite deposits on mild steel via electrodeposition route

In majority of industrial applications zinc electrodeposition has been widely used for the corrosion resistant coating on steel due to its unique properties, low cost and sacrificial nature. Steel remains the most widely used material in most applications due to its excellent properties but its faults cannot be over emphasis in term of deterioration. A thin film of Zn on steel substrates was prepared by electrodeposition technique using incorporated rare earth metallic composites to form an optimised bath plating solution. Quaternary Zn-Ni-MoO2-NbO2 alloy coatings, as a potential replacement for Zn-Ni coatings were deposited from an acid sulphate solution. The mechanical wear and corrosion behaviours of Zn-Ni-MoO2-NbO2 Coated Mild Steel in 3.65% NaCl are described; these were studied by means of MTR-300 dry abrasive wear and polarization measurements respectively. The crystal particles present were observed by X-ray diffraction pattern (XRD) and energy dispersive X-ray diffraction spectrometer (EDS). The microhardness of deposited plate were investigated by means of Vickers microhardness. Scanning electron microscope and was used to study the surface morphology, and synergistic influence content in bath on surface morphology revealed that morphological changes observed in presence of additives exhibits synergistic influence on improving corrosion resistance and hardness of the deposit.

Effect of wear parameters on dry abrasive wear of RZ5-TiC in situ composite

PurposeThe purpose of this study is to increase the wear resistance of Mg alloy by adding hard ceramic particles to it. The inclusion of hard ceramic particles further strengthen the Mg alloy, resulting in higher wear resistance. Mg alloys containing Zn, rare earth and Zr exhibit high specific strength and excellent creep resistance, making them suitable for aerospace components such as aircraft gearboxes and generator housings.Design/methodology/approachIn the present study, composites have been produced in situ by using RZ5 mg alloy as matrix and TiC as reinforcement by self-propagating high-temperature synthesis technique. The abrasive wear behavior of RZ5 Mg alloy matrix reinforced with TiC particulates has also been examined. The pin-on-disc apparatus has been used for the tests. The abrasive paper is used as a counter body, and the results are obtained by changing sliding distance and applied load.FindingsA notable enhancement in the wear resistance and mechanical properties of tested composite has been observed as compared to the RZ5 Mg alloy as a matrix. There is a uniform increment in the change in weight loss of RZ5-TiC composite with increasing sliding distance and applied load, but it decreases with increasing TiC content. The coefficient of friction (µ) also decreases uniformly with an increase in the reinforcement of TiC, but it decreases with an increase in applied load and sliding distance. The investigation of the worn composite, which determines dominant wear mechanisms as abrasion and plowing grooves on tested samples, has been done using field emission scanning electron microscopy.Originality/valueThe current manuscript provides a detailed abrasive wear analysis of RZ5-TiC composite by using different wear parameters. Specifically, extensive experimental data have been provided for RZ5-TiC composite. The effects of parameters such as applied load, sliding distance and Wt.% of TiC on the weight loss and coefficient of friction of the composites have been analyzed and discussed thoroughly.

Potentials of niobium carbide (NbC) as cutting tools and for wear protection

Apart by vacancies, the different pseudo-cubic phases NbC, Nb4C3 and Nb6C5, can accommodate any stoichiometry of NbCx (0.75 ≤ x ≤ 1.0) in the binary phase diagram and enable a large process window. Properties, like micro-hardness, hot hardness, sliding wear resistance, elastic modulus and toughness can be tailored by the C/Nb ratio, the addition of secondary carbides and the type of binder. SPS sintered and cobalt bonded (NbC0.88-12Co SPS). NbC and Nb2O5 have so far no REACH classifications related to human toxicology and are not listed as substances of very high concern contrary to Co3O4. The NiMo-bonded stoichiometric NbC1.0 grades enable the substitution of cobalt by nickel, SPS by conventional sintering and NbC0.88 by NbC1.0 in view of functional properties. Nickel bonded NbC grades have improved toughness versus cobalt bonded NbC grades, but loosed in hardness. NiMo and NiMo2C bonded NbC1.0 grades in combination with secondary carbides compensated the loss in hardness while keeping the toughness. The tool lifes of uncoated NbC1.0-12Ni4Mo4VC and NbC0.88-12Co under dry turning of 42CrMo4 and C45E were between +30% to +200% higher and up compared to WC-6Co (extra fine grain). Niobium is today largely available as resource. NbC grades displayed lower dry sliding friction over WC grades. The softer Ni- and NiMo-bonded NbC1.0-grades have a higher dry abrasive wear resistance (ASTM G65), even with lower toughnesses, as the tougher WC-Co grades.

Effect of heat treatment on dry sand abrasive wear behavior of Al7075-Albite particulate composites

Al7075 alloy reinforced with Albite particulate composite were developed by stir casting method with different weight percentages of Albite particulates from 0wt% to 10wt% in steps of 2wt%. The As-cast matrix alloy and Al7075-Albite particulate composites were heat treated at solutioning temperature of 470° C for 2 hours then quenched in ice and artificial ageing was done for 6 hours at 120° C. The microstructure analysis indicates uniform distribution of Albite particulates in Al7075 matrix alloy. Density tests were conducted for both on Al7075 matrix alloy and Al7075-Albite particulate composites. Sand abrasive wear and hardness test were performed as per ASTM E8-82 and ASTM G65-81 standards at room temperature. The results revealed that the increase wear resistance, hardness and decrease in the density of the Al7075-Albite particulate composite compared to the Al7075 matrix alloy.

Determination of Abrasive Wear Behaviour of Al-Fly ash Metal Matrix Composites Produced by Squeeze Casting

Squeeze casting is one of the processes in liquid metallurgy in which a molten metal is poured into a metallic die and is solidified under the action of a relatively high external pressure. The primary objective of this paper is to study the influence of the process parameters on wear resistance and hardness of squeeze cast LM6 Al-flyash composite. In this investigation Aluminium metal matrix composites, reinforced with flyash (from 5% to 12.5%wt.) was synthesized using stir-squeeze casting route. The influence of parameters like reinforcement content and squeeze pressure on the hardness and wear rate has been studied. The experimental results of the hardness and wear rate of the composites are compared with base alloy produced by squeeze casting. The results have shown that the wear resistance of the composites is very much superior to that of the base alloy produced by squeeze casting method. The abrasion tests were carried out by using a dry sand-rubber wheel abrasion wear testing machine. The test was carried-out at three different speeds (250, 300 & 350 rpm) and loads (2kg, 3kg & 4kg). The hardness test was conducted using Brinnel’s hardness tester. The macrostructural and microstructural studies of the MMCs were made using the TESCAN – VEGA3 scanning electron microscope in order to investigate the distribution of flyash particles in the matrix and on observation it was found that there is a reasonable uniform distribution of flyash in the matrix without any voids and discontinuities.

Three-body abrasion wear performance of glass/carbon fiber reinforced polymer hybrid composites

This study focused on the effect of the arrangement of glass/carbon fiber inter-ply sequence on abrasion wear performance of hybrid composites. Three types of composites were fabricated such as carbon fiber reinforced polymer composite [C]10, glass fiber reinforced polymer composite [G]10 and hybrid composite [G2C2G]S. The dry abrasive wear performance of these composites were carried out by using different input parameters such as hardness of the composites(H), sliding distance(D), applied load(L). Fifteen numbers of experimental runs were performed according to the Box-Behnken design of experiment. To achieve the minimum specific wear rate, Response Surface Methodology (RSM) has been adopted to model and optimize the operating parameters. The model predicted optimum conditions for lowest specific wear rate are the hybrid composite [G2C2G]S, sliding distance (1184m) and applied load (33N). Moreover, the model estimated results were compared with the experimental one and found a close agreement between them.

Heat treated twin wire arc spray AISI 420 coatings under dry and wet abrasive wear

The influence of applying two different heat treatments such as: deep cryogenic and tempering on dry/wet abrasive wear resistance of twin wire arc spray martensitic AISI 420 coatings was evaluated by using a modified rubber wheel type test apparatus. A load dependency was observed on the abrasive wear rate behavior of both; dry and wet tests. Three body (rolling) and two body (sliding) wear mechanisms were identified in dry conditions, prevailing rolling at lower and higher loads. However, at higher loads, more presence of grooving and pits formation was observed. Coatings tempered at 205 °C/1 h displayed better wear resistance than cryogenic treated ones. A change in wear mechanism between dry and wet conditions was observed; two body wear mechanism predominated respect to three body. In both; dry and wet conditions the microstructure (several inter-splat oxides) as well as strain and residual stress promotes brittle material removal which was more evident in cryogenic and as-sprayed samples during dry test and at higher loads in wet conditions.

Preparation of Ni-P-diamond coatings with dry friction characteristics and abrasive wear resistance

The Ni-P-diamond composite coatings that contained diamond particles with various sizes in microns have been prepared by electroless plating. The effects of diamond particle size and heat-treatment on the microstructure, mechanical properties, dry friction behavior and abrasive wear performance of the Ni-P diamond composite coatings were investigated. It was discovered that a Ni-P diamond composite coating with the thickness of 30μm could be obtained. The diamond particles (2–9μm) could be homogeneously dispersed in the coatings with the volume fractions of 21%–25%. Subsequently to 400°C for 2h of heat treatment, the hardness of the Ni-P diamond coatings increased to approximately 1200HV. The friction coefficients of the Ni-P diamond composite coatings were stable in the range of 0.4–0.52, whereas the Ni-P coating coefficient increased with time and finally reached to beyond 0.50. The addition of diamond particles could improve the wear resistance significantly, whereas as the diamond particle sizes increased, the friction wear resistance and the abrasive wear resistance increased.