Dry Sliding Wear Behavior Research Articles

Dry sliding wear behaviour of AA6082/BN/Mos2 hybrid metal matrix composites synthesized using stir casting process

This study examines the wear behaviour of AA6082/x Boron Nitride (BN) (x = 1, 2, 3 wt.%)/1 wt.% of Molybdenum Disulphide (MoS2), a novel hybrid metal matrix composite (MMC), under dry sliding conditions. The composite was fabricated through liquid-state processing, i.e., stir casting. A pin-on-disk tribometer was used to estimate the coefficient of friction (COF) and wear rate by varying tribological process parameters under dry sliding conditions. The results show that at the maximum load of 40 N, the wear rate of the unreinforced alloy is observed 4.077 × 10−2 mm3/m, while at the AA6082/3 wt. of %, BN/1 wt. % of the MoS2 composite's wear rate is reduced to 2.162 × 10−2 mm3/m. Further, the wear rate increases as the sliding distance increases from 500 m to 2000 m. Moreover, the friction coefficient of the unreinforced alloy is observed 0.37, whereas the AA6082/3 wt.% of BN/1 wt.% of MoS2 composites is observed 0.31 under reduced loads. It might be due to the presence of hard ceramic BN and MoS2 reinforcements enhancing the developed composite's resistance to wear by forming a mechanically mixed layer (Fe2O3) on the sliding contact surface. Moreover, the novel hybrid composite materials exhibit a lower coefficient of friction at higher sliding velocities, sliding distances, and applied loads. However, minimal fine grooves with limited abrasion are observed on the worn surface, which was examined through a scanning electron microscope.

Influence of nanodiamond on compressive and dry-sliding wear behaviors of Al2O3–Al interpenetrating-phase composites

In this research, the effects of nanodiamond (ND) addition at different loadings on the compressive and wear properties of the interpenetrating phases hybrid aluminum/alumina (Al/Al2O3) composite were investigated. The samples were fabricated in a two-step process. First, the Al2O3-ND preforms were fabricated via the replica method. Second, the squeeze casting route was employed to infiltrate the molten pure Al. The ceramic preforms were made by immersing a polyurethane foam with 17 ppi pores in a slurry containing α-Al2O3 powder (1 μm), ND particles (0–10 vol%), and natural egg white. After sintering at 1500 °C for 4 h, the preheated preforms were infiltrated with molten Al. The microstructural evaluations of the preforms and composites revealed a proper distribution of the ND particles in the preform, as well as the formation of the ND agglomerates at higher volume percentages. Also, the hardness of the samples enhanced with an increase in the ND loading, reaching a maximum of 263.8 Vickers for the 10 vol% ND-loaded composite. The compressive strength of the samples enhanced up to 3 vol% ND addition and then decreased due to the agglomeration. The wear test results indicated that the best behavior was related to the 3 vol% ND-loaded composite. Embedding the 3 vol% ND decreased the weight rate and friction coefficient of the interpenetrating phases hybrid Al/Al2O3 composite by 16 % (from 8.2396×10−3 to 6.9269×10−3 mm3/m) and 12 % (0.8165 to 0.7238), respectively. The study of the worn surfaces of the samples after wear testing revealed that the dominant wear mechanisms were abrasive and adhesive for the higher and lower volume fractions of the ND, respectively.

Influence of cryogenic treatment and tempering temperature on microstructural evolution and dry sliding wear behavior of AISI D3 cold-work tool steel

Abstract AISI D3 cold work steel was shallow and deep cryogenically treated and double tempered at 150, 250, and 350 °C temperatures. Cryogenic processes transformed the retained austenite into martensite, while double tempering produced Fe, Cr, and W-rich carbides. The wear losses of cryogenically treated specimens decreased by up to 60% compared to conventionally heat-treated samples. Worn surfaces mainly experienced abrasive and adhesive wear mechanisms. Due to the formation of homogeneously dispersed fine carbides at 250 °C, oxidative wear occurred at the matrix phase, resulting in the lowest wear rate. The samples tempered at 150 °C suffered from the severe abrasive action of hard carbide particles, while the samples treated at 350 °C failed because of carbide coarsening.

Wear studies on friction stir processed surface modified AZ61 magnesium alloy with nano titanium oxide

ABSTRACT Surface modification of magnesium alloy enables the improvement of wear characteristics for use in sliding applications and places where surface hardness improvement is essential without affecting the microstructure of the underneath material. In this study, a pin-on disc wear test was used to examine the dry sliding wear behaviour of AZ61 Mg alloy reinforced with nTiO2 by a recursive friction stir processing technique. The trio-behavior of the surface-modified Mg alloy was detailed by the response surface methodology-central composite design matrix with the use of design experiments, considering three levels of reinforcement (%), sliding speed, and axial load parameters. In order to achieve the desired results of minimal wear loss, lower friction coefficient (COF), and lower friction force between surfaces (FF), this present work employed design expert software to develop a generative mathematical model to optimize the process parameters. Wear mechanisms were investigated using images captured by scanning electron microscope.

Effect of microwave hybrid heating on high temperature dry sliding wear behavior of Al2O3 reinforced WC–Co HVOF coating

Effect of microwave hybrid heating on high temperature dry sliding wear behavior of Al2O3 reinforced WC–Co HVOF coating

Effect of Laser Surface Texturing Process on Dry Sliding Wear Behavior of NiTi Shape Memory Alloy Used in Airplane

In this study, the effect of laser surface texturing (LST) applied to NiTi Shape Memory Alloy (SMA) on the dry sliding wear behavior of the material was investigated. After polishing and cleaning the material surface, a pitted surface texturing process was performed using a femtosecond laser under atmospheric conditions. After the surface texturing process, dry sliding wear tests were performed at room temperature. When the wear behavior of the laser-applied and non-laser-applied test samples was evaluated comparatively, it was determined that the coefficient of friction (COF) of the laser-applied samples under 1N load was approximately 17% lower. It was determined that the decrease in the COF value decreased with increasing load. However, the wear amount of the LSD-applied NiTi SMA was higher than the untreated sample. It was evaluated that this situation was due to thermal softening that occurred depending on the ablation geometry and dimensions.

Dry Sliding Wear Behavior of Cemented Carbide at Elevated Temperatures

The material for a cutting tool needs to be carefully selected to withstand high temperatures during cutting and have good wear performance. The use of cutting tools made from cemented carbide material was studied due to its potential in terms of mechanical properties that are ideal at high temperatures up to 1000 °C and being cheaper than other materials. This investigation of the dry wear of this cutting material focused on temperatures of 25 °C, 200 °C, and 300 °C, with loads of 50 N, 100 N, and 150 N. The weight loss, friction coefficient, and change of the pin microstructure were determined. It was found that the higher the temperature and load applied to the cemented carbide pin, the more the microstructure changed, and the percentage of weight loss increased up to 0.55%. The wear rate on the cemented carbide pins was higher when applied to a stainless steel disc compared to a mild steel disc. The simulation revealed that the von Mises stress on the stainless steel disc was 51.759 Pa, while that on the mild-steel disc was 60.379 Pa. This indicates that both materials did not fail because the von Mises stress was lower than the disc yield stress.

A comprehensive study on dry sliding wear and in-vitro degradation of AZ31 composite with 6 wt% Sn and 1.5 wt% TiO2 fabricated by stir casting

Abstract This experimental study investigates the dry sliding wear behaviour of novel AZ31 composite with 6 wt% Sn and 1.5 wt% TiO2 samples, focusing on the influence of sliding distance and normal load. Additionally, the research examines degradation rates during a 120-hour immersion period in simulated body fluid (SBF). The wear volume loss increased significantly with higher loads and longer sliding distances, showing a 142% rise from 1000 m to 2000 m and 76% from 2000 m to 3000 m under a 5 N load, peaking at a 25 N load over 5000 m. The specific wear rate dropped by 39% from 5 N to 15 N but increased with distance due to thermal softening, while the coefficient of friction decreased from 0.284 at 1000 m to 0.213 at 5000 m under 5 N. FESEM analysis revealed a transition from abrasive to delamination wear, with a protective oxide layer forming during sliding. Sn in the composite formed hard Mg2Sn intermetallic compounds, affecting crack formation and propagation under higher loads. Wear debris analysis showed both abrasive and delamination wear mechanisms, highlighting the protective role of the oxide layer. The degradation rate increased rapidly during the initial immersion stage in simulated body fluid (SBF), reaching 15.9 mm year−1 after 24 h, and then stabilizing after 48 h. Hydrogen evolution rose sharply from 0.28 ml cm−12 at 2 h to 7.6 ml cm−12 within 24 h, with a 92% increase by 48 h and an additional 38% increase from 48 to 72 h. Post-immersion FESEM analysis showed corroded surfaces with protective layers, cracks, and pitting corrosion. Magnesium hydroxide (Mg(OH)2) and hydroxyapatite played crucial roles in inhibiting corrosion. This analysis provides insights into the wear, and degradation dynamics of the AZ31-6Sn/1.5TiO2 composite, with implications for engineering applications and the development of biodegradable implants in biomedical fields.

Optimization and Analysis of Dry Sliding Wear Behavior of AlCrTiSiN Coated SKD61 Steel Using Response Surface Methodology

The aim of this research is to investigate the wear behavior of SKD61 steel coated with AlCrTiSiN using the Filtered cathodic arc plasma deposition coating method while adhering to VDI 3198 standards for coating adhesion assessment. Dry sliding wear tests, conducted according to ASTM G133-05. The experiment is designed using response surface methodology (RSM) to determine the response parameter as the wear rate, with independent parameters of interest including load, sliding velocity, and sliding distance ranging from 5 to 11N, 0.1 to 0.2 m/s, and 250 to 550 m, respectively. Additionally, wear characteristics are analyzed using SEM-EDS analysis. The wear test results demonstrate that load had the most significant impact on the wear rate, followed by distance and speed, respectively. The target of achieving minimal wear rate was attained with a load of 5 N, a sliding velocity of 0.11 m/s, and a sliding distance of 550 m. Model significance testing revealed that the determination coefficient (R2) and adjusted determination coefficient values, indicating the accuracy of the model, were equal to 93.96% and 88.53%, respectively.

Dry sliding wear behavior of the high-strength nanostructured bainitic steel containing 3.5 wt% aluminum

The acceptable wear behavior of nanostructured bainitic steels has enhanced their potential to be industrialized, and their applications in the automotive industry. This study focused on the wear behavior of the high-strength nanostructured bainitic steel containing 3.5 wt% aluminum (low-cost and low-density) to assess the dominant sliding wear mechanism and the correlation between the microstructure and applied load on the sliding wear resistance. A pin-on-disk tribometer was used to evaluate dry sliding wear behavior, and the SWR was computed by weighing the specimens. To identify the wear mechanism, the worn surfaces and cross-sections were analyzed using XRD, FESEM, and EDS. The results showed that the retained austenite volume fraction and carbon content of austenite (the stabilizer of the retained austenite) of high-strength nanostructured bainitic steels are not the only determinants of wear behavior. Indeed, the thickness of bainitic ferrite plates (strength source) is the major parameter affecting wear resistance. An increase in the Vαb/tαb ratio due to a decreased austempering temperature reduced the SWR and enhanced wear resistance. Moreover, the change from a normal load of 50 N to a load of 150 N changed the dominant wear mechanism from oxidative to adhesive. Also, increasing the isothermal transformation temperature and applied load by increasing the thickness of the tribological-transition-zone (TTZ) causes a decrease in sliding wear resistance. In summary, the formation of a thin TTZ due to the increase in the Vαb/tαb ratio is the main reason for the improvement of the wear resistance of the austempered sample at the lowest temperature (250 °C).

Investigation of the Microstructure and Dry-Sliding Wear Behavior of Co Containing Al-Si-Fe Scrap Alloy

This study investigates the influence of cobalt (Co) addition on the microstructural and wear properties of an aluminum (Al) scrap alloy containing high iron (Fe) impurity content (3%). Microstructural analysis using scanning electron microscopy and optical microscopy confirmed the presence of Co in Fe-rich intermetallics. Upon increasing the Co concentration, β-Al5FeSi phase was seen to be refined without significant morphological modifications. Furthermore, Co addition promoted the formation of a new quaternary phase Al32Si7Fe4Co phase, which was finely distributed throughout the microstructure and acts as a tribo-layer in the Al scrap alloy, offering enhanced wear resistance and improved stability against wear. Standard EN-31 steel disk with compositions chromium (Cr)-1.6%, manganese (Mn)-0.75%, silicon (Si)-0.35%, and carbon (C)-0.9% was used for the wear test. Microhardness and wear properties were evaluated for both the as-cast and heat-treated alloys, with the as-cast samples exhibiting superior wear resistance and a lower coefficient of friction compared to the T6 heat-treated samples. Addition of Co showed refinement in the β-Fe rich intermetallics over the morphological modifications. Similarly, Co addition enhanced the hardness and wear resistance in the as cast alloys. This work provides a detailed analysis contributing significant understandings into the wear mechanisms and potential applications of Co modified recycled Al in various industrial sectors.

Influence of shot-peening treatment on wear resistance of medium manganese steel

The effect of shot peening treatment on dry sliding wear behavior of medium manganese steel in as-hot rolled and solution-aging states were studied. The results show that before shot peening, the wear resistance of the solution-aging sample was better than that of hot-rolled steel. The excellent wear resistance was due to the synergistic effect of Ti (C, N) particle precipitation strengthening and grain refinement in the matrix, resulting in high strain hardening ability. After shot peening, different microscopic evolution mechanisms caused great contrast in properties. The as-hot rolled sample released internal stress by generating deformation twins (DTs) during shot peening. With the increased shot peening time, the DTs thickened and interacted with dislocations, effectively reducing the free dislocation path, releasing residual stress, and significantly improving wear resistance. However, solution-aging steel generated many dislocations, resulting in residual stress concentration at Ti (C, N) particles, promoting crack initiation and propagation, and deteriorated wear resistance.

DRY SLIDING WEAR AND CORROSION BEHAVIOR OF AA7075–SiC COMPOSITES

DRY SLIDING WEAR AND CORROSION BEHAVIOR OF AA7075–SiC COMPOSITES

Reciprocating dry sliding wear behaviour of BN@MXene@AA7075 composites

Aluminium alloys are preferred in various fields, especially in the aviation and automotive sectors, due to their lightweight and durable nature. However, their usage is limited due to weak tribological properties such as low hardness and high adhesion tendency against steel. In order to overcome this deficiency, this study aimed to develop AA7075 matrix composites reinforced with BN and MXene. The productions were conducted by powder metallurgy method with these reinforcements in different ratios, both together and separately. The produced composites were characterized primarily by XRD and SEM analyses, followed by measurement of density and porosity values. Wear tests were conducted using the reciprocating ball-on-flat method, at a frequency of 3 Hz, a sliding distance of 100 m, and a stroke distance of 5 mm, with Inox steel ball. The highest improvement in wear rate was realized under 5 N load at 5 wt.% reinforcement ratios of 48% and 42% for BN and MXene, respectively. When 2 wt% BN and MXene reinforcements were applied together, the improvement rate remained around 34%. It can be said that BN and MXene show promising results by providing significant improvements compared to their counterparts in the literature, with MXene especially warranting further investigation.

Effect of TiO2-SiC and heat treatment on tribological characteristics of bimodal hybrid aluminium composites under dry sliding condition

Abstract The dry sliding wear behavior of bimodal TiO2np/SiCp/Al6082 composites was studied using a pin-on-disk tribometer. The investigation included both as-cast alloy and T6 heat-treated composites, with variations in applied load (40 N, 60 N, and 80 N) and sliding distance (600, 900, 1200, 1500, 1800, and 2100 m) at a constant sliding speed of 2 m/s. The microstructure of the composites and the worn surface were examined using a scanning electron microscope. A linear increase in wear rate was observed with sliding distance up to the transition limit. It was found that at 40 N, a shield began to develop between the disc and pin surface, reducing the coefficient of friction (COF), and friction and oxide were the primary processes of wear mechanisms. A larger load caused the protective layer to be destroyed; increasing COF, and adhesion and delamination were the two types of wear that were noticed. The wear resistance of alloys and bimodal composites were increased by heat treatment because it strengthened the matrix.

NiCrBSi/WC Composite Claddings Processed on AISI 316L Steel Alloy by the Direct Laser Deposition Process: Studies on Dry Sliding Wear Behavior and Wear Mechanism Maps

Abstract This study presented the wear behavior of the NiCrBSi/WC composite claddings processed on an AISI 316L steel alloy substrate by laser cladding approach. The scanning electron microscope (SEM) morphology of the claddings has shown excellent substrate–cladding interface bonding, good WC particulate distribution, and no noticeable cracks and voids. The electron dispersion spectroscope (EDS) spectra have confirmed the presence of respective NiCrBSi alloy matrix and WC elements. The XRD spectra have identified various phases and compounds such as gamma-Ni, FeNi3, Ni3B, Cr23C6, Ni3Si, and W2C commonly in all the processed composite claddings. The microhardness of the claddings was measured between 791 and 1086 HV0.2 for increasing the reinforcement WC particulate percentage from 15 wt% to 60 wt%. It is about 470% surface hardness enhancement with the processed composite claddings compared with the substrate alloy. The reinforcement of WC from 15 wt% to 60 wt% with the composite claddings resulted in wear resistance enhancement from 21.85% to 60.64% and the coefficient of friction from 56.87% to 77.92% against the substrate. The wear-rate maps and their respective cladding's worn surface morphology have described the wear mechanisms typically as adhesive, abrasive, oxidation, and delamination. The wear mechanisms are mainly influenced by the WC particulate percentage. The increased WC particulate content has increased the dominance of the abrasive wear mechanism while reducing the window of the adhesive wear mechanism. The windows of various wear mechanisms and their ranges, such as adhesive 0.0033 to 0.028, abrasion 0.010 to 0.067, oxidation 0.012 to 0.093, and delamination 0.015 to 0.120 mm3/m, for NiCrBSi/WC composite claddings comprehensibly represented the wear behavior for the varied conditions of dry sliding wear parameters.

High temperature dry sliding wear behaviour of selective laser melted Ti-6Al-4V alloy surfaces

The present study investigates the sparsely documented tribological performance of selective laser-melted Ti-6Al-4V over a wide range of temperatures (room temperature to 450 °C). The evolution of wear mechanism was traced by examining the phase changes, chemical composition, and morphology of wear tracks in the material. The native oxide layer developed on the surface of the material was found to mitigate adhesive wear during dry sliding at room temperature. At elevated temperatures, this oxide layer contributed to oxidative wear, as evidenced by the formation of a tribo-oxide layer with increased oxygen penetration. Further, abrasive wear was found to increase with increasing temperatures, which could be attributed to the presence of entrapped oxidized wear particles (third-body wear) and material softening.

Dry Sliding Wear Behavior of Experimental Low-Cost Titanium Alloys

The high cost and potential toxicity associated with the common commercial Ti-6Al-4V alloy are major concerns against its continued use in the biomedical industry. Low-cost, less toxic titanium alloys have been developed as a possible alternative to Ti-6Al-4V. Because of the various wear processes that take place in the human body, it is imperative to have a good understanding of the wear properties and wear resistance of these alloys. This study, therefore, investigated the resistance to wear of the low-cost Ti-3Fe, Ti-4.5Al-1V-3Fe, and Ti-4.5Al-1V-3Fe alloys under dry sliding conditions in contrast to the common commercial alloy, Ti-6Al-4V. The findings revealed that among the tested alloys, Ti-3Fe exhibited the lowest resistance to wear as it displayed the highest coefficient of friction (0.55) and wear rate (5.55E-06 mm3/Nm). The Ti-4.5Al-1V-3Fe alloy demonstrated superior wear resistance compared to the rest of the alloys, including Ti-6Al-4V, as it had the lowest wear rate (4.27E-06 mm3/Nm) and wear volume (0.0026 mm3). Overall, the experimental alloys displayed very similar wear resistance to Ti-6Al-4V, making them promising commercial alloys that can replace Ti-6Al-4V in bioimplant applications.

Influence of B4C and ZrB2 reinforcements on microstructural, mechanical and wear behaviour of AA 2014 aluminium matrix hybrid composites

Considering their affordability and high strength-to-weight ratio, lightweight aluminium alloys are the subject of intensive research aimed at improving their properties for use in the aerospace industry. This research effort aims to develop novel hybrid composites based on AA 2014 alloy through the use of liquid metallurgy stir casting to reinforce dual ceramic particles of Zirconium Diboride (ZrB2) and Boron Carbide (B4C). The weight percentage (wt%) of ZrB2 was varied (0, 5, 10, and 15), while a constant 5 wt% of B4C was maintained during this fabrication. The as-cast samples have been assessed using an Optical Microscope (OM) and a Scanning Electron Microscope (SEM) with Energy Dispersive Spectroscopy (EDS). The properties such as hardness, tensile strength, and wear characteristics of stir cast specimens were assessed to examine the impact of varying weight percentages of reinforcements in AA 2014 alloy. In particular, dry sliding wear behaviour was evaluated considering varied loads using a pin-on-disc tribotester. As the weight % of ZrB2 grew and B4C was incorporated, hybrid composites showed higher hardness, tensile strength, and wear resistance. Notably, the incorporation of a cumulative reinforcement consisting of 15 wt% ZrB2 and 5 wt% B4C resulted in a significant 31.86% increase in hardness and a 44.1% increase in tensile strength compared to AA 2014 alloy. In addition, it has been detected that wear resistance of hybrid composite pin (containing 20 wt% cumulative reinforcement) is higher than that of other stir cast wear test pins during the whole range of applied loads. Fractured surfaces of tensile specimens showed ductile fracture in the AA 2014 matrix and mixed mode for hybrid composites. Worn surfaces obtained employing higher applied load indicated abrasive wear with little plastic deformation for hybrid composites and dominant adhesive wear for matrix alloy. Hence, the superior mechanical and tribological performance of hybrid composites can be attributed to dual reinforcement particles being dispersed well and the effective transmission of load at this specific composition.

Study of Mechanical and Tribological Behavior of Fly ash with E-Glass fibre Reinforced AL MMC’s

AMC’s specimen made by liquid stir casting technique, by addition of fixed 3% E-glass fibers and fly ash particles in different proportions (4, 6 and 8 wt.%) prepared the matrix phase. A uniform distribution of reinforcement is obtained with good bonding with matrix. Dry sliding wear behavior of the aluminum alloy and the composites has been studied and tested using a pin-on-disc wear and friction monitor. The testing carried out on sliding velocity of 1.5, 2.5 and 3.5 m/s and load ranges from 1, 2 and 3kgf. The composite shows better mechanical properties than the base alloy. Abrasive wear resistance improves by addition of fly ash reinforcement