Dry Sliding Wear Performance Research Articles

Dry sliding wear performance of hybrid composites, comprising AlMg1SiCu alloy, titanium carbide, and molybdenum disulfide fabricated through stir casting process at different temperature condition

Dry sliding wear performance of hybrid composites, comprising AlMg1SiCu alloy, titanium carbide, and molybdenum disulfide fabricated through stir casting process at different temperature condition

Effects of silicon content and test conditions on the dry wear behaviour of Zn–30Al–3Cu–(0–5)Si Alloys

ABSTRACT Dry sliding wear performance of Zn-30Al-3Cu-(0-5)Si alloys was studied using a block-on-disc type test apparatus. Their microstructure consisted of β dendrites, α, η, and ϵ (CuZn4) phases, and silicon particles. Hardness and tensile strength of the alloys increased with silicon content but above 1% Si the trend reversed for the tensile strength. Total percent elongation, impact energy, compressive strength, and quality index of the alloys decreased with silicon content. However, the friction coefficient and wear volume showed different changes with silicon content, sliding distance, contact pressure, and sliding velocity. Worn surface examinations indicated that the wear of these alloys occurs by both abrasion and adhesion. Non-linear regression analysis showed that the friction coefficient and wear volume of the alloys can be calculated in terms of silicon content and either sliding distance or contact pressure and sliding velocity using the empirical equations developed in this work. Zn-30Al-3Cu-0.5Si alloy exhibited the highest quality index and wear resistance among the alloys tested. It was concluded that the hardness and tensile strength of the alloys containing hard and brittle phases have opposite effects on their dry wear behaviour. The wear volume of such alloys decreases with increasing hardness but increases with tensile strength.

Elevated temperature wear and friction performance of WC-CoCr/Mo and WC-Co/NiCr/Mo coated Ti-6Al-4V alloy

The effect of adding Mo to WC-based coatings on the microstructure and dry sliding wear performance at elevated temperatures is investigated. The WC-based coatings are deposited using a high-velocity oxy-fuel process on the titanium-31 substrate. The coating was characterized by microstructure, microhardness, porosity, surface roughness, density, and bond strength. The wear and friction behavior of coatings was evaluated using a ball-on disc tribometer at temperatures of 200, 400, 600, and 800 °C and loads of 20 and 30 N. SEM-EDS and an optical profilometer were utilized to evaluate the wear rate and mechanism. The microhardness and bond strength of WC-CoCr/10%Mo coating is more than that of WC-Co/20%NiCr/10%Mo coatings. The WC-CoCr, WC-CoCr/10%Mo, and WC-Co/20%NiCr/10%Mo coatings exhibited decreasing wear rates up to 600 °C, transitioning to an increase at 800 °C. The oxide phases of CoWO4, WO3, MoO3, CoMoO4, and NiMoO4, formed at 600 °C, aid in reducing the rate of wear and friction coefficient. However, the wear rate slightly increased at 800 °C due to vigorous oxidation and softness of coatings. The friction coefficient of WC-CoCr, WC-CoCr/10%Mo, and WC-Co/20%NiCr/10%Mo coating decreases with increasing temperatures due to the lubricating properties of oxide phases on the worn surface. The WC-CoCr/10%Mo coating demonstrates a lower friction and wear rate than the WC-CoCr and WC-Co/20%NiCr/10%Mo coating. At 200 °C, the predominant wear mechanisms were abrasive and fatigue wear, while at 800 °C, oxidative wear, abrasive wear, and adhesive wear were observed.

Effect of Ageing Temperature on the Hardness, Microstructural and Dry Sliding Wear Performance of the Functionally Graded A356 Alloy

Effect of Ageing Temperature on the Hardness, Microstructural and Dry Sliding Wear Performance of the Functionally Graded A356 Alloy

Grey-Taguchi approach to optimize the tribological performance of hybrid composites

Modern manufacturing technology is evolving, necessitating the creation of materials with higher wear resistance. This research endeavors to forecast the dry sliding wear performance of AL6061-B4C-RM hybrid composites by employing Taguchi and grey relational analysis approaches. Present study applies the L16 Taguchi approach to optimize the process parameters specific wear, and coefficient of friction (COF) at four different levels. Using multiple responses for optimization for both responses, a single process parameter setting is obtained via grey relational analysis. In AL6061 composites, varying weight proportions of Boron Carbide particles (B4C) were added as reinforcements while keeping the red mud (RM) content constant at 2 %. To recognize the dominant factor, analysis of variance (ANOVA) was implemented, and the outcomes of the assessment showed speed plays a crucial role, followed by the weight percent of reinforcement and the load in determining the specific wear rate and COF. A research trial was completed to confirm the outcomes obtained from the combination of optimal parameters.

Synthesis and wear characterization of Al7075/molybdenum disulfide/zirconium diboride hybrid composites

AbstractThe manuscript presents the synthesis and dry sliding wear performance of Al7075 alloy‐based composites. Five compositions namely Al7075 alloy, Al7075+3 vol % molybdenum disulfide, Al7075+3 vol % molybdenum disulfide+3 vol % zirconium diboride, Al7075+3 vol % molybdenum disulfide+6 vol % zirconium diboride and Al7075+3 vol % molybdenum disulfide+9 vol % zirconium diboride were stir cast and characterized for hardness, x‐ray diffraction, microstructure, and tribological properties. In‐situ formed zirconium diboride particles increase the hardness of Al7075 alloy whereas molybdenum disulfide shows the opposite trend due to its self‐lubricating nature. X‐ray diffraction analysis identifies subsequent phase particles in the matrix while microstructural images exhibit the dispersion and morphology of reinforcement particles. The wear tests and friction coefficient were analyzed with variations of sliding velocity, normal load, sliding distance, and compositions. Further, the obtained wear results were also correlated with microstructure and wear surface topography. Al7075+3 vol % molybdenum disulfide composite shows the lowest coefficient of friction because of its self‐lubricating nature. Al7075+3 vol % molybdenum disulfide+9 vol % zirconium diboride hybrid composite exhibits the lowest wear rate at high velocity as well as at high load and can be potentially used in manufacturing and tribological applications. Moreover, the use of this material may lead to the minimum requirement of external toxic lubricants that make it cost‐effective and environmentally sustainable.

Investigating the load and temperature-dependent dry sliding wear performance of Al–12Ce alloys with Si and Mg additions

The current study investigates the effect of load and temperature on the wear characteristics of gravity-cast Al–12Ce, Al–12Ce-X alloys (where X = 4Si, 0.4Mg, and 4Si+0.4Mg), and commercial A356 alloys at 5, 10, and 20 N; and at 25, 100, and 200 °C newly fabricated for diesel engine applications. The addition of 4Si and 0.4Mg increased the Al–12Ce alloy's hardness and decreased the volumetric wear rate of the alloy at all loads and temperatures. However, the Al–12Ce–4Si-0.4Mg alloy had the lowest wear rates at all loads and temperatures. The friction coefficient and surface roughness diminish with 4Si and 0.4Mg addition to Al–12Ce alloys, which was the lowest in the Al–12Ce–4Si-0.4Mg alloy. Under the loading and temperature conditions, friction coefficient and surface roughness are the lowest in the Al–12Ce–4Si-0.4Mg alloy. All of the alloys are subject to abrasion, adhesion, oxidation, and delamination wear mechanisms under experimental conditions. However, the wear mechanisms are the most severe and mildest in the Al–12Ce and Al–12Ce–4Si-0.4Mg alloys, respectively. The superior wear response of the alloy Al–12Ce–4Si-0.4Mg is attributed to its smaller grain size, less amount of Al11Ce3 phase, and higher amount of thermally stable CeAlSi2 phases.

Tailored carburization gradient microstructure and enhanced wear properties of M50NiL steel via introduced prior cold rolling

M50NiL (Chinese grade G13Cr4Mo4Ni4V) steel is widely used in aircraft bearing raceways that require excellent wear resistance under harsh service conditions. However, the impact of cold rolling, as an advanced forming process for bearings, on the carburization process and wear properties is still unknown. Therefore, the gradient microstructure and dry sliding wear performance of the cold-rolled M50NiL disc against Si3N4 ceramic ball have been investigated. The results show that with the increase of cold rolling reduction to 40 %, the carbon concentration of surface is increased by 17.1 % due to the growing percentage of grain boundaries (GB) and dislocation density. The carbide content is increased by 29 % with average size declined by 21.2 %, which contributes to a 7.4 % increase in the surface hardness. Additionally, the wear test indicates that the average friction coefficient and wear rate are respectively reduced by 17.3 % and 47.1 % when the rolling reduction increases to 40 %. After prior rolling, the wear mechanism changes from severe abrasion to adhesion and tribochemical reactions accompanied with the enhancement of wear properties, which is mainly attributed to the uniform distribution of finer carbides with higher fraction on the surface and subsurface.

Sliding wear study of WC-10Co4Cr clad on SS-316 using microwave energy

The current study comprises the changing surface morphology of austenitic stainless steel (SS-316) with WC-10Co4Cr powder using an affordable microwave route. The surface modification was achieved by utilizing a microwave apparatus (power: 1.2 kW; frequency: 2.45 GHz). The x-ray diffraction (XRD) study reveals the presence of various carbide phases in the deposited clad layer. The scanning electron microscope (SEM) examination reveals the unequally dispersed reinforced skeleton carbide in a metal-based matrix with an average porosity of less than 1%. The deposits exhibit significantly higher hardness than that of the SS-316. A pin-on-disc tribometer was utilized to assess the dry sliding wear performance of deposits. The results revealed that the deposits exhibited better wear resistance than the SS-316 substrate due to the presence of reinforced hard carbides in a tougher metal-based matrix. The improvement in microhardness also leads to enhancement in the wear resistance of the deposits. The loss of material from the deposit surfaces during sliding was primarily due to micro-cutting and rupturing of the unstable tribofilm layer.

Development of a Neural Network Model and Taguchi-Based Optimization for Dry Sliding Wear Performance of Al 6065 Alloy Reinforced with Nano SiC and Graphene Nanoplatelets

The Al6065 alloy is widely used in various applications, including tubing for furniture, railway and bus structures, pylons, platforms, and pipelines. However, due to the wear experienced in these applications, it is essential to enhance the wear confrontation of this alloy. To address this issue, this research focuses on reinforcing Al6065 with nanoparticles of silicon carbide and graphene by means of the stir casting method. The wear behaviour of the alloy is studied by varying the rotational speed, load, and composition of reinforcement in the stir casting machine using Taguchi design of experiment. The rate of wear and friction coefficient are measured as responses. The obtained results are then analysed and optimized for the minimum of the output responses using S/N ratio analysis. Further, ANOVA is carried out to determine the influence of each parameter, and a model of the neural network is developed to predict the response. The findings indicate that cumulative the percentage of reinforcement enhances the wear resistance of the alloy. The optimized values of the rotational speed, load, and composition of reinforcement lead to improved wear resistance, with a corresponding decrease in the coefficient of friction. The ANOVA results reveal that the rotational speed and load significantly affect the responses, while the reinforcement composition has a moderate effect. The developed neural network model accurately predicts the response with a high degree of accuracy. The model can be used to optimize the wear behaviour of Al6065 alloy reinforced with nanoparticles of silicon carbide and graphene, as well as for prediction of the alloy's wear behaviour in various application environments. In conclusion, this research delivers a complete thoughtful of the wear behaviour of Al6065 alloy reinforced with nanoparticles of silicon carbide and graphene. The findings can be used to optimize the wear resistance and improve the routine of this alloy in various applications.

Experimental investigation on wear behaviour of heat-treated ductile cast iron

The present work reports an experimental investigation on influence of heat-treatment on dry sliding wear performance of different amounts of spherodising agents of SG cast iron-ductile cast iron. Ductile cast iron was produced with various levels of spherodising agent (Magnesium) and subjected to austempering. Austemperd ductile cast iron was tested for its wear behaviour at different temperatures. Produced ductile cast iron was chemically analysed and SEM analysis is carried out for austempered ductile cast iron. Mg additions influenced the wear and frictional forces. Both wear loss and frictional force were considered. E-Dax analysis was also made and SEM image of worn surface was studied. It was observed that wear loss increases at lower percentage of spherodising agent. It is observed that ductile cast Iron has high wear at high magnesium content at moderately high temperature 200°c. The optimum conditions of ductile cast Iron for minimum wear loss are temperature 32°c and magnesium 0.04% and the same for minimum frictional forces are temperature 200°c and magnesium% 0.03 are observed. Temperature has greater influence on both wear loss and frictional forces.

Mechanical and dry sliding wear performance evaluation of marble dust particulates–lapinus fiber–polyamide 66 polymer composites with ranking analysis using hybrid AHP-R method

This research investigates the physical, mechanical, thermal, thermomechanical and dry sliding wear performance of marble dust particulates (0–20 wt.% @ step of 5%) and lapinus fiber (10 wt.% constant) reinforced polyamide 66 polymer composites, resulting in five hybrid polymer composite namely PLM-0, PLM-5, PLM-10, PLM-15 and PLM-20, respectively. A twin screw extruder and injection molding machine were used for the fabrication. Taguchi's method and ANOVA tools are used to optimize and determine the significant order of the input parameters for the sliding wear process, followed by surface morphology investigations. Finally, the hybrid AHP-R ranking method was applied to rank the compositions on their merits. It is observed that PLM-10 hybrid polymer composites have shown relative overall optimized performance. It shows the lowest density of 1.21 g/cc, voids content of 6.47%, water absorption of 4.51% and a specific wear rate of 1.03 × 10−3 mm3/Nm. In comparison, it shows the highest tensile strength of 112.64 MPa, flexural strength of 150.40 MPa, Rockwell hardness of 60.40 HRM, fracture toughness of 4.27 MPa√m, impact strength of 1.96 J, thermal conductivity of 0.98 W/mK and storage modulus of 1824.29 MPa. Finally, these subjective findings were found to be in tune with the findings of the hybrid AHP-R method.

Dry sliding wear and mechanical investigations on flyash particulates - Lapinus fibre - polyamide 66 polymer composites: Ranking analysis using hybrid Analytic Hierarchy Process-R method

This research work examines the physical, mechanical, thermal, thermo-mechanical, and dry sliding wear performance of hybrid waste flyash particulates (F-class; 0-20 wt% @ step of 5%) – Lapinus fibres (fixed 10 wt%) reinforced Polyamide 66 polymer composites fabricated using the twin screw extruder and injection moulding machine. This follows worn surface morphology to understand the prevailing wear mechanisms responsible for surface damage during sliding. Optimization of control parameters and identification of their order of significance in the dry sliding wear process is performed using Taguchi’s design of experiments and analysis of variance (ANOVA). Further, ranking optimization of the hybrid composite specimens based on their performance metrics is analysed using the hybrid AHP-R method. It has been observed that the hybrid composite specimens having 10 wt% flyash particulates optimize the overall performance metrics; therefore, it may be recommended to fabricate parts or components for industrial usage. It tends to have an experimental density of 1.18 g/cc, voids content of 7.11%, water absorption of 3.87%, tensile strength of 105.95 MPa, flexural strength of 144.86 MPa, Rockwell hardness of 58.12 HRM, fracture toughness of 4.11 MPa√m, Impact strength of 1.86 J, thermal conductivity of 1.08 W/mK, and specific wear rate of 1.12 × 10−3 mm3/Nm. This observation was attuned to the ranking analysis using the hybrid AHP-R method.

Optimization of dry sliding wear performance of TiO2 filled bamboo and flax fiber reinforced epoxy composites using Taguchi approach

PurposeThis paper aims to report the effect of titanium oxide (TiO2) particles on the specific wear rate (SWR) of alkaline treated bamboo and flax fiber-reinforced composites (FRCs) under dry sliding condition by using a robust statistical method.Design/methodology/approachIn this research, the epoxy/bamboo and epoxy/flax composites filled with 0–8 Wt.% TiO2 particles have been fabricated using simple hand layup techniques, and wear testing of the composite was done in accordance with the ASTM G99-05 standard. The Taguchi design of experiments (DOE) was used to conduct a statistical analysis of experimental wear results. An analysis of variance (ANOVA) was conducted to identify significant control factors affecting SWR under dry sliding conditions. Taguchi prediction model is also developed to verify the correlation between the test parameters and performance output.FindingsThe research study reveals that TiO2 filler particles in the epoxy/bamboo and epoxy/flax composite will improve the tribological properties of the developed composites. Statistical analysis of SWR concludes that normal load is the most influencing factor, followed by sliding distance, Wt.% TiO2 filler and sliding velocity. ANOVA concludes that normal load has the maximum effect of 31.92% and 35.77% and Wt.% of TiO2 filler has the effect of 17.33% and 16.98%, respectively, on the SWR of bamboo and flax FRCs. A fairly good agreement between the Taguchi predictive model and experimental results is obtained.Originality/valueThis research paper attempts to include both TiO2 filler and bamboo/flax fibers to develop a novel hybrid composite material. TiO2 micro and nanoparticles are promising filler materials, it helps to enhance the mechanical and tribological properties of the epoxy composites. Taguchi DOE and ANOVA used for statistical analysis serve as guidelines for academicians and practitioners on how to best optimize the control variable with particular reference to natural FRCs.

Microstructure evolution and tribological properties of (TiB+TiC)/Ti–6Al–4V composites fabricated via in situ laser-directed energy deposition of wire and powders in an underwater environment

Titanium-matrix composite-reinforced restored layers are used to repair cracks and dents on titanium alloy shells to impart the deposition layer with the same properties as the base metal. However, there are few studies on their underwater applications. Underwater laser-directed energy deposition is a rapidly-developing technique that shows great application potential for underwater restoration projects. This paper reports the effect of the Ti/(B+C) ratio on the microstructure and mechanical properties of a layer restored underwater using CWPLDED. The results showed that the ceramic-reinforced phase transitioned from a quasi-continuous mesh distribution to a multi-point distribution as the Ti/(B+C) ratio changed. The matrix grain was refined because the reinforcing phase promoted the non-spontaneous nucleation of β-Ti and α-Ti and limited grain growth during both solidification and solid-state phase transformation. The composite layer restored underwater had a maximum ultimate tensile strength of 1231.18 ± 6.37 MPa and a maximum yield strength of 1158.11 ± 8.71 MPa. When Ti: B: C = 3: 4: 4, the improved wear resistance of the restored layer was attributed to the higher microhardness caused by an increased precipitated phase content and Ti matrix grain refinement. When Ti: B: C = 3: 4: 1, the restored layer exhibited better wear resistance due to the excellent spatial configuration of the reinforced phase. The intrinsic relationship between the (B+C) content, reinforced phase space, and dry sliding wear performance was revealed. This provides a design window for preparing (TiB+TiC)/Ti64 composite restored layers with excellent comprehensive performance by CWPLDED and offers new insights for repairing titanium alloys underwater.

Modelling of Dry Sliding Wear Performance of Al-WC Nanocomposites

Modelling of Dry Sliding Wear Performance of Al-WC Nanocomposites

Support recycling in additive manufacturing: A case study for enhanced wear performance of Ti6Al4V alloy

The production of metals by additive manufacturing is developing rapidly. After production, support structures emerge as waste materials. In this study, Ti6Al4V support structures recycled from the selective laser melting process were consolidated by vacuum hot pressing. Spherical and irregularly shaped Ti6Al4V alloy particles were also used for the comparison as raw materials. All raw materials have been subjected to the same sintering process by hot pressing. The microstructures of the samples were carried out, and their dry sliding wear performance was studied. The samples produced from support structures showed the highest wear performance compared to the powder forms of raw materials. This study showed that the support structures from additive manufacturing could be recycled and transformed into full dense structures by pressure-assisted sintering techniques, and enhanced wear performance can be obtained.

Influences of Nanosilica Particles on Density, Mechanical, and Tribological Properties of Sisal/Hemp Hybrid Nanocomposite

Focusing on natural fibers are the prominent substitution for synthetic fiber and reinforced into polymer matrices found unique properties such as lightweight, cost-effectiveness, and good mechanical and wear properties. Incompatibility and low adhesive behavior are the primary drawbacks found during the fabrication of natural fiber-bonded polymer matrix composites. The constant weight percentage (10 wt%) of sisal and hemp fiber is treated with a 5% NaOH solution for improving adhesive behavior and bonded with epoxy. The prepared sisal/hemp/epoxy combination is blended with 0 wt%, 3 wt%, 6 wt%, and 9 wt% silica nanoparticles, which results in reduced voids (1.32%) and increased flexural strength (56.98 MPa). Based on the compositions of fiber and reinforcement, the density of the composite varied. Samples 3-6 wt% of silica nanoparticle-blend sisal/hemp/epoxy composite offered maximum tensile and impact strength of 52.16 MPa and 2.1 J. An optical microscope analyzed the tensile fracture surface, and the failure nature was reported. The dry sliding wear performance of composite samples is tested by pin-on-disc setup with a 10 N-40 N load of 10 N interval at 0.75 m/sec. Sample 3 found good wear resistance compared to others.

Analysis of Dry Sliding Wear Performance of Tribaloy T-800/Tungsten Carbide Coating Deposited via Laser Cladding Assisted with Preheating

Analysis of Dry Sliding Wear Performance of Tribaloy T-800/Tungsten Carbide Coating Deposited via Laser Cladding Assisted with Preheating

Fe-based amorphous coating for high-temperature wear, marine and low pH environments

Fe-based amorphous coatings have been manufactured by the high-velocity oxygen fuel (HVOF) process to explore their applications for high-temperature wear, marine and acidic corrosion environments. The microstructural and mechanical characterization of the coating was performed using XRD, SEM-EDS, micro and nanoindentation techniques. The dry sliding wear performance of the coating was analyzed against an Al2O3 ball at room temperature (RT) and 600°C. In addition, the corrosion behaviour of coating was evaluated in filtered seawater and 0.5M H2SO4 solutions. The coating retained the amorphous state. Substantial enhancement in nano and micro-mechanical properties were observed after exposure at 600°C. Dry sliding wear tests indicated that the coating displayed three times better wear resistance at 600°C than at RT. The combined effects of enhanced mechanical properties due to nanocrystal precipitation and stimulated splat-to-splat cohesion behaviour and a compact, dense oxide glazed layer improved the overall wear resistance at 600°C. The coating exhibited higher corrosion resistance than 316L stainless steel and other Fe-based amorphous coatings in seawater and acidic solutions. In both environments, the coating demonstrated passivation behaviour derived from a layer composed of a stable Cr-based oxide reinforced with Mo and W-based oxides.