Dry Sliding Wear Rate Research Articles

Mechanical characteristics and optimization of wear parameters of hybrid (TiO2 + Y2O3) nanoparticles with Al matrix using squeeze casting technique

Purpose The purpose of this paper is to examine the mechanical characteristics and optimization of wear parameters of hybrid (TiO2 + Y2O3) nanoparticles with Al matrix using squeeze casting technique. Design/methodology/approach The hybrid aluminium matrix nanocomposites (HAMNCs) were fabricated with varying concentrations of titanium oxide (TiO2) and yttrium oxide (Y2O3), from 2.5 to 10 Wt.% in 2.5 Wt.% increments. Dry sliding wear test variables were optimized using the Taguchi method. Findings The introduction of hybrid nanoparticles in the aluminium (Al) matrix was evenly distributed in contrast to the base matrix. HAMNC6 (5 Wt.% TiO2 + 5 Wt.% Y2O3) reported the maximum enhancement in mechanical properties (tensile strength, flexural strength, impact strength and density) and decrease in porosity% and elongation% among other HAMNCs. The results showed that the optimal combination of parameters to achieve the lowest wear rate was A3B3C1, or 15 N load, 1.5 m/s sliding velocity and 200 m sliding distance. The sliding distance showed the greatest effect on the dry sliding wear rate of HAMNC6 followed by applied load and sliding velocity. The fractured surfaces of the tensile sample showed traces of cracking as well as substantial craters with fine dimples and the wear worn surfaces were caused by abrasion, cracks and delamination of HAMNC6. Originality/value Squeeze-cast Al-reinforced hybrid (TiO2+Y2O3) nanoparticles have been investigated for their impact on mechanical properties and optimization of wear parameters.

Optimizing the Dry Sliding Wear Behavior of Stir-Casted Al6061/Nano-Al2O3/Quartz Hybrid Metal Matrix Composite Using Taguchi Method

The increased demand for wear-resistant and low-weight components in the automobile industry has led to the utilization of aluminum metal matrix composite parts due to their improved performance. The current work focused on optimizing the tribological factors such as applied load, rotational speed, and percentage weight fraction of the reinforcing particles for minimum dry sliding wear rate of Al6061/nano-Al2O3/quartz hybrid composite fabricated by stir casting. The optimization is performed by using the Taguchi L27 orthogonal array experimental plan, and the result is analyzed by the help of analysis of variance (ANOVA). The result of the optimization reveals that the optimum levels of factors for the minimum wear rate are 10 N, 200 rpm, and 12.5%. Furthermore, the ANOVA result depicts that the applied load has the highest impact (87.83%) on the wear rate, followed by rotational speed (10.06%) and percentage weight fraction of the reinforcement (1.60%). The developed linear regression model reveals that the applied load and the rotational speed have a positive relation with the sliding wear rate. However, the percentage weight fraction of the reinforcement has a negative relation. The confirmation test proves that the predicted value of wear rate using the regression equation at optimum levels has a closer agreement with the experimental result having a 6.934% error. Furthermore, the physical property test reveals that the rise in the weight percentage of quartz particles results in a corresponding increase in the percentage porosity of the hybrid composite.

Dry sliding wear behavior of additively manufactured cenosphere-filled PETG syntactic foam composites

PurposeThis study aims to deal with developing composite filaments and investigating the tribological behavior of additively manufactured syntactic foam composites. The primary objective is to examine the suitability of the cenosphere (CS; 0–30 Wt.%) to develop a high-quality lightweight composite structure with improved abrasion strength.Design/methodology/approachCS/polyethylene terephthalate glycol (PETG) composite feedstock filaments under optimized extrusion conditions were developed, and a fused filament fabrication process was used to prepare CS-filled PETG composite structures under optimal printing conditions. Significant parameters such as CS (0–30 Wt.%), sliding speed (200–800 rpm) and typical load (10–40 N) were used to minimize the dry sliding wear rate and coefficient of friction for developed composites.FindingsThe friction coefficient and specific wear rate (SWR) are most affected by the CS weight percentage and applied load, respectively. However, nozzle temperature has the least effect on the friction coefficient and SWR. A mathematical model predicts the composite material’s SWR and coefficient of friction with 87.5% and 95.2% accuracy, respectively.Practical implicationsBecause of their tailorable physical and mechanical properties, CS/PETG lightweight composite structures can be used in low-density and damage-tolerance applications.Social implicationsCS, an industrial waste material, is used to develop lightweight syntactic foam composites for advanced engineering applications.Originality/valueCS-reinforced PETG composite filaments were developed to fabricate ultra-light composite structures through a 3D printing routine.

PLASTICITY INDEX A MEASURE OF DRY SLIDING WEAR FOR Ni-BASED COATING

Ni-based coatings are extensively used in industry for the surface properties enhancement and improving the system performance under different operating conditions. The resistance to wear and corrosion of the components is found to be improved when the substrate is coated with the coating powder. However, determining the wear rate and wear mechanism is very important and time-consuming process. The coating and counter material properties play important role in the wear rate and wear mechanism. The plasticity index in the dry sliding condition may be used as wear measuring indicator which is governed by the hardness of the coating, asperity radius and the reduced elasticity modulus. In this paper, the plasticity index for different combinations of tribopair (Coating and counter materials) is compared with the dry sliding wear rate obtained for respective pairs. The outcomes show that the specific wear rate obtained for the dry sliding wear can be directly related to the plasticity index.

Wear Investigation of Aluminum Alloy Surface Layers Fabricated through Friction Stir Welding Method

In this research paper, an effort was made to investigate the dry sliding wear rate of friction stir welded AA6262/AA5456 composite performed by the Taguchi approach. Wear experiments are carried out by selecting suitable process parameters such as load (LD), sliding speed (SS), and sliding distance (SE) to recognize the individual and combination effects of parameters. Orthogonal array L27 mode is applied to make numbers of experiments to find the extreme and minimum wear amount. The experimental works are conducted on Pin on Disc (POD) apparatus and measured the weight of samples before and after test for calculating wear rate (WR) and then various analyses are performed such as ANOVA, interaction plot between parameters, and regression model with support of MINITAB software. The results revealed that maximum wear rate is found as 0.01215 mm3/Nm at LD of 50 N, SE of 600 m, and SS of 4 m/s, whereas minimum 0.00414 mm3/Nm at the grouping process parameters which are LD of 30 N, SE of 400 m, and SS of 6 m/s. From the observation of ANOVA, the most significant factor is identified as load, followed by sliding distance, sliding speed, and combination of each parameter. The load is considered as main parameter which contributes about 83.75% to achieve the maximum wear rate of developed AA6262/5456 composites. The contribution of sliding distance and speed are 3.75% and 1.85%, respectively.

The dry sliding wear rate of a Fe-based amorphous coating prepared on mild steel by HVOF thermal spraying

Wear-resistant amorphous coatings Fe49.7Cr18Mn1.9 Mo7.4W1.6B15.2C3.8Si2.4 of about 300 μm thickness were deposited on mild steel substrate using a high-velocity oxygen fuel (HVOF) thermal spray method. The median Vickers hardness of the as-sprayed coating is 751.9 HV300 g, which further increases by 127% and by 112% when the coating is vacuum heat treated at 650 °C and 800 °C, respectively. The longer the amorphous phase is, the higher the Vickers hardness is. The relatively low porosity indicates excellent wear resistance of these amorphous coating, which were measured using a pin-on-disc method. The wear mechanism of the current Fe-based amorphous coating varies from oxidative wear to delamination wear when the sliding speed changes from low (0.4 cm/s) to high (4.0 cm/s). It is believed that the upsurge in hardness and the wear resistance of the applied coating is due to the optimized selection of the heat treatment process (i.e., at 650 °C), which has a significant impact on the microstructure, as well as the low porosity, with better coating adherence and fewer cracks. Under dry sliding wear circumstances, the coating demonstrated good wear resistance, with wear rates of (2.81–16.30) x 10−6 mm3/N m. Due to the properties, low porosity, and high hardness especially in case vacuum heat treatment 650 °C, these coatings produced by (HVOF) exhibit a high ability to resist better friction and wear performance that indicates to ability application it in facilities steel.

Experimental Study of a Dry Sliding Wear for a Different Materials Using a Pin-on-Disk Apparatus

In the present work, an experimental investigation has been made of a dry sliding wear rate for aluminum, aluminum alloy (Al-Fe-V-Si), bronze, stainless steel 304 and structural steel ASTM A36, using a pin-on-disk apparatus under the effect of sliding speed and time at constant load. The materials were tested on two types of abrasive surfaces with a grit surface of 24 and 36. The applied load was equal to 2500 grams and the same load was used for all of the pins that were tested. The relative wear was indicated by the loss in length and loss in mass. The results show that the wear rate will directly proportional with sliding speed and time, and the stainless steel has less wear rate than the other materials.

Study of Dry Sliding Wear Behavior of a Fe-Based Amorphous Coating Synthesized by Detonation Spraying on an AZ31B Magnesium Alloy

A Fe-based amorphous coating was successfully deposited on an AZ31B magnesium alloy substrate by detonation spraying. The microstructure and sliding wear behavior of the coating were investigated in detail under dry conditions in ball-on disk mode by using a Si3N4 ball as the counterpart. It was found that the Fe-based amorphous coating presents an almost perfect amorphous structure, and the thickness, microhardness, porosity and amorphous content are 200 ± 30 μm, 825 ± 15 Hv0.1, 1.0% and 89.3 ± 2%, respectively. The dry sliding wear tests indicate that the Fe-based amorphous coating presents a fairly low dry sliding wear rate of 3.14-11.5 × 10−6 mm3 N−1 m−1, which is two orders of magnitude lower than that of the AZ31B substrate under a normal load of 5 N and at a sliding speed of 0.25 m/s. This distinguished wear resistance is mainly attributed to the fact that the Fe-based amorphous coating prepared by detonation spraying has an extremely low porosity and high amorphous phase content. Moreover, as the increase in load and sliding speed, the dry sliding wear mechanism of the Fe-based amorphous coating changes from fatigue wear and oxidative wear to delamination wear and oxidative wear.

Machine Learning and Statistical Approach to Predict and Analyze Wear Rates in Copper Surface Composites

This research demonstrates the application of machine learning models and statistics methods in predicting and analyzing dry sliding wear rates on novel copper-based surface composites. Boron nitride particles of varying fractions was deposited experimentally over the copper surface through friction stir processing. Experimental and statistical analysis proved that the presence of BN particles can reduce wear rate considerably. Analysis of worn-out surface revealed a mild adhesive wear during low load condition and an abrasive mode of wear during higher load conditions. Artificial neural network based feed forward back propagation model with topology 4-7-1 was modeled and prediction profiles displayed good agreement with experimental outcomes.

Effect of SiC/Fly Ash Reinforcement on Surface Properties of Aluminum 7075 Hybrid Composites

Friction stir processing (FSP) has emerged as a valuable technique in the surface metal matrix composite fabrication field. In this process, solid-state processing mostly avoids the formation of detrimental phases inside composites. Despite having a high specific strength, further extensive Al alloy applications are limited due to their poor surface properties. A hybrid reinforcement approach can be used to improve surface properties. In this study, industrial waste fly ash material is mixed with hard SiC ceramic particles. The main focus of this research is to improve wear resistance under dry sliding conditions and microhardness of aluminum 7075-T651 by dispersion of silicon carbide-fly ash (SiC/fly ash) powder in a base alloy by FSP. The parameters used for this investigation are: tool rotation rpm (500, 1000 and 1500), the tool traverse mm/min (20, 30 and 40), the reinforcement’s hybrid ratio HR (60:40, 75:25 and 90:10) and the volume percentage vol.% (4%, 8% and 12%). The influence of these parameters on the resultant composite’s microstructure, dry sliding wear rate and micro-hardness was studied. By using response surface methodology (RSM), desirable ranges of process parameters for lower wear rate and higher microhardness were obtained. The interaction effect of SiC/fly ash volume percentage and hybrid ratio had the most influential effect on the wear rates, as well as microhardness of composites. Moreover, microhardness increased with an increase in the volume percentage of SiC/fly ash powders towards high SiC content in hybrid ratio. Interestingly, among stirring parameters, tool traverse speed was found to be more influential than tool rotational speed. The minimum wear rate was observed for the Run 20 sample (w: 1000 rpm, v: 40 mm/min, HR: 75:25, vol.%: 8). A maximum microhardness of 241.20 HV was achieved for Run 15 (w: 500 rpm, v: 40 mm/min, HR: 90:10, vol.%: 12) sample. Mainly, reinforcement distribution—in accordance with the stirring action generated by the tool—had a major role in controlling the surface properties of the resultant composites.

Effects of T4 and T6 Heat Treatments on the Wear Behaviour of WC-Reinforced Mg Alloy Matrix Composite

Collective outcomes of WC particle reinforcement and heat treatment on the dry sliding wear rate of AZ91 magnesium metal matrix composite have been presented. The vacuum-assisted semi-solid stir casting method was employed to fabricate the composites. Wear study was conducted on the specimens using a pin-on-disc tribometer with EN8 steel as a counter material. The experiments were designed using Taguchi L27 array, with control factors viz. applied load (20, 40 and 60 N), sliding speed (1, 2 and 3 m/s), heat treatment (no treatment, T4 and T6) and WC wt% (0, 1.5 and 3). Energy-dispersive X-ray spectroscopy and scanning electron microscopy analyses were performed to study the surface of the tested specimens. T6-treated AZ91/3.0WC composite showed 63% enhanced resistance to wear due to the presence of β-phase (Mg17Al12) precipitation during the heat treatment process and WC reinforcements.

Microstructure, corrosion-resistance, and wear-resistance properties of subsonic flame sprayed amorphous Fe–Mo–Cr–Co coating with extremely high amorphous rate

The low-cost Fe-based amorphous coating with the composition of Fe49.9Mo32.9Cr9.32Co4.55Si2.28Al1.55 (wt.%) were deposited on 316L stainless steel substrate by subsonic flame spraying under optimum spraying parameters. The microstructure, phase composition, microhardness, corrosion-resistance, and wear-resistance properties of the coatings were systematically investigated. The prepared coating primarily consists of amorphous phase (calculated amorphous phase content was 90.23%), and the hardness of the prepared coating can reach 981.6 HV0.1, which is much larger than that of the substrate material 316L stainless steel. The corrosion potential and corrosion current density of the prepared Fe-based amorphous coating in 3.5 wt.% NaCl solution are −438 mV and 6.9 μA/cm2, respectively. Compared with 316L stainless steel and some newly published Fe-based amorphous coatings, the prepared coating shows better corrosion resistance properties. The dry sliding wear rate of the coatings with 0.45% C steel balls at 19.6 N is 1.68 × 10−5 mm3/Nm. The friction coefficient of the coating is at an ultra-low level (about 0.26) and can keep relatively steady throughout the sliding test. The study shows that the prepared Fe-based amorphous coating has high amorphous phase content, high hardness, superior corrosion-resistance, and wear-resistance properties.

Optimization of wear behaviour on AA6061/Al2O3/SiC metal matrix composite using squeeze casting technique – Statistical analysis

In the current scenario aluminium and their alloys are replaced by composite materials in the automotive field due to low corrosiveness, high strength and less weight. Need for improved wear behaviour performance has led to the design and selection of newer variants of the composite. This present paper investigates the study of wear behaviour of AA6061/Al2O3/SiC metal matrix composite (MMC) using squeeze casting method. Wear test has been carried out on a Pin on Disc apparatus. The effect of three levels and three process parameters such as load, sliding velocity and sliding distance were considered. Statistical analysis plays a significant role in analyzing aluminium matrix composites. Specifically, Taguchi techniques found to be efficient, systematic and simple relative to the optimization of wear test parameters. So that experimental study employed the Taguchi method. L9 orthogonal array was selected to carry out the experiment. Dry sliding wear rate has analyzed on “smaller the best” basis. ANOVA and regression equation carried out to understand the impact of individual factors and interactions on the wear rate as well as the coefficient of friction. Results show that load has the highest influence followed by sliding speed and sliding distance. Scanning Electron Microscope was done on wear surfaces.

Friction and sliding wear studies on functionally graded Al LM25/WC composite

Functionally graded LM25/15 wt.% Tungsten carbide composite of dimension Øout 150 mm x Øin 110 mm x 100 mm and thickness 20 mm was studied to understand the influence of process parameters (applied load, sliding velocity, sliding distance) on the dry sliding wear rate and co-efficient of friction. A 5-level 3 parameter central composite design was developed using response surface methodology considering applied load (10-50N), sliding velocity (1-3 m/s) and sliding distance (500-2500 m) as input parameters. Dry sliding experiments were performed on pin-on-disk tribometer at ambient conditions. Significance tests, Analysis of Variance and confirmation experiments were done to check the accuracy of generated regression model. Generated surface plots revealed wear rate to be increasing as applied load and sliding distance increases and decrease as sliding velocity increases. Worn surface analysis performed revealed formation of deep grooves at high load, MML formation at high velocities and heavy delamination and particle pull-out at high sliding distances.

Optimization of dry sliding wear behavior of aluminum LM4-Ta/NbC nano composite using Taguchi technique

Dry sliding wear behavior of aluminum LM4 based composite reinforced with Tantalum niobium carbide ceramic powder by varying percentage of reinforcement as 0.5 wt% to 2 wt%. Powder metallurgy method was used to develop the composites. Pin-on-disc apparatus was used to evaluate the dry sliding wear behavior of the developed composites. Taguchi design of experiment was used to optimization. The influence of various parameters are investigated by analysis of variance (ANOVA). From the wear results, it was observed that the applied load is having more influence on dry sliding wear followed by sliding speed. Also it was observed that percentage of reinforcement of (Tantalum Niobium carbide) Ta/NbC shows some influence on dry sliding wear rate. The worn surface analysis was done by using scanning electron microscopy (SEM). The analysis shows that incorporation of hard ceramic composites in alloys plays a major role in dry sliding wear resistance properties.

Evaluation of Wear Properties of Heat-treated Al 7075/Graphite Powder/Bagasse ash Hybrid Metal Matrix Composites

This research work investigated the in?uence of graphite powder on the wear behavior of Al 7075/Graphite Powder (Gr)/Bagasse ash (BA) hybrid composite. The investigation reveals the effectiveness of incorporation of graphite powder in the composite for gaining wear reduction. The Al 7075 (Aluminium alloy 7075) reinforced with graphite powder and Bagasse ash were investigated. The conventional liquid casting technique was used for the fabrication of composite material and subjected to T6 heat treatment. The reinforcement content was chosen as 1, 3, and 5wt. % of graphite powder to identify its potential for self-lubricating property under dry sliding conditions. Hybrid composite is processed at 1wt% of Gr with 2, 4 and 6wt% of BA. The effect of load on dry sliding wear rate and coefficient of friction performance of Al 7075 casting alloy and its composites was evaluated by using a pin-on-disc with two different loads with constant speed at room temperature. Wear tests were conducted by using pin on disc apparatus to evaluate the tribological behaviour of the composite and to determine the optimum content of graphite powder for its minimum wear rate. The wear rate decreases with addition of graphite powder content and reaches its minimum at 5wt. % graphite. The coefficient of friction decreases with addition of graphite content and was found to be minimum at wt. 5% graphite. The wear properties of the hybrid composites containing graphite exhibited the superior wear-resistance properties.

Influence of molybdenum on the mechanical properties, electrochemical corrosion and wear behavior of electrodeposited Ni-Mo alloy

In the present work, the influence of molybdenum (Mo) content on the grain size, hardness, corrosion and wear behavior of Ni-Mo alloy coatings electrodeposited from citrate electrolyte has been studied. Crack free Ni-Mo alloy with different Mo content (3, 5, 6, 9 and 12 at.%) was obtained using direct current and pulsed current electrodeposition. It was observed that the grain size of Ni-Mo alloy decreased with increase in Mo content. Hardness of the coatings increased with Mo content and decreased subsequently above 9 at.% Mo as per inverse Hall-Petch effect. Potentiodynamic polarization tests carried out in 2 N H2SO4 suggested increase in both corrosion current and passive current density with increase in Mo content. In addition, both friction coefficient and dry sliding wear rate of Ni-Mo coatings decreased with increase in Mo content. The results are rationalized based on grain size and Mo content in the coatings. Finally, Ni-Mo and Ni-W coatings were compared with hard chrome with respect to mechanical properties, wear and corrosion resistance. Results indicated that, Ni-Mo coatings exhibit least friction coefficient (0.2–0.3) amongst Ni-W and hard chrome coatings.

New-Generation Aluminum Composite with Bottom Ash Industrial Waste

Industrial waste bottom ash (BA) from a pulverized coal combustion boiler containing hard wear-resistant particles was utilized in this study to form an aluminum composite through a liquid metallurgy route. Composites comprising 5 wt.% and 10 wt.% bottom ash were characterized for their physiochemical, microstructural, mechanical, as well as tribological properties, along with pure aluminum. Scanning electron microscopy (SEM) microstructure revealed uniform distribution of BA particles throughout the matrix of the composite, whereas x-ray diffraction (XRD) analysis confirmed presence of aluminosilicate phase. Addition of 10 wt.% BA improved the Brinell hardness number (BHN) from 13 to 19 and ultimate tensile strength (UTS) from 71 MPa to 87 MPa, whereas ductility was adversely reduced after 5% BA addition. Incorporation of BA particles resulted in reduced dry sliding wear rates examined up to 80 N load compared with aluminum. Hence, such composites having lower cost could be applied as significantly hard, wear-resistant materials in applications in the automotive industry.

Effect of reinforcement and wear parameters on dry sliding wear of aluminum composites - A review

Aluminium Alloy composites are used in engineering applications such as aircraft, aerospace, automobiles and various other fields due to having excellent mechanical properties such as high strength, high stiffness,high load to weight ratio and better wear resistance. In the automobile sector the components like brake drum, cylinder, cylinder liners, pistons,piston insert rings are manufactured by aluminium composites where dry sliding wear is a predominant process. The dry sliding wear properties of aluminium composites at room temperature investigated by using Pin-on-disk wear testing machine. The parameters which influence dry sliding wear rate are applied load, sliding distance, sliding velocity and reinforcement. In this paper an attempt has been made to study the mechanical and dry sliding wear behaviour of aluminium alloy composites with various influence wear parameters

Development and Dry Sliding Wear Map for Al 7075/Al2O3 Particulate Composites

Particulate composite was developed with Al 7075 as matrix and Alumina (Al2O3) as reinforcement. Dry sliding wear map for Al7075/Al2O3 particulate was developed for studying dry sliding wear rate and wear mechanisms. The wear rate and coefficient of friction depends on load and speed in pin on disc wear testing machine. Transition from ultra-mild wear to mild wear and mild wear to severe wear depends on tribolayer, speed, and load. Pin on Disc wear test are carried out at load of 1kg to 14 kg and speed of 200 rpm to 1400 rpm. The wear rate and wear coefficient are evaluated for all the load and speed used in the test. Wear maps are constructed for 5%, 10%, 15% and 20% volume fraction reinforced composite. Wear rate, wear track morphology, wear debris and noise during wear test are considered for the identification of wear mechanism. From the developed wear map it is concluded that four wear regions for composite and three wear regions for unreinforced alloy exists. The transition load and speed for various wear mechanisms are determined from the developed wear map. Particulate composite subjected to dry sliding wear increase in volume fraction, decrease in speed and load delays the transition of wear mechanism. Seizure occurs at high load and high speed with large deposits of softer material. Wear map for the composite with higher volume fraction indicates lower wear rate and wider mild wear region