Improved Wear Resistance Research Articles

Effect of Electrofriction Treatment on Microstructure, Corrosion Resistance and Wear Resistance of Cladding Coatings

In recent years, the issue of increasing the wear resistance of the working bodies of agricultural machinery designed for cutting and breaking the soil has received special attention. The surface layers of working bodies of agricultural machinery during operation are subjected to intensive abrasive wear, which leads to rapid wear of equipment and a reduction in its service life. The induction cladding method using materials such as Sormait-1 is widely used to increase the wear resistance of tool working surfaces. However, after coating, additional heat treatment is required to improve the physical and mechanical properties of the material and increase its durability. In electrofriction technology (EFT) hardening, the surfaces of the parts are subjected to melting under the influence of electric arcs. In this work, three types of surface treatment of L53 steel have been investigated: induction cladding using Sormait-1, electrofriction treatment, and a combination of induction cladding followed by electrofriction treatment. The microstructure was analyzed using optical microscopy and scanning electron microscopy. Erosion and abrasion tests were carried out in accordance with ASTM G65 and ASTM G76-04 international standards to evaluate the wear resistance of the materials under mechanical stress. A dendritic structure was formed after the induction cladding of the Sormait-1 material, but subsequent electrofriction treatment resulted in a reduction of this dendritic structure, which contributed to an increase in the hardness of the material. However, the highest hardness, reaching 965 HV, was recorded after electrofriction treatment of L53 steel. This is explained by needle martensite in the structure, which is formed as a result of quenching. Further, the influence of structural characteristics and hardness on erosion and abrasion wear resistance was examined. The analysis showed that the material microstructure and hardness have a decisive influence on the improvement of wear resistance, especially under conditions of intensive erosion and abrasive friction.

Increasing the Wear Resistance of the Impellers of Electrical Centrifugal Submersible Pumps Through Repair

Objective: This research investigates the challenges of maintaining electrical submersible pumps (ESP) and develop effective repair techniques to enhance their reliability and efficiency. Theoretical Framework: The research draws upon theories and models related to pump maintenance, materials science, and corrosion prevention. Methodology: A case study approach was adopted, focusing on a Weir VTP submersible pump in continuous operation for 15 years. The pump's condition was assessed, and the root causes of erosion and corrosion were identified. Laser cladding with a TiC coating was applied to the damaged areas. Results and Discussion: The results demonstrated a significant improvement in the pump's wear resistance and overall efficiency following the laser cladding treatment. The TiC coating effectively mitigated the effects of erosion and corrosion, extending the pump's lifespan and reducing maintenance costs. Research Implications: The findings of this research contribute to the development of more effective maintenance strategies for submersible centrifugal pumps. The use of laser cladding with TiC coatings can be applied to other types of pumps and machinery operating in harsh environments. This research also highlights the importance of regular inspections and preventive maintenance. Originality/Value: This study provides a practical solution to the problem of erosion and corrosion in submersible centrifugal pumps. The application of laser cladding with a TiC coating is a relatively novel approach, offering a more effective repair method compared to traditional techniques. The results can be applied to improve the reliability and efficiency of pumps in various industries.

Cold‐Sprayed Boron‐Nitride‐Nanotube‐Reinforced Aluminum Matrix Composites with Improved Wear Resistance and Radiation Shielding

In this study, the influence of cold‐spray processing on the integration of 1D boron nitride nanotubes (BNNTs) into aluminum (Al) matrix composite deposits is delved into. Successful deposition of Al‐BNNT composite is achieved by pre‐spray dispersion of BNNTs in Al powder via wet mixing aided by ultrasonication. Pure Al powder deposition at 380 °C is limited by nozzle clogging, restricting the deposit thickness to 0.2 mm, while the presence of BNNTs enables longer spraying due to nozzle cleaning and damping by hard BNNTs, allowing thicker Al‐BNNT deposits of about 2 mm. Microstructural analysis reveals severely deformed Al splats decorated with a uniformly distributed network of BNNTs at the intersplat boundaries, reducing the porosity from 8% to 4% and increasing the splat flattening by 40%. Tribological testing demonstrates resistance of BNNTs to normal force, resulting in a 21% improvement in coefficient of friction and a 65% reduction in wear volume in the Al‐BNNT composite. Additionally, incorporating 3 vol.% BNNTs enhances the neutron radiation shielding by 35%. These improvements in the composites are attributed to reduced porosity and the inherent properties of BNNTs, such as high strength, the ability to produce tribofilm lubrication during dry sliding wear, and their high neutron absorption cross‐sectional area.

Investigation of phase transformation and mechanical properties of silicon addition on AlCrFeMnNi high entropy alloys

Abstract This paper examines the impact of silicon in the AlCrFeMnNi high-entropy alloy system, focusing on both its microstructural and mechanical properties. Alloys with varying silicon content (x = 0, 0.3, 0.6, 0.9 atomic ratio) were synthesized using vacuum arc melting. The phase formation of these high-entropy alloys was analyzed using X-ray diffraction to comprehend the alloying process behaviour. The findings revealed that the solidification of the AlCrFeMnNi alloy occurred in dendritically, with dendrite cores containing Cr, Fe, and Ni, while interdendritic regions were enriched in Al and Ni after adding Silicon. Increasing the silicon content from 0 to 0.9 led to significant improvements in microhardness and wear resistance. This improvement is attributed to the reinforcement of grain boundaries provided by silicon. The formation of an Al and Ni rich B2 phase is crucial in resisting dislocation motion and preventing further deformation. Additionally, the addition of silicon led to improved corrosion resistance, as demonstrated by potentiodynamic polarization measurements. However, a trade-off was observed between compressive strength and ductility: compressive strength increased with higher silicon concentrations, but at the expense of ductility.

Improving tribological efficiency of isopropyl palmitate oil with cellulose nanocrystals: a sustainable approach for high-performance lubricants

AbstractThis article explores the potential of cellulose nanocrystals (CNCs) as a lubricant additive for isopropyl palmitate (IPP) oil to enhance its tribological performance. CNCs, derived from renewable sources, offer a sustainable and environmentally friendly alternative to traditional lubricant additives. A two-step method was used to prepare the nanolubricants, with visual control and dynamic light scattering measurements to assess their temporal stability. The viscous behavior of the nanolubricants, in terms of viscosity and viscosity index, was evaluated at different temperatures. The study assesses the effectiveness of CNC/IPP oil blends as lubricants through tribological tests, including evaluations under pure sliding and rolling–sliding conditions. Studies on worn surfaces were conducted using surface roughness analysis, Raman mapping, and XPS, and the thermal stability was examined to determine their suitability for different operating conditions. CNCs significantly reduce friction by up to 44% and improve wear resistance compared to the neat IPP base oil, presumably due to a self-repairing effect. Furthermore, an improvement of the thermal conductivity of pure IPP base oil has been revealed with increasing CNC concentration. This study enhances the understanding of cellulose nanocrystals as lubricant additives and their potential to transform traditional lubricating oils into high-performance and sustainable solutions.

Enhanced tribological performance of PLA/CNC composites: A comparison with phenolic resin and nylon

PLA has been developed to replace plastic because it is degradable. For more advanced applications, more research is needed on PLA. This study investigates the tribological properties of phenolic resin, nylon, and PLA/CNC composites under varying sliding distances and loads. Both phenolic resin and nylon demonstrate exceptional wear resistance and stable friction coefficients. PLA/CNC composites exhibit improved wear resistance, showing a 17% reduction in friction coefficient at a 3 wt.% CNC content. While the wear volume of PLA/CNC composites increases with sliding distance, the addition of CNC enhances PLA’s self-lubricating properties and overall wear resistance. The correlation between dissipated energy and wear volume confirms that higher CNC content significantly improves the durability of PLA. These findings suggest that CNC has considerable potential as an additive to enhance the tribological performance of PLA composites, making it a valuable material for various applications requiring superior wear resistance.

Effects of Al variations on the microstructure and mechanical properties of laser-cladding AlxNbMo0.5Ti1.5Ta0.5Cr0.5 refractory high-entropy alloy coatings

Lightweight refractory high-entropy alloy coatings (RHEAcs) of AlXNbMo0.5Ti1.5Ta0.5Cr0.5 (where x = 0, 0.1, 0.2, and 0.3) were fabricated on 316L stainless steel surface by pre-placed powder laser cladding (LC) technology. The incorporation of Al element significantly enhanced the forming quality of coatings, resulting in nearly defect-free coatings with a thickness of 1.2-1.4mm. Microstructural analysis revealed that the coatings were primarily composed of body-centered cubic (BCC) solid solution and C15-Laves phase. Due to the influence of a single brittle BCC phase, the Al-free coating exhibited high strength and brittleness, leading to numerous defects caused by thermal stress. The introduction of Al element refined the microstructure and facilitated the formation of Laves phases at grain boundaries, thereby alleviating stress to a certain extent. Consequently, the microhardness of the RHEAcs was significantly higher than that of the substrate, with the Al-free coating achieving the highest microhardness of 1250 HV, which was 5.89 times that of the substrate. Wear resistance results indicated that, prior to annealing, RHEAcs with varying Al content outperformed 316L stainless steel. Post-annealing, the coatings exhibited significantly lower friction coefficients compared with the annealed 316L substrate. The Al-free coating showed significant accumulation of abrasive particles, leading to severe abrasive and oxidative wear. Conversely, post-annealing oxidation induced the formation of dense and directional oxide accumulation, resulting in a notable improvement in wear resistance. Finally, the underlying strengthening mechanisms have been proposed and analyzed.

Enhancing microstructure, nanomechanical and tribological properties of TiAl alloy processed by spark plasma sintering with Si3N4 ceramic particulates addition

TiAl matrix composites reinforced with varying weight fractions of Si3N4 ceramic particles were successfully fabricated by the spark plasma sintering method. The microstructure, nanomechanical and tribological properties of the sintered composites were investigated. The microstructural characterization revealed the evolution of a quasi-continuous and continuous network structure consisting of minor fractions of in-situ formed Ti2AlN, unreacted Si3N4 ceramic particles and dominant Ti5Si3 intermetallic phases within the TiAl matrix at Si3N4 content above 1.5 wt%. The in-situ precipitated phases enhanced the nanomechanical and tribological properties of the composites. The 7Si3N4/TiAl composite displayed the best nanomechanical properties, including nanohardness, elastic modulus, and H/Er ratio among the sintered samples. The specific wear rate of the composites decreases with increasing reinforcement content. 7Si3N4/TiAl composite exhibited the lowest specific wear rate of 0.38 ± 0.55 10-4 mm3/Nm, representing a 95.6% improvement in wear resistance compared to the unreinforced pure TiAl alloy. The improved wear performance of the composites was attributed to their load-bearing capacity and wear resistance of the hard, in-situ Ti2AlN, Ti5Si3 and unreacted Si3N4 particles in the TiAl matrix. The composites displayed a transition from adhesive wear to predominantly abrasive wear where the hard Si3N4 particles prevented direct metal-to-metal contact and facilitated the formation of a protective tribolayer, resulting in enhanced wear resistance. Hence, the developed Si3N4/TiAl composites are suitable for various structural and tribological applications.

The effect of cryogenic treatment on a high Co bearing DIN 1.2888 steel used as die in hot forging process

Abstract Hot work steels used as dies in metal forming processes must endure harsh conditions, typically achieved through a martensitic structure. However, retained austenite can persist after martensitic transformation, negatively impacting mechanical properties. Cryogenic treatment (CT) refines martensite, reduces retained austenite, and increases fine carbide density, thus enhancing performance. DIN 1.2888, a hot work tool steel with high cobalt content (~10%) and low carbon content (~0.2%), is less studied concerning the effects of CT. The objective of this study was to investigate how cryogenic treatment affects the mechanical and microstructural properties of DIN 1.2888 steel. Samples underwent conventional heat treatment (HT) and CT at -100, -140, and -180°C for 6 hours, followed by double tempering. Various analytical methods, including X-ray diffraction (XRD), scanning electron microscopy with energy-dispersive X-ray spectroscopy (SEM-EDS), and Vickers Microhardness tests, were used to examine the samples. Wear mechanisms were evaluated through pin-on-disc tests under different loads, and impact toughness was measured both at room temperature and the working temperature of dies (350°C). Results indicated that lowering the cryogenic treatment temperature resulted in a slight increase in hardness values from 507HV for the heat-treated sample to 529HV for the sample treated at -180°C. Additionally, the impact toughness improved significantly, with values rising from 12.35J for the heat-treated sample to 23.44J at 350°C for the cryogenically treated sample at -180°C. Wear rates also decreased by approximately 50%, particularly at higher cryogenic treatment temperatures. The improvement in wear resistance was attributed to finer carbide precipitation and a more homogeneous distribution of carbides. These findings suggest that deep cryogenic treatment has a positive effect on DIN 1.2888 steel by decreasing retained austenite and increasing fine carbide density, leading to enhanced mechanical properties and extending the lifespan of the steel in die applications.

Effect of B/N dual doping on mechanical and tribological properties of Mo-S-B-N sputtered films

Doping with non-metal element is effective to improve the porous morphology and enhance the mechanical and tribological properties of transition metal dichalcogenides (TMDs) based film. However, the mechanical properties of TMDs based film with single additive should be enhanced further for better wear resistance. In this work, B/N dual-doping was used to further enhance the deformation resistance and toughness of MoS2 based films deposited by magnetron sputtering, while the effect of B/N dopants on the structure, mechanical and tribological properties has been investigated. Mo-S-B-N film with B content of 20.91 at. % and N content of 18.13 at. % consists of MoS2 and amorphous nitride/boride, in which B/N dual doping film forms a higher ordered MoS2 lamellar structure compared to B doping film. With a hardness of 11.6±0.9 GPa and improved toughness, the film achieves a low wear rate and average friction coefficient is achieved. Comparing B/N dual doping film to B doping film, the stable formation of tribolayer with more strengthened deformation resistance results in the steady friction and the improved wear resistance, while the limited TMDs reorientation leads to the slight increase of friction coefficient.

Tribological properties of polyimide coating filled with solvent-free covalent carbon quantum dots nanofluids

Novel organic coatings were developed by incorporating solvent-free covalent carbon quantum dots nanofluids (CQDs NFs) into a polyimide (PI) matrix. The tribological properties of CQDs NFs/PI composite coatings were tested using a ball-on-disk tribometer, revealing that even a low loading of CQDs NFs significantly improved tribological performance of PI. Molecular dynamics (MD) simulations and nanoindentation tests showed that CQDs NFs restricted PI molecular chain movement, enhancing mechanical properties. Additionally, CQDs NFs promoted the formation of stable transfer films on steel surfaces, improving wear resistance. This study confirms CQDs NFs' effectiveness in modifying PI composite coatings' friction and wear properties.

Simultaneous improvement of wear and corrosion resistance of microarc oxidation coatings on ZK61 Mg alloy by doping with ZrO2 nanoparticles

Simultaneous improvement of wear and corrosion resistance of microarc oxidation coatings on ZK61 Mg alloy by doping with ZrO2 nanoparticles

Improve wear resistance of C/C composites as artificial bone using diamond-like carbon coatings

In this study, diamond-like carbon (DLC) coatings and silicon-doped diamond-like (Si-DLC) coatings were prepared on the surface of C/C composites by a combination of plasma-enhanced chemical vapor deposition (PECVD) and magnetron sputtering processes. The film composition, microstructure and atomic bond structure were characterized using X-ray photoelectron spectroscopy, field-emission scanning electron microscopy and Raman spectroscopy. The mechanical properties and friction behavior related to the Si element were investigated using nanoindentation and HT-1000 high temperature friction and wear tester. The biocompatibility of the materials was also evaluated by the MG-63 proliferation test. The results indicate that Si elements were successfully incorporated into the DLC films, bonding with C and O atoms, which altered the thermal stability and microstructure of the coatings, reduced the internal stress of the films, and increased disorder. Compared to C/C composites, all coated layers exhibited lower coefficients of friction, with the formation of transfer layers and graphitization induced by friction contributing to the excellent tribological performance. Both coatings showed no cytotoxicity and demonstrated good biocompatibility. Both coatings are effective in reducing wear and chip losses in C/C composites when used as artificial bones. This work suggests that diamond-like carbon coated C/C composites can be excellent structural materials for human body in biomedical science.

Review of Surface Treatment Technology for Improving Wear Resistance of Magnesium Alloys

Background: As the lightest metal structural material in engineering, magnesium alloy has excellent mechanical properties, such as high specific strength, high specific stiffness, good damping performance, and good machinability. It is widely used in the fields of precision parts, automobiles, aerospace, and military. However, poor friction and wear performance are significant magnesium defects of the alloys, which make its use limited in some areas with high working conditions, so it is essential to improve the wear resistance of the magnesium alloy surface. Objective: The aim of this study was to summarize the technology of improving the wear resistance of magnesium alloy in recent year. The influence of different surface treatment technology for enhancing friction and wear properties was also analyzed, which could provide a reference for related scholars and researchers. Method: In this paper, the literature related to friction and wear properties of magnesium alloys in recent years were reviewed, the principles of various surface treatment technology of magnesium alloys were explained, and the advantages and disadvantages of each technology were analyzed. Results: Based on the literature analyses related to the wear resistance of magnesium alloys, the problems existing in the surface treatment technology for improving the wear resistance of magnesium alloys are summarized, and future development directions are put forward. Conclusion: Among the technologies to improve the wear resistance of magnesium alloys, the combination of various techniques can better meet the working demands. The environmentally friendly and efficient manner has a good prospect for development.

Boronize Coatings Studied with a New Mass Transfer Model.

This study examined the development of Fe2B (diiron boronize) coatings on the surface of 35NiCrMo4 steel through the thermochemical surface hardening process called boronizing. The morphology and thickness of the boronize coatings were assessed using Scanning Electron Microscopy (SEM) and optical microscopy (OM). A novel mathematical mass transfer model was developed to estimate the diffusion coefficients of boron in hard coating. The presence of uniformly distributed boronize coatings with a typical sawtooth pattern on the surface of the substrate was confirmed. The boronize coating's chemical composition and phase constituents were analyzed utilizing X-ray energy dispersive spectroscopy (EDS) and X-ray diffraction analysis (XRD). The study confirmed the presence of a single-phase boronize coating (Fe2B). Furthermore, microhardness tests indicated that the boronized specimen's surface demonstrated an average hardness of approximately 1953 HV. The wear study were conducted using the pin-on-disk method under dry debonding conditions at room temperature to estimate the coefficient of friction (COF) of the boronized (average ≈ 0.35) and untreated (0.725) specimens. The results revealed approximately 200% improvement in wear resistance due to the boronized coating. The empirical validation of the mathematical model was carried out for two additional boronizing conditions at 1223 K for 3 h and 1273 K for 1.5 h, resulting in an estimated percentage error of around 2.5% for both conditions. Additionally, an ANOVA analysis was performed, taking into account the temperature and time factors. The findings indicate that both factors exert a substantial influence on the dependent variable (u), with temperature (T) contributing 64.68%, time (t) contributing 27.37%, and the interaction of both factors (T × t) contributing 5.13%.

Combined Carburizing and Shot Peening to Increase Gear Sprocket Surface Hardness

The sprocket is a crucial motorcycle component that transferengine rotational force to the wheels. However, friction between the chain and gear during the operation leads to wear. This study aimed to enhancethe surface hardness of sprocket by combining pack carburizing and shot peening. Pack carburizing was conducted by embedding the sprocket in coconut shell charcoal powder and heating it to 850°C for 60 minutes,followed by quenching in water at 30°C. Shot peening was then applied to the carburized specimen using steel ball particles for 20 minutes at a pressure of 8 bar. Hardness testing was performed according tothe ASTM 92-17 Vickers method, andmicrostructuralanalysis was conducted using Scanning Electron Microscopy (SEM) on the best specimen results. The hardness values for untreated, carburized, and carburized + shot peened specimens were found to be 284, 302, and 424 VHN, respectively. In this study, transverse observation of the specimen showed a carburizing layer with a depth of about 8 µm. The phenomenon was related to the increase in hardness of the carburized specimen, while the effect of shot peening for 20 minutes was about 100 µm from the surface of the specimen. This caused the hardness of the combined carburizing and shot peening specimen with a pressure of 8 bar for 20 minutes to increase hardness by about 49% compared to the non-treatment specimen. This combination significantly improved the surface hardness, potentially increasing the sprocket’s wear resistance and operational lifespan.Transverse analysis revealed an approximately 8 µmdeeo carburized layer, with the shot peening effect penetrating about 100µm from the surface. This treatment combination increased the specimen’s, suggesting a significant improvement in surface hardness, wear resistance, and overall durability of the sprocket.

Micro abrasion in Fe-Cr-C-Nb alloys samples: The role of niobium

This paper addresses to analyze the role played by Niobium (Nb) in the microstructure of Fe-Cr-C alloys being tested in micro abrasion conditions (ball abrasion test). Three alloys with differences in Cr content and one of them with 5% Nb have been prepared as weld tracks under Fe-C substrate. The resulting microstructures contain carbides embedding in a metallic matrix (MMC). Significant changes in mechanical properties are expected depending on the morphology, size and distribution of carbides. Results pointed out to an improvement in wear resistance of Fe-Cr-C-Nb alloy although it showed lower values of hardness and volume fraction of carbides in comparison to the other alloys. The coefficient of friction was also affected by Nb addition. Such results evidence the possibility of using such alloy in applications that require high performance in wear resistance as mining and agriculture equipment.

Tribological and corrosion characteristics of aluminium–copper alloys reinforced with alumina nickel aluminide cermet powder

Aluminium–Copper (Al-10Cu) alloys are widely used for structural components in the aviation sector. This study focuses on the synthesis and characterisation of Al-10Cu alloy reinforced with Al2O3-30(Ni-20Al) cermet particles to evaluate their microstructural, mechanical, tribological and corrosion properties. The Al-10Cu alloy was cast with varying percentages of cermet (2% and 4%) using a controlled casting process. Comprehensive microstructural analyses, including optical microscopy, SEM and EBSD, were performed to assess the grain structure and cermet distribution. The mechanical properties were evaluated through Vickers microhardness and tensile testing, while tribological performance was assessed using a Pin-on-Disc tribometer. Corrosion resistance was investigated through exfoliation and immersion corrosion tests. The results indicated significant improvements in microhardness and wear resistance with the addition of cermet particles, while the tensile strength showed a complex interplay between ductility and brittleness. Corrosion tests revealed enhanced resistance in cermet-reinforced specimens. This study demonstrates the potential of Al2O3-30(Ni-20Al) cermet as an effective reinforcement for aluminium alloys to achieve superior performance in structural applications.

Assessing Wear Characteristics of Sprayable, Diacetylene-Containing Sensor Formulations.

This work extends recent developments in diacetylene-based, sprayable sensors by identification and assessment of formulations which facilitate their use for wearable sensing. Diacetylene-based spray-on sensors have the potential to be a widely deployed sensing technology, as they require no power and can be applied as thin coatings onto surfaces to provide a colorimetric response to target exposure. In responding to radiation, liquid-phase targets, or gas-phase targets specifically determined by the formulation of the sprayable sensor used, this technology is amenable to wearable sensors for measuring exposure to different environmental risks. Here, we provide the means to improve wear resistance, reduce false-positive signals due to wetting, and enhance color fastness for coatings of sprayable, diacetylene-based sensor formulations on cotton fabric. These sensor formulations possess polymethyl methacrylate (PMMA), which enhances the coating stability to only 8% color loss due to wear compared to 18-25% without PMMA, while maintaining the inherent ability of diacetylene-component formulations to detect radiation as well as gas or liquid phase analytes. This represents a significant step toward the use of diacetylene-based sensing formulations for wearable sensing. In the future, the form of spray-on sensor materials demonstrated here may find use in wearable sensing applications for detection of cumulative exposure to UV radiation, hydrogen peroxide vapors, or solvent exposure. We expect trends toward applications toward other wearable sensors for environmental monitoring given the well-known customizability in target response of diacetylene-containing monomers by modifying their headgroup chemistry.

Fabrication and Characterization of Advanced Selective Plated Copper Coatings Incorporating Nanosized Particles of ZnO and TiO2

This study reports preliminary results on the fabrication and characterization of selective plated copper-based coatings with enhanced surface properties and durability through the incorporation of zinc oxide and titanium oxide particles. The coatings were produced using an electrolyte containing 3% wt. zinc oxide and 1% wt. titanium oxide particles, and their microstructures, phase compositions, and mechanical properties were investigated. The results show that the incorporation of ceramic particles leads to the formation of metal-matrix composite materials with finer grain structures, improved microhardness, and enhanced wear resistance. The coating incorporating ZnO particles exhibits superior wear resistance, maintaining stable roughness values and minimal material loss, while the coating with TiO2 particles also shows improved wear resistance with moderate roughness increases.