Material Volume Loss Research Articles

Effect of Cr3C2 content on the tribo-corrosion behaviors of Cr3C2-NiCr/DLC duplex coatings

Duplex coatings consisted of a Cr3C2-NiCr intermediate layer with varying carbide content and a top DLC film were fabricated by combining high-velocity oxygen-fuel (HVOF) and physical vapor deposition (PVD) methods. The study focused on effect of Cr3C2 content in the intermediate layer on the tribo-corrosion behaviors of the Cr3C2-NiCr/DLC duplex coatings. The result showed that as the Cr3C2 content increased, the porosity of the duplex coating increased gradually, leading to a decrease in corrosion resistance. The tribo-corrosion behaviors of the duplex coatings were ultimately governed by the synergistic effect of their tribological and electrochemical performances. Notably, the Cr3C2 (35 wt%)-NiCr/DLC duplex coatings exhibited a relatively positive corrosion potential, a low corrosion current density, and the lowest wear rate, indicating superior tribo-corrosion resistance. Further increasing the Cr3C2 content led to a continuous increase in the promotion effect of corrosion on wear, especially when the Cr3C2 content was 80 wt%, the material volume loss caused by this effect accounted for 61.37 % of the total. The predominant wear mechanism of the duplex coatings changed from abrasive wear to corrosion wear with the increase of Cr3C2 content.

Evaluation of the Depth and Width of Cuts after Controlled-Depth Abrasive Water Jet Machining Using Low Pressure.

The presented paper is focused on the evaluation of material removal during machining via an abrasive water jet with a controlled depth of cut. In the introductory parts of the work, a theoretical analysis of water jet technology and an analysis of the current state of the problem are presented. The experimental part of the work is devoted to testing the effects of technological parameters on material removal from the point of view of the maximum erosion depth and volume loss of material during machining with a low water pressure of 50 MPa. The tested material was a Ti 6Al 4V titanium alloy. The experiments were carried out by changing the traverse speed of the cutting head, the mass flow of the abrasive and the angle of inclination of the cutting head, according to the DoE 33 experiment plan. The obtained values were evaluated using the method of variance (ANOVA) and regression analysis. Furthermore, the values of the width of the erosion track and the maximum and minimum erosion effects for both tested materials were evaluated.

Evaluation of tribocorrosion performance of Ti6Al4V alloy in simulated inflammatory and hyperglycemic microenvironments

The poor tribocorrosion resistance of the Ti6Al4V alloy limits its wide applications in orthopedics. In addition, the tribocorrosion performance and mechanism of the Ti6Al4V alloy are not clear in some clinically specific pathological settings, such as peri-implantitis and diabetes. In this work, the tribocorrosion performances of the Ti6Al4V alloy in simulated body fluids (SBF) containing H2O2 and glucose were investigated to analyze the degradation behavior in the simulated inflammatory and hyperglycemic microenvironment. The tribocorrosion tests were carried out on a tribometer equipped with a three-electrode system electrochemical workstation. The material volume loss of the Ti6Al4V alloy in the high glucose environment (6 g/L) is 3.1 times more than that in the glucose-free environment, while H2O2 does not increase the material volume loss. The continuous corrosion product film on the Ti6Al4V surface in the SBF with H2O2 acts as a lubricant in mechanical wear, while the Ca and Mg-containing mineralized film formed in the high glucose environment increases the coefficient of friction (COF) during sliding. These results suggest that diabetic patients may be at a higher risk of the implant failure due to the tribocorrosion. This finding also provides a valuable reference for the placement of titanium-based implants in specific pathological settings in orthopedics.

Performance Evaluation of Austempered Ductile Iron Camshaft Low Alloyed with Vanadium on an Electric Spin Rig Test

Arbomex S.A. de C. V. is one of the largest worldwide manufacturers of ductile cast iron camshafts, produced by means of the phenolic urethane no-bake sand mold casting method and cold box by stack molding technology. As a result of the development of high-strength ADIs, low alloyed with vanadium, for camshaft manufacturing, previous results were published on the as-cast process and the austempering heat treatments applied to the camshafts. In the present work, camshafts of ADIs, low alloyed with 0.2 and 0.3 wt.% V, were produced at austempering temperatures of 265 and 305 °C. The performance of the new camshafts was evaluated by wear testing to ensure the function and durability of the camshafts by means of the block-on-ring wear test and a valve train system to evaluate the volume loss of material removed and the geometrical changes of the camshaft, respectively. The ADIs heat treated to 265 °C showed a microstructure constituted of fine ausferrite that aided in obtaining the highest wear resistance in the block-on ring wear test. No wear or pitting evidence was detected on the camshaft lobes and roller surfaces after the OEM test protocol during the electric spin ring test at low and high conditions for the ADI alloyed with 0.2 wt.% V heat treated at 265 °C.

Organic-inorganic in-situ hybrid aluminum dihydrogen phosphate binder for enhancing tribocorrosion resistance of ceramic coatings

Aluminum dihydrogen phosphate (AP) is modified through organic-inorganic in-situ hybridization and employed as a binder to prepare the chemically bonded phosphate ceramic coatings on AISI 304 L stainless steel. The chemical structure of the hybrid AP binder, mechanical properties and tribocorrosion behavior of the hybrid AP coatings (HAPC) are investigated. The results demonstrate that AP is successfully hybridized with methyltriethoxysilane (MTES) and a chemical structure with P-O-Si as the framework is created. The hybrid AP as a binder improves the hydrophobicity, cohesion and bonding strength of ceramic coatings. In addition, the corrosion current density and total material volume loss of HAPC are lower than those of pure AP coatings, whether under pure corrosion or tribocorrosion. In tribocorrosion experiments, the pure mechanical wear and the wear induced by corrosion dominate the total volume loss of the coating. The filamentous substances generated inside the HAPC enhance the pull-out resistance of the alumina particles and the cohesion of coatings, which can reduce the purely mechanical wear behavior. Besides, the filamentous substances can also fill the holes and cracks inside the coating, extending or blocking the diffusion path of the corrosive medium, which can significantly reduce the friction behavior generated by corrosion induction. Based on these two aspects, the hybrid AP binder effectively enhances the tribocorrosion resistance of ceramic coatings.

INEW method for experimental-numerical locomotive studies focused on rail wear prediction

Locomotive-track interaction is commonly represented by a complex mechanical system which is modelled in numerical studies. Numerical studies alone are not enough to precisely describe the behaviour of this mechanical system due to the various elements that can only be delivered from field and laboratory experimental programs. One such element is wheel-rail wear that has been found to contribute a considerable portion of the total cost of maintaining heavily used railway systems. Simulation studies are typically used for predicting wear of wheels and rails, but the majority of these do not consider in-train forces nor provide detailed modelling of traction and braking events and often rely on historic wear rates for comparable materials, reducing the accuracy of the wheel-rail volume loss estimation. This paper proposes a methodology for wear rate experimental measurements that allow improving the accuracy of wear analyses using dynamic simulations. The proposed method considers in-train forces by performing longitudinal train simulations whose results are then implemented on a detailed locomotive vehicle dynamic model with a traction mechatronic system co-simulation approach. The wheel-rail contact stress and slip results are then post-processed into a Dynamic Load Spectrum that contains contact stress and wheel slip occurrences. The Dynamic Load Spectrum was used to measure the wear rates for Australian AS60 head hardened rail steel material operating in combination with Class B wheel steel material. The experimental program delivered more realistic wear rates that correspond to actual industry operational scenarios. The measured wear rates were used to estimate the rail material volume loss for a specific train trip.

A novel use of hybrid Cryo-MQL system in improving the tribological characteristics of additively manufactured 316 stainless steel against 100 Cr6 alloy

Reflecting the broad interest in additive manufacturing (AM), this study focuses on the tribological behavior of 316 L stainless steel against 100 Cr6 alloy under various cooling environments. Tribological experiments were conducted on additively manufactured 316 stainless steel using a ball-on-flat tribometer under dry, minimum quantity lubrication (MQL), cryogenic, and hybrid cryo+MQL conditions. Subsequently, the most critical tribological variables such as friction forces, volume loss, wear depth, and micrographs were investigated. The results revealed that the combination of cryo and MQL cooling conditions are helpful in improving the tribological performance while minimizing material volume loss and wear rates. Cryo+MQL condition shows better performance based on volume loss as 2.33, 11.2 and 14.8 times than MQL, cryo and dry conditions, respectively.

A baseline-free method for damage identification in pipes from local vibration mode pair frequencies

As structural systems approach their end of service life, integrity assessment and condition monitoring during late life becomes necessary in order to identify damage due to age-related issues such as corrosion and fatigue and hence prevent failure. In this paper, a novel method of level 3 damage identification (i.e. detection, localisation and quantification) from local vibration mode pair (LVMP) frequencies is introduced. Detection is achieved by observation of LVMP frequencies within any of the vibration modes investigated while the location of the damage is predicted based on the ranking order of the LVMP frequency ratios and the damage is quantified in terms of material volume loss from pre-established quantification relations. The proposed method which is baseline-free (in the sense that it does not require vibration-based assessment or modal data from the undamaged state of the pipe) and solely frequency-dependent was found to be more than 90% accurate in detecting, locating and quantifying damage through a numerical verification study. It was also successfully assessed using experimental modal data obtained from laboratory tests performed on an aluminium pipe with artificially inflicted corrosion-like damage underscoring a novel concept in vibration-based damage identification for pipes.

Using the developed cavitation test to evaluate erosion resistance of cermet thermal sprayed coatings

Many machinery parts working in contact with a fast-flowing fluid flow (e.g. turbine blades of hydroelectric power plants, valves, pump impeller blades, ship propellers, cooling systems for various units, etc.) are subjected to such type of wear as cavitation erosion. An important objective is to eliminate or reduce cavitation erosion so as to achieve a considerable economic effect. This research uses a patented technique developed to evaluate the cavitation erosion resistance of cermet thermal spray coatings (WC–10Co4Cr and WC–20CrC–7Ni). These coatings were prepared using high velocity air fuel thermal spraying (HVAF). The aim of this study is to test a new technique for evaluating coating cavitation resistance, which differs from the standard one by specimen positioning relative to the testing liquid. In addition, scanning electron microscopy (SEM) was used to analyze the initial structure of the coatings prepared and study their behavior after cavitation exposure. The material volume loss criterion during the cavitation test was used to evaluate the coating resistance. The results of cavitation tests showed that the WC–20CrC–7Ni coating has a somewhat higher cavitation resistance than that of WC–10Co4Cr despite its slightly lower average hardness (850±90 HV0.5 versus 950±60 HV0.5). The study of coating surfaces and cross-sections showed that they feature by different erosion mechanisms. It can be concluded that the presence of defects (pores) in the coating structure is the main reason for reducing their cavitation erosion resistance. Therefore, the developed technique proved effective in obtaining experimental data to analyze cermet thermal spray coatings for cavitation wear.

The tribocorrosion behaviour of YSZ coating deposited on stainless steel substrate in 3.5 wt% NaCl solution

The YSZ coating was applied to 304 stainless steel substrate by atmospheric plasma spraying technology, and its electrochemical and tribological properties in 3.5 wt% NaCl solution were studied. In electrochemistry, under the action of cathode and anode potential, observe the changes of corrosion current density and EIS before and after wear. The results show that the YSZ coating has a very low corrosion current density during wear and corrosion compared to 304 stainless steel, and after the condition of the anode potential is applied, the effect of friction on the electrochemical impedance of the YSZ coating is very low, while the 304 stainless steel Impedance performance decreases; In terms of tribology, the friction coefficient of 304 stainless steel in 3.5 wt% NaCl solution is easily affected by potential, and the friction coefficient of YSZ coating relative to 304 stainless steel only changes under high potential. As the potential increases, the material volume loss of 304 stainless steel and YSZ coating increases linearly. From the data, the volume loss caused by the corrosion and wear of 304 stainless steel is much higher than that of YSZ coating.

The Wear Behavior of Various Monolithic Ceramics after Wear Simulation against Human Enamel.

Abstract Purpose: To evaluate and compare the surface roughness (SR), weight loss and volume loss of three monolithic ceramics; monolithic zirconia functional explore (f.explore), lithium disilicate glass ceramic (IPS.e. max CAD), and lithium silicate (Obsidian) and their wear effect on the natural enamel. Materials and Methods Twenty four ceramic disc and twenty four natural tooth antagonist were used. Samples were divided according to ceramic materials into 3 groups (n=8). Group I: f.explore, Group II: Obsidian, and Group III: IPS e.max CAD. SR, weight loss and volume loss of the discs and the enamel were verified before and after exposing the specimens to chewing simulator. Digital and Scanning electron microscopic evaluations were used. Results: The roughness differences changes between all groups was non-significant. While Obsidian antagonist cusp recorded the highest roughness followed by f.explore, whereas, e.max recorded least value. The greatest mean weight loss of materials was recorded in e. max followed by f.explore, where the lowest was recorded for Obsidian significantly.The greatest mean weight loss for antagonist cusp was recorded for f.explore followed by obsidian with insignificant difference ,while the lowest weight loss significantly was recorded in e.max antagonist cusp . The greatest mean volume loss of materials was recorded in e. max followed by f.explore where Obsidian recorded least value significantly. The greatest mean antagonist cusp volume loss was recorded in f.explore followed by e.max , whereas obsidian recorded least value. Conclusions: Obsidian is more wear resistant than e.max and f.explore and produced the least wear in opposing enamel.

Resistance of an Optimized Ultra-High Performance Fiber Reinforced Concrete to Projectile Impact

The scope of this paper is to investigate the performance of ultra-high performance fiber reinforced concrete (UHPFRC) concrete slabs, under projectile impact. Mixture performance under impact loading was examined using bullets with 7.62 mm diameter and initial velocity 800 m/s. The UHPFRC, used in this study, consists of a combination of steel fibers of two lengths: 6 mm and 13 mm with the same diameter of 0.16 mm. Six composition mixtures were tested, four UHPFRC, one ultra-high performance concrete (UHPC), without steel fibers, and high strength concrete (HSC). Slabs with thicknesses of 15, 30, 50, and 70 mm were produced and subjected to real shotgun fire in the field. Penetration depth, material volume loss, and crater diameter were measured and analyzed. The test results show that the mixture with a combination of 3% 6 mm and 3% of 13 mm length of steel fibers exhibited the best resistance to projectile impact and only the slabs with 15 mm thickness had perforation. Empirical models that predict the depth of penetration were compared with the experimental results. This material can be used as an overlay to buildings or to construct small precast structures.

Three-body dry abrasive wear properties of 15–5 precipitation hardening stainless steel produced by laser powder bed fusion process

Additive manufacturing (AM) has been widely considered as a popular manufacturing technique for the production of specific engineering components by various industries. Among the various AM techniques, laser powder bed fusion process (L-PBF) has the potential to make defect-free parts with good material properties. However, the mechanical properties are greatly dependent on the part quality, and the heat treatment processes they are subjected. The current study compares the abrasive wear resistance property of L-PBF 15-5 Precipitation Hardening (PH) Stainless Steel to that of the conventionally manufactured wrought counterpart in the aged condition (W_H900). The L-PBF parts were tested in as-built (S_AB), solution annealed (S_SA) and aged (S_H900) conditions. The test results showed better wear resistance for the L-PBF specimens as compared to the wrought specimens. The fine grain size of the L-PBF specimens formed a large network of grain boundaries and strengthened the bulk properties. The material volume loss of S_H900 specimens decreased by 21.45% compared to the W_H900 specimens during dry abrasion tests. From the microstructural characterization of the wear surface, micro-cutting and micro-ploughing appeared to be the primary material removal mechanisms, along with some regions showing micro-cracking effect.

In Vitro Wear Resistance of Self-Adhesive Restorative Materials.

To investigate simulated localized and generalized wear of self-adhesive restorative materials. Three commercially available restorative materials and one experimental material with self-adhesive properties were evaluated. The experimental material was tested in both light-cured and self-cured conditions. Activa (A), Fuji II LC (F), and Equia Forte (E) and the experimental material ASAR-MP4 (S) were investigated. Two kinds of wear were simulated in an Alabama wear machine. Localized wear was simulated with a stainless-steel ball bearing antagonist and generalized with a flat-ended stainless-steel cylinder antagonist. The wear challenge was carried out in an aqueous slurry of polymethyl methacrylate beads. Material volume loss was measured on polyvinyl siloxane replicates of each worn surface using a Proscan 2100 noncontact profilometer in conjunction with Proscan and AnSur 3D software. There were significant differences (p < 0.05) among the materials for both generalized and localized wear. The experimental material in both curing modes exhibited significantly less localized wear than F and A and significantly less generalized wear than F and E. Self-adhesive materials offer unique handling properties for direct placement of posterior restorations in permanent teeth. The experimental material ASAR-MP4 generated similar wear values to the other self-adhesive materials tested.

Tribofilms on CoCrMo alloys: Understanding the role of the lubricant

The tribological activation of a passive metal alloy in an aqueous biological environment have been highlighted by many researchers; better known as bio-tribocorrosion. Tribocorrosion processes, which can be found at a number of metal-based biomedical implant interfaces, can be affected by lubricant species such as proteins, amino acids and salts. To date, researchers have quantified how the presence of organic species and the environment affect the tribological and corrosion process. However, the nature of the bio-films is still broadly to be explored. This study aims to understand how the lubricant - surface interactions influence the evolving frictional, corrosion and material volume loss from CoCrMo alloys and how the formation of any tribo-film at the interface may influence the aforementioned processes. This current research uses reciprocating tribocorrosion tests of CoCrMo surfaces in saline, protein, and protein-free cell culture medium lubricants (0.9% NaCl, 25% Foetal Bovine Serum (FBS) diluted in Phosphate Buffered Saline (PBS), Dulbecco's Modified Eagle Medium (DMEM) and 25% FBS in DMEM solutions). Results show the addition of organic constituents give a better tribology and corrosion performances. XPS confirmed that chemical reactions happened on the tested surfaces. Calcium, phosphorus and sulphur are shown to be catalysed to react in tribology-induced processes and have important roles in tribocorrosion. These results contribute to the understanding of protein-metal interactions occurring in tribofilm formation on wearing surfaces.

Focus variation measurement and advanced analysis of volumetric loss at the femoral head taper interface of retrieved modular replacement hips in replica

This paper offers a technique for non-contact assessment of material volume loss at the femoral head taper interface of modular replacement hips with novel use of the focus variation principle. A novel 3D to areal data conversion technique also allows powerful areal data analysis techniques to be applied to point cloud (3D) measurements for volume loss optimisation. Accurate characterisation of retrieved femoral head tapers is important to assess their in vivo performance particularly with respect to the bio toxicity of wear and corrosion products.A cohort of 8 retrieved femoral heads showing a wide range of degradation (0.5mm3 < volume loss < 12mm3) [1] was selected for the development of this technique. Using this common cohort of retrieved hips, the current technique was benchmarked against the well proven roundness measurement machine (RMM) method. This existing technique generates areal (2.5D) data and exploits a range of existing areal analysis techniques to optimise volume loss assessment. For benchmarking continuity and to exploit the same areal techniques, volume loss analysis for the current technique was carried out using the software written for the existing RMM method.The focus variation instrument’s integrated language was used to write script to convert (un-wrap) the taper surface 3D data into areal format.The current method shows a mean absolute difference in volume loss of 14% (-12% signed) from that of the benchmark with a range of 1% to 27%. The spread of measured values is significantly higher for the current method than for the benchmark. However, it is noted that replication can offer the advantage of capturing the whole taper surface on some taper types where physical access is limited for a stylus based roundness method.The current technique is also compared to the existing Redlux™ technique in which replicated female tapers are measured using a confocal instrument. The current technique is shown to have comparable performance to the Redlux™ technique but offers a more sophisticated methodology for volume loss analysis. In addition the current technique offers new instrumentation and analysis tools to the field.Small uncontrolled casting variations are noted in the current technique, resulting in poorer performance with small volume loss samples where the influence of this effect is most pronounced. However, given the simplified assumptions of the volume loss calculation where results may be skewed by deposits, some uncertainty will be evident with any approach.

Fracture resistance and 2-body wear of 3-dimensional–printed occlusal devices

Statement of problemPolymeric material for 3-dimensional printing can be used to fabricate occlusal devices. However, information about fracture resistance and wear is scarce. PurposeThe purpose of this in vitro study was to investigate the fracture resistance and 2-body wear of 3-dimensional–printed (3DP) (FotoDent splint; Dreve Dentamid GmbH), milled polymethylmethacrylate (CAM) (Temp Basic; Transpa 95H16, Zirkonzahn GmbH), and conventionally fabricated polymethylmethacrylate (CAST) (Castdon; Dreve Dentamid GmbH) occlusal devices. Material and MethodsA total of 96 occlusal devices were prepared according to the 3 different manufacturing techniques 3DP, CAM, and CAST (n=32). For each manufacturing technique, specimens were further divided into initial fracture resistance tests (n=16) and artificial aging in the mastication simulator (50 N, 37°C) with 2-body wear followed by fracture resistance tests (n=16). The fracture resistance was determined using a universal testing machine (1 mm/min). The wear was measured after 20 000 and 120 000 mastication cycles with the replica technique, mapped with a laser scanner, and quantified in R software. Data were analyzed using a 2-way ANOVA followed by a 1-way ANOVA with Scheffé or Games-Howell post hoc tests, repeated measures ANOVA with corrected Greenhouse-Geisser P values, and the Levene, Mann-Whitney, and paired t tests (α=.05). ResultsCAM presented higher initial fracture resistance than 3DP or CAST (P<.001). After mastication simulation, CAM followed by 3DP showed higher fracture resistance than CAST (P<.001). Mastication simulation decreased the fracture resistance for CAM and CAST (P<.001) but not for 3DP (P=.78). Three-dimensional–printed occlusal devices showed the highest material volume loss, followed by CAM and the lowest in CAST (P<.001). ConclusionsThree-dimensional–printed occlusal devices showed lower wear resistance and lower fracture resistance than those milled or conventionally fabricated. Therefore, only short-term application in the mouth is recommended. Further developments of occlusal device material for 3-dimensional printing are necessary.

Specific energy and the modified rubber wheel abrasion test

In the oil sands industry a single ultra-class shovel tip can lose more than 35kg of steel mass in one operating day. Equipment downtime is significantly increased with frequent stoppages to replace worn shovel teeth. This leads to a substantial loss in shovel availability and utilization, as well as a considerable increase in consumable cost.This paper develops a means to predict the wear performance of shovel tips based on field data through the use of specific energy (Es), which is defined as the friction energy required to cause a unit volume loss of material (Nm/m3). A modified rubber wheel abrasion test (similar to ASTM-G65) is presented for the determination of Es. Results show that it is possible to predict the performance of shovel tips. It is also found that Es provides an index to quantify the resistance of wear materials to abrasion under specific abrasive conditions.

Relationship of surface damage appearance and volumetric wear in retrieved TKR polyethylene liners.

Recently developed techniques have enabled volume loss measurements on surgically retrieved total knee replacements (TKR). However, it is not well understood how volume loss relates to polyethylene surface damage appearance. Sixty-four fixed bearing cruciate retaining components retrieved from revision and postmortem surgeries were analyzed for penetration and volume loss on the topside articular surface. An autonomous reconstruction method was used to approximate the original unworn surfaces. Surface damage patterns were also mapped using a video microscope, and each pattern's contribution to volume loss was calculated. With consideration for creep, a total wear rate of 12.9 ± 5.97 mm3 /year was found for the population. The penetration rate was 0.035 ± 0.017 mm/year medially and 0.034 ± 0.011 mm/year laterally, of which the location on the plateau varied greatly. Although striated patterns contributed to most to volume loss, damage patterns generally were only moderate predictors of material volume loss. © 2016 Wiley Periodicals, Inc. J Biomed Mater Res Part B: Appl Biomater, 105B: 2053-2059, 2017.

Solid Particle Erosion of Selected HVOF Sprayed Coatings

The paper involves the subject and the chosen results of up to now solving of work package “Development of advanced surface treatment of components used in parts of turbines working under the condition of operational temperatures of steam using the HP/HVOF technology of thermal spraying” of the Competence Centre project “Centre of Research and Experimental Development of Reliable Energy Production”. The subject belongs to the field of material engineering and results of solving contribute to fulfilling the main project aim, which is a long time safeguarding of safe, reliable and financially available both classical thermal and nuclear sources of electric power, which consists in extending service life of existing and building new turbo generator blocks. The erosion wear resistance is one of the areas, which were observed. The impact of hard particles on the surface under variable impact angles was simulated in laboratory conditions using an in-house equipment. The wear resistance of selected HVOF sprayed hardmetal and super-alloy coatings was measured and the wear mechanism was evaluated. A strong influence of impact angle on both material volume loss and wear mechanism was monitored. The superior erosion wear properties of super-alloy coatings were proved, regardless the higher hardness of hardmetal coatings.