Partial Slip Regime Research Articles

Effect of external magnetic field on the fretting wear mechanism of the ferromagnetic materials

With the widespread implementation of maglev technology in fields such as rail transit and military, it is imperative to investigate the effects of magnetic fields on fretting damage in metallic materials. This study conducted multi-parameter fretting wear tests on typical ferromagnetic counterparts in the presence of an external permanent magnetic field. Subsequently, the wear behavior and damage mechanism of the fretting interface were elucidated through multi-scale characterization analysis. The results indicated that the operation state of the fretting interface was shifted towards the partial slip regime under the magnetic field. Meanwhile, the external magnetic field transformed the dominant wear mechanism from abrasive wear to adhesive wear. The influence of the external magnetic field on fretting wear has been demonstrated to manifest in dual aspects: Firstly, the Hertzian contact stress at the interface is enhanced by the magnetic field induction force, resulting in a remarkable reduction of about 79.83 % in accumulated dissipation energy; Secondly, the effectiveness of debris being expelled from the worn interface decreased, and the wear progression was further impeded by the accumulated debris, so that the abrasion loss is significantly reduced by about 60.66 %. These findings provide valuable theoretical data and practical reference for the protection of fretting damage in ferromagnetic materials under the action of a magnetic field.

Dependence of fretting wear resistance on the α morphology and stress-induced martensite transformation in a metastable β titanium alloy

Systematic experimental investigations concerning the influence of α morphology on the fretting wear behaviors of metastable β titanium alloys are carried out. A Ti-10V-2Fe-3Al titanium alloy was subjected to different heat treatment routes to create dual phase microstructures consisted of β phase plus α phase with three different morphologies. The effect of α morphology on the fretting wear resistance, the resulting failure mechanisms, and stress induced martensite transformation (SIMT) were unraveled. Results show that the α morphology has a significant influence on fretting wear behaviors depending on the fretting run regimes. In the partial slip regime (PSR) and mixed fretting regime (MFR), the microstructure with lath α morphology has a lowest fretting wear volume accompanied by relatively strong SIMT effect. While in gloss slip regime (GSR), the globular α microstructure has a lowest fretting wear volume along with strongest SIMT response, yet a highest fretting wear volume for the acicular α morphology microstructure due to its brittleness nature. The subsurface observations demonstrates that a compacted and thick plastic deformation layer, especially for the mechanical mixture layer, can well protect the material surface against the fretting wear damage.

Comparative study on tribological behaviors of interproximal tooth enamel against zirconia under fretting and sliding conditions

Interproximal contact loss (ICL) between zirconia crown and adjacent natural teeth is a common complication that could lead food impaction and compromise the periodontal/peri-implant tissue health and patient’s satisfaction. Both fretting and sliding wear mode can be found in the frictional pair between zirconia crown and interproximal enamel during mastication. In this study, fretting and sliding wear behavior of interproximal enamel against zirconia in artificial silva was investigated. The wear damage of the interproximal enamel in a sliding movement was higher than in a fretting movement. In fretting mode, the running condition fretting map (RCFM) composed of partial slip regime (PSR), gross slip regime (GSR), and mixed fretting regime (MFR) was constructed depending on different normal loads and displacement amplitudes. Intact surface was observed in the PSR. Plastic deformation at contact center and microcracks at contact margin were detected in the MSR. Severe wear damage occurred in the GSR, predominated by microfracture, brittle deformation. Macroparticles generation, fatigue delamination and abrasive wear prevailed in sliding mode. In contrast, enamel debris could be transferred on zirconia surface while the material loss of the antagonist zirconia was negligible in both fretting and sliding test.

Fretting-corrosion mechanisms of Ti6Al4V against CoCrMo in simulated body fluid under various fretting states

Ti6Al4V alloy–CoCrMo alloy pair is commonly applied for modular head–neck interfaces for artificial hip joint. Unfortunately, the fretting corrosion damage at this interface seriously restricts its lifespan. This work studied the fretting corrosion of Ti6Al4V–CoCrMo pair in calf serum solution. We established this material pair’s running condition fretting map (RCFM) regarding load and displacement, and revealed the damage mechanism of this material pair in various fretting regimes, namely partial slip regime (PSR), mixed fretting regime (MFR), and gross slip regime (GSR). The damage mechanism of Ti6Al4V alloy was mainly abrasive wear induced by CoCrMo alloy and tribocorrosion. Adhesive wear (material transfer) also existed in MFR. The damage mechanism of CoCrMo alloy was mainly abrasive wear induced by metal oxides and tribocorrosion in GSR and MFR, while no apparent damage in PSR. Furthermore, a dense composite material layer with high hardness was formed in the middle contacting area in GSR, which reduced the corrosion and wear of Ti alloys and exacerbated damage to Co alloys. Finally, the ion concentration maps for Ti and Co ions were constructed, which displayed the transition in the amount of released Ti and Co ions under different displacements and loads.

Effect of fretting wear regimes on stress corrosion cracking of Alloy 690TT in high-temperature pressurized water

Stress corrosion cracks initiation and propagation of Alloy 690TT under different fretting regimes were investigated. The results indicated that mixed regime had the highest susceptibility to stress corrosion cracking, followed by gross slip regime, and then partial slip regime. Crack initiation depended on the distribution of residual strain induced by fretting regimes. In partial slip and mixed regimes, cracks were mainly initiated at the edge of the wear scar, while in gross slip regime, cracks were randomly distributed on the wear scar. Crack propagation was related to the type of grain boundaries and geometrically necessary dislocation density induced by fretting loading. In partial slip and gross slip regimes, cracks usually tended to propagate intergranularly. While in MR, cracks mainly propagated in a transgranular manner.

Influence of Chloride Concentration on Fretting Wear Behavior of Inconel 600 Alloy.

The nickel-based alloy Inconel 600, strengthened by solution treatment, finds extensive application as a heat exchange pipe material in steam generators within nuclear power plants, owing to its exceptional resistance to high-temperature corrosion. However, fretting corrosion occurs at the contact points between the pipe and support frame due to gas-liquid flow, leading to wear damage. This study investigates the fretting wear behavior and damage mechanism of the nickel-based alloy Inconel 600 and 304 stainless steel friction pairs under point contact conditions in a water environment. Characterization was performed using laser confocal scanning microscopy and scanning electron microscopy equipped with energy-dispersive spectroscopy. Results indicate that the friction coefficient remains consistent across different chloride ion concentrations, while the wear volume increases with increasing chloride concentrations. Notably, friction coefficient oscillations are observed in the gross slip regime (GSR). Moreover, the stability of the oxide layer formed in water is compromised, diminishing its protective effect against wear. In the partial slip regime (PSR), friction coefficient oscillations are absent. An oxide layer forms within the wear scar, with significantly fewer cracks compared to those within the oxide layer in the GSR. It is worth noting that in GSR, the friction coefficient oscillates.

Improving frictional state at fretting interfaces through the covalent structure of diamond–graphite–graphene

This study proposes a novel approach based on the covalent structure of diamond–graphite–graphene (CDGG) to integrate the outstanding properties of diamond, graphite, and graphene, synergistically improving frictional behavior of fretting interfaces. The results demonstrated that in-situ CDGG significantly reduced the alternating stress at the contact interface, the friction coefficient decreased by 40–62 % over pristine diamond coatings under gross slip regime, accompanied by a shorter running-in period. The counterpart pair wear corresponding to in-situ CDGG was lower, and no delamination caused by metal adhesion. The surface graphene/graphite exhibited good frictional toughness, effectively absorbing the relative displacement at contact interface, enabling CDGG to exhibit partial slip regime under higher loads and smaller displacement amplitudes.

Investigating fretting wear mechanisms in Ti-6Al-4V: insights from residual stress and equivalent plastic strain analysis

Purpose The study delves into the influence of wear cycles on these parameters. The purpose of this paper is to identify characteristic patterns of σRS and εPEEQ that discern varying wear situations, thereby contributing to the enrichment of wear theory. Furthermore, the findings serve as a foundational basis for nondestructive and in situ wear detection methodologies, such as nonlinear ultrasonic detection, known for its sensitivity to σRS and εPEEQ. Design/methodology/approach This paper elucidates the wear mechanism through the lens of residual stress (σRS) and plastic deformation within distinct fretting regimes, using a two-dimensional cylindrical/flat contact model. It specifically explores the impact of the displacement amplitude and cycles on the distribution of residual stress and equivalent plastic strain (εPEEQ) in both gross slip regime and partial slip regimes. Findings Therefore, when surface observation of wear is challenging, detecting the σRS trend at the center/edge, region width and εPEEQ distribution, as well as the maximum σRS distribution along the depth, proves effective in distinguishing wear situations (partial or gross slip regimes). However, discerning wear situations based on εPEEQ along the depth direction remains challenging. Moreover, in the gross slip regime, using σRS distribution or εPEEQ along the width direction rather than the depth direction can effectively provide feedback on cycles and wear range. Originality/value This work introduces a novel perspective for investigating wear theory through the distribution of residual stress (σRS) and equivalent plastic strain (εPEEQ). It presents a feasible detection theory for wear situations using nondestructive and in situ methods, such as nonlinear ultrasonic detection, which is sensitive to σRS and εPEEQ. Peer review The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-01-2024-0005/

An improved energy wear model of three-dimensional ball-plane contact structure and its fretting wear dynamic behaviors study

This paper proposes a method that combines the finite element method with an improved energy wear model to establish a three-dimensional (3D) ball-plane contact structures fretting wear model. The correctness of the model was verified by Hertz contact theory and fretting wear experiments. Then, the fretting wear dynamic behaviors of 3D ball-plane contact structures were investigated in detail. The results show that when the contact structure is in the partial slip regime (PSR), the cross-sectional wear scar profile changes from the “W” shape to the “U” shape along the fretting direction. When the contact structure is in the gross slip regime (GSR), the cross-sectional wear scar profile always maintains a “U” shape along the fretting direction. In addition, it was also found in the study that when the contact structure is at GSR under a low normal load or PSR under a high normal load, it will help reduce wear. This study can provide significant theoretical guidance for reducing and protecting fretting wear in contact structures.

Fretting and mechanically-assisted crevice corrosion (MACC) of rail steel U75V with PA66 liner

Strong evidence has been reported on the occurrence of mechanically-assisted crevice corrosion (MACC) between the upper surface of the rail foot and the liner of the fastener, but there is still a lack of attention regarding its effect on materials degradation. A novel testing apparatus was self-developed in this study to simulate the MACC between the rail foot and the liner (disc-on-disc), and a typical rail steel (U75V) and a typical material for the liner (PA66) have been utilized. The fretting regimes, electrochemical behaviors and morphology of the contact surface have been investigated. It has been found that the fretting was mainly controlled by partial slip regime under the condition in this study, and the OCP and anodic current were both increased with increasing fretting frequency and displacement amplitude. The presence of PA66 debris in the form of large spalling particles has been found to inhibit crevice corrosion and relieve the surface damage to some extent. Cracks and local surface collapse were typically noticed on U75V steel which have been ascribed to the accumulation of plastic deformation and the comprehensive effect of fretting wear and corrosion fatigue.

Fretting corrosion running regime and damage mechanism evolution of zirconium alloy mated with Inconel 718 alloy in high temperature high pressure water environment

Fretting corrosion behavior and damage mechanism of Zr-4 alloy mated with Inconel 718 alloy under different fretting regimes in high temperature high pressure water were studied. The corresponding running condition fretting corrosion map (RCFM) and material response fretting corrosion map (MRFM) were established. The results showed that the change of fretting regime led to the differences of fretting corrosion behavior and damage mechanism. Based on the damage mechanism, the MRFM could be divided into partial slip regime with only slight surface damage; mixed fretting regime-I dominated by cracks; mixed fretting regime-II dominated by cracks and abrasive wear; and gross slip regime dominated by severe adhesive wear and oxidation. The transformation of fretting regime also resulted in different oxides.

A numerical model to simulate the transient frictional viscoelastic sliding contact

Sliding motion has always been one of the major concerns when it comes to the analysis of viscoelastic contact problems. A new model simulating the transient sliding contact of smooth viscoelastic surfaces is developed in this paper. By taking the dry contact friction and the coupling between shear tractions and normal pressure into account, the effect of the early partial slip period, which is often neglected in the study of viscoelastic sliding contact problems, is investigated numerically. Compared with solutions based on the frictionless assumption, the steady-state pressure profile is found to be slightly different under the effect of the partial slip regime, including a lower peak pressure and the shift of the contacting region in the direction opposite to the sliding motion. Furthermore, the time required for the viscoelastic contact to reach its steady state is delayed owing to the partial slip period preceding the global sliding motion.

Mechanistic understanding on the fatigue cracking in fretting corrosion of alloy 690TT under partial slip regime in 100 ℃ and 290 ℃ water

This study comparatively investigated the fretting corrosion fatigue cracking of alloy 690TT under partial slip regime in 100 ℃ and 290 ℃ water. The results revealed that the occurrence of continuous dynamic recrystallization. The process at 290 ℃ was considerably faster resulting in smaller size of ultra-fine grained structure. The increase in the water temperature resulted in the transformation of the crack initiation mechanism from intrusion/extrusion theory to the low-angle dislocations boundary attack mode. Furthermore, an increase in water temperature resulted in corrosion overcoming the influence of mechanics in crack propagation. In addition, the relevant mechanisms were discussed.

Frictional boundary condition for lattice Boltzmann modelling of dense granular flows

Hydrodynamic approaches that treat granular materials as a continuum via the homogenization of discrete flow properties have become viable options for efficient predictions of bulk flow behaviours. However, simplified boundary conditions in computational fluid dynamics are often adopted, which have difficulty in describing the complex stick–slip phenomenon at the boundaries. This paper extends the lattice Boltzmann method for granular flow simulations by incorporating a novel frictional boundary condition. The wall slip velocity is first calculated based on the shear rate limited by the Coulomb friction, followed by the reconstruction of unknown density distribution functions through a modified bounce-back scheme. Validation is performed against a unique plane Couette flow configuration, and the analytical solutions for the flow velocity profile and the wall slip velocity, as functions of the friction coefficient, are reproduced by the numerical model. The transition between no-slip and partial-slip regimes is captured well, but the convergence rate drops from second order to first order when slip occurs. The rheological parameters and the basal friction coefficient are calibrated further against the discrete element simulation of a square granular column collapsing over a horizontal bottom plane. It is found that the calibrated continuum model can predict other granular column collapses with different initial aspect ratios and slope inclination angles, including the basal slip and the complex internal flow structures, without any further adjustments to the model parameters. This highlights the generalization ability of the numerical model, which has a wide range of application in granular flow predictions and controls.

Effect of pv values on dry fretting and wear characteristics of aromatic thermosetting co-polyester (ATSP)-MoS2 coatings

For components affected by vibration, fretting wear is one of the most common failure types. In this work, the fretting behavior of ATSP-MoS2 coating was investigated and analyzed in detail. The tested coating only has two fretting states: partial slip regime (PSR) and gross slip regime (GSR). The coefficient of friction (COF) can be maintained at 0.1 when the pv＜1 MPa·m·s−1, meanwhile the COF and wear rate are significantly affected by the Hertzian contact stress p. The wear mechanism of the coating mainly includes three aspects, the mechanical damage of the original coating, especially the abrasive wear, the densification of surface film, as well as the formation and rupture of blisters on the surface film.

Hexagonal boron nitride nanosheets eco-friendly dispersed in pure water for lubrication in fretting contacts between steel pairs

The lubricating effect of h-BN nanosheets, dispersed in pure water without the use of any chemicals, was investigated under fretting contacts. The resistance against oxidation of sliding pairs was also considered using AISI 52100 and AISI 304 steel pairs separately, given that oxidation is inevitable on steel surfaces. In the partial slip regime, effects of the type of lubricant and oxidation on wear and friction were insignificant. In the mixed slip regime, the mending effect of h-BN counteracted the oxidation of sliding surfaces, resulting in mild wear. In the gross slip regime, the mending effect collapsed due to oxide debris, resulting in severe wear. Moreover, the results showed that the presence of h-BN nanosheets influenced the transition of fretting regimes. These findings suggest that aqueous-dispersed h-BN nanosheets can be an effective eco-friendly lubricant additive, particularly when fretting conditions enable a stable mending effect and sliding surfaces exhibit high corrosion resistance.

Effect of rolling on fretting fatigue assessment of cylindrical contact in partial slip regime

The present research work deals with the fatigue assessment of an Al 7075-T651 subjected to fretting fatigue testing characterised by cylindrical contact. A small rolling of the pads is experimentally observed and, consequently, the contact surface stresses are different to the hertzian one. Therefore, the methodology, recently proposed by some of the present authors for the fatigue assessment of fretting-affected metallic components, is here employed for the first time in conjunction with a FE numerical model able to take into account the effect of the rolling of the pads, in order to find out both the crack nucleation orientation and the lifetime for each specimen of the experimental campaign analysed.

An Investigation Into the Synergistic Effect of CAPVD Cr/CrN Nanolayered Coating Deposition and Hard-Anodizing Methods on Fretting Fatigue Life of 7075-T6 Aluminum Alloy

The influence of duplex surface treatment including a Cr/CrN nanolayered coating deposited by cathodic arc physical vapor deposition (CAPVD) and an alumina layer coated by hard-anodizing method on the fretting fatigue strength of Al7075-T6 alloy is studied in this investigation. Although fretting fatigue life of both single Cr/CrN coated alloy and Cr/CrN coating deposition onto hard-anodized alloy was increased in high cycle fatigue (HCF) regime, employing an alumina layer as a pretreatment for the Cr/CrN deposition enhanced the life improvement in the HCF regime. In low cycle fatigue (LCF) regime, despite a decrease in fretting fatigue life of both Al7075-T6-coated alloys, using the alumina layer beneath the Cr/CrN coating resulted in mitigation of fretting fatigue life deterioration. Interestingly, a single-hard-anodized specimen represented a completely different variation trend of fretting fatigue life in HCF and LCF regimes. Unlike the as-received and single-hard-anodized specimens, Cr/CrN-coated specimens did not bear the maximum axial stress, 260 MPa. Partial slip regime was mostly seen at the contacting area.

Tangential contacts of three-dimensional power-law graded elastic solids: A general theory and application to partial slip

New technologies in additive manufacturing have enabled the cost-effective production of gradient materials with desired multifunctional properties. In mechanical engineering, such functionally graded materials (FGMs) are often used within mechanical joints, as they ensure higher strength as well as wear resistance and prevent fretting fatigue. However, due to the variations in their composition and structure, theoretical predictions of their contact-mechanical behavior are significantly complicated. In this work, a general theory for solving tangential contacts between 3D power-law graded elastic solids of arbitrary geometry is presented. For multiple contacts, such as those occurring between two nominally flat but rough half-spaces, the well-known Ciavarella–Jäger theorem is established accompanied by a discussion of tangential coupling. Nevertheless, the focus of the work is on axisymmetric single contacts under arbitrary unidirectional tangential loading, for which closed-form analytical solutions are derived based on the Mossakovskii–Jäger procedure. In comparison to the results of common approximate methods, the solutions include the non-axisymmetric components of tangential displacements, which are indispensable for the accurate determination of the relative slip components and thus the surface density of frictional energy dissipation in the partial slip regime. Although a simplified approach is used for the calculation of the dissipated energy density, the results in the limiting case of homogeneous material are in excellent agreement with those from a full numerical computation. As an application example, the complete solutions for the tangential contact of parabolically shaped power-law graded elastic solids in the partial slip regime are derived and the influence of the material gradient as well as Poisson’s ratio on the surface density of dissipated energy is investigated.

Fretting Damage Evolution of Copper-Magnesium Alloy in Mixed Fretting Regime

The fretting damage evolution of copper-magnesium alloy in the mixed fretting regime was studied. Based on the characteristics of F t-D-N curves and the morphologies of wear scars, the fretting running condition of the alloy was divided into a partial slip regime (PSR), mixed fretting regime (MFR), and gross slip regime (GSR). Fretting in the MFR not only leads to strong adhesive wear but also promotes the initiation and propagation of fatigue cracks, resulting in serious fatigue wear. The damage evolution of the alloy in the MFR includes four stages, namely, the initial shear deformation stage, adhesion and crack initiation stage, crack growth and fatigue wear stage, and final fatigue damage accumulation stage. The propagation and connection between the fatigue cracks at the stick–slip boundary and the microcracks in the subsurface plastic strain layer are the main reasons for the serious fatigue wear in the MFR.