Sliding Wear Performance Research Articles

Study of wear performance of wheel and rail steels under dry sliding conditions

The demand for efficient railway services has significantly increased in the past years due to an increased demand for the high-speed transportation of goods with high loads. The increase in loads and velocities has resulted in increased problems associated with rolling contact fatigue (RCF), rolling and sliding wear on the wheel and rail materials causing a reduction of service life of wheel/rail systems. Rail operating companies spend significant funds in maintenance and replacing damaged rails and wheels caused by wear. In addition, unscheduled maintenance due to wear and RCF often lead to poor availability of railway networks. For this study, dry sliding wear was investigated on wheel and rail steels using RTEC Multi-Function Tribometer. The results demonstrated that the rig was successful in simulating sliding wear, and that the fractions of the wear components could be varied, and it also provided instrumentation. Information on coefficient of friction against sliding distance and applied force were obtained which were used to compare sliding wear performance of both wheel and rail steels. The wheel was found to perform better than the rail under the same conditions due to its high initial hardness values and smaller interlamellar spacing.

Study of wear and friction properties of a Co-free CrFeNiAl0.4Ti0.2 high entropy alloy from 600 to 950 °C

Sliding friction and wear performance of an economical Co-free CrFeNiAl0.4Ti0.2 high entropy alloy was studied over a wide temperature range. The homogenised alloy comprised a mixture of three distinct phases: B2, BCC and FCC phases. Sliding temperature had a significant influence on friction coefficient, wear rate and worn surface morphology. The maximum friction coefficient and minimum wear rate are achieved at 800 °C. An increase in friction coefficient and a drop in wear rate are observed when temperature is below 800 °C, however, an opposite trend is seen above 800 °C. The main wear mechanism is abrasion at 600 °C, but oxidation contributes more at higher temperatures. Formation of oxide layers and subsurface tribo-layers improves wear resistance at high temperatures.

Parametric Optimization and Ranking Analysis of Hybrid AA2024–SiC/Si3N4 Alloy Composites Based on Mechanical and Sliding Wear Performance

Parametric Optimization and Ranking Analysis of Hybrid AA2024–SiC/Si3N4 Alloy Composites Based on Mechanical and Sliding Wear Performance

Dry sliding wear performance of Semi-Solid Al/LM6 cast Composite: Effect of silicon particles on worn surfaces

Abrasive behavior for the wear properties according to the effect of silicon particles has been investigated for powder chip reinforced LM6 Aluminium alloy fabricated via. Semi-solid casting. Initially, a novel reinforcement was fabricated with the help of a ball milling process for 13% addition of silicon particulates inside the LM6 aluminium alloy powder and chip. In this process, fine aluminium powder (81microns) and chips of LM6 alloy (less than 60 μm) have been refined due to the impact of hard balls via the ball milling process. After the fabrication of reinforcement particulates, semi-solid casting was used to fabricate Si-rich semi-solid cast composite. Dry sliding wear for the fabricated composite has been conducted against the EN-31 steel plate hardened to 62HRC. Microstructure, EDX, and XRD have been analyzed to form the tribo-layer due to added Si particulates.

Wear analysis of natural-inorganic fiber reinforced automotive brake composites

Brake friction composite materials comprising varying proportions of natural (banana) and inorganic (lapinus) fibers were designed, fabricated by compression molding, and characterized for sliding wear performance. The sliding wear properties of the manufactured friction composites have been studied by the Taguchi method. An orthogonal array (L 16) was used to investigate the influence of sliding wear parameters. A series of tests were conducted on a pin-on-disc machine by considering four control parameters: composition, normal load, sliding velocity, and sliding distance, each having four levels. The results showed that the wear in terms of weight loss decreases with increasing banana fiber and increases with increasing lapinus fiber, normal load, sliding velocity, and sliding distance. The results indicate that the normal load emerges as the most significant control parameter affecting wear performance, followed by sliding distance and sliding velocity.

Analysis of Mechanical and Sliding Wear Performance of Hybrid AA7075-SiC/Gr/Cu Alloy Composites Fabricated by High Vacuum Stir Casting Process

Analysis of Mechanical and Sliding Wear Performance of Hybrid AA7075-SiC/Gr/Cu Alloy Composites Fabricated by High Vacuum Stir Casting Process

Constructing highly aligned crystalline structure to enhance sliding wear performance of bulk polyamide 6

High performance wear-resistant polyamide 6 (PA6) not only needs low friction and wear, but also requires high thermal conductivity and outstanding mechanical strength. Introducing lubricants into polymers has proved to be a feasible method, however, the contribution of intrinsic structure of PA6 to tribological properties is often ignored. Herein, a novel approach to fabricate high performance wear-resistant bulk PA6 via constructing a highly aligned crystalline structure was proposed. Firstly, an intense flow field applied by force assembly elements (FAEs) was introduced into extrusion processing to prepare PA6 precursor sheets with initially aligned molecular chains. Next, the precursor sheets were uniaxially drawn at 120 °C to achieve highly aligned crystalline structure at low draw ratio. The X-ray diffraction results showed the crystal orientation of the precursor sheets is 42% higher than that of samples prepared without FAEs. Furthermore, tensile stress induced γ-α phase transition and improved the crystallinity. As a result, the friction coefficient and wear rate of the bulk PA6 decreased 50.8% and 64.9%, respectively. Note that the maximum contact surface temperature reduced from 109.8 to 64.8 °C during high-speed friction because of the increasement of the thermal conductivity, effectively avoiding the aggravation of wear caused by surface softening. Moreover, the bulk PA6 also has excellent mechanical properties with a yield strength of 242 MPa and an elongation at break of 90%. Such remarkable enhancements in both mechanical and tribological properties are primarily attributed to the highly aligned crystalline structure with high α crystal form content. This work provides a way to design mechanically robust, wear-resistant polyamide applied in industry, transportation, etc.

Sliding Wear Performance of AlCrN Coating on TiB2/Ti Composites at High Temperatures.

The aim of the study was to investigate effect of Ti/TiB2 composite composition and manufacturing technology parameters on the tribological behaviour of AlCrN coating-composite system. The AlCrN coating was deposited by PVD (Physical Vapour Deposition) method. The composites were manufactured by spark plasma sintering (SPS) from three variants of powders mixtures: Ti with TiB2, Ti6Al4V with TiB2 as well as Ti with B, using (five) different sintering temperatures. For each of the developed coating-composite systems, the wear resistance was evaluated using ball-on-disc SRV tester, at six temperatures (from room temperature up to 900 °C). The results confirmed that high-temperature wear resistance of the coating–substrate combination depends on Ti/TiB2 composite composition and manufacturing technology parameters. In the case of uncoated composite, two processes manage the wear at high temperatures: cracking propagation and surface oxidation. The presence of AlCrN coating on the composite surface protects the surface against deep cracking and surface oxidation. The composites of Group I, sintered at 1250 °C from a mixture of pure Ti and TiB2 (50/50 wt.% ratio) as well as Group III, sintered at 1350 °C from a mixture of pure Ti and B allow the achievement of a satisfactory surface quality, a high adhesion of the PVD coating and moderate wear at high temperatures. However, the composite made of pure Ti and B seems to be a better solution for temperatures exceeding 600 °C.

Sliding wear performance of Al–Co alloys fabricated by vacuum arc melting and correlation with their microstructure

Al–Co alloys of various compositions (2–20 wt% Co) have been fabricated by vacuum arc melting and evaluated with respect to their microstructure and dry sliding wear performance. A variety of microstructures have been attained, ranging from that of a dual fibrous and lamellar Al/Al9Co2 eutectic (Al-2 wt. % Co), to that of coarse primary Al9Co2 plates within an Al-matrix (Al-20 wt% Co). Despite their hypereutectic compositions, the alloys behave as in-situ Al9Co2/Al composites: with increasing the Co content and, consequently, the Al9Co2 volume fraction, the hardness of the alloys increases and their wear rate decreases. The alloys exhibit lower wear rates compared to widely used Al-alloys, as-fabricated and heat-treated. The friction behavior has been analyzed and correlated with the good interfacial Al9Co2/Al bonding and the promotion of abrasive wear by the reinforcement. Raman spectroscopy of wear debris manifested its contribution to a mild wear mode through the absolute predominance of oxide-based phases with lubricating properties. A wear mechanism has been formulated based on the wear track morphology, debris nature and friction coefficient trends. Adhesive wear and abrasive wear assisted by oxidative wear have been identified as the main wear modes. The predominance of adhesion decreases and that of abrasion increases as the Co content increases.

Significance of plasma electrolytic oxidation treatment on corrosion and sliding wear performances of selective laser melted AlSi10Mg alloy

In this investigation, Plasma Electrolytic Oxidation (PEO) process was used to prepare an alumina (Al 2 O 3 ) coating for corrosion and wear protection of a Selective Laser Melted (SLM) AlSi10Mg alloy radiator. The phase compositions, microstructures, mechanical properties, corrosion properties and wear resistance of the SLM AlSi10Mg alloy and the PEO coatings were investigated systematically. It was observed that the AlSi10Mg alloy prepared by SLM displayed a denser microstructure, finer grains and excellent mechanical properties with an average ultimate tensile strength of 402 MPa and an elongation of 9.9%. In addition, a double-layered coating with Al 2 O 3 as the top layer having a thickness of ~20 μm and a hardness of 1051HV 0.01 was realizable on the SLM AlSi10Mg alloy by PEO treatment. The corrosion current density and wear rate of the PEO Al 2 O 3 coatings were 5.7 and 279.3 times lower compared to the plain SLM AlSi10Mg alloy. The results indicate that the PEO treatment can significantly improve the wear and corrosion resistance of the AlSi10Mg alloy prepared by the SLM process. • AlSi10Mg alloy prepared by SLM exhibits dense microstructure and fine grain size. • AlSi10Mg alloy prepared by SLM process has excellent mechanical properties. • PEO film has dense outer layer and less dense inner one whose main phase is γ-Al 2 O 3. • PEO can provide excellent corrosion and wear protection for the SLM AlSi10Mg parts.

Dry sliding wear performance of AA7075/MoS2 composite materials

This article aims in exploring the dry sliding wear performances on the aluminum (AA7075) metal matrix composites reinforced with molybdenum disulphide which is a solid lubricant using response surface methodology (RSM). Specific Wear Rate (SWR) for the AA7075 pure alloy, AA7075+2wt% molybdenum disulphide and AA7075+4wt% molybdenum disulphide were measured according to ASTM G99 standards in pin-on-disc apparatus. Design of experiments was selected with changed parameters like the varying percentage of molybdenum disulphide (%), applied load (N), and sliding velocity (m/s) based on Central Composite Design in response surface methodology considering them as continuous factors. Experiments for the specific wear rate of pure alloy and the composites were conducted. The volume loss was measured using the pin-on-disc apparatus from which the specific wear rate value was calculated. The obtained results are analyzed and a mathematical model was formulated using the response surface methodology. The optimum level parameters for the specific wear rate has been identified and the results of the experiment specify that the sliding velocity and molybdenum disulphide percentage have a substantial role in controlling the wear behaviour of composites when compared with the other parameter. The optimum condition for the specific wear rate was identified and experimented with for studying the result.

Influence of Ni content on the microstructure and reciprocating wear of Fe-based/B4C composite coating by vacuum cladding

Fe-based/B4C composite coatings without and with 1–5 wt% Ni (Ni-free and Ni-added, respectively) were fabricated on the surface of ASTM 1045 steel via vacuum cladding. The effects of Ni addition on the microstructure, hardness and reciprocating wear of Fe-based/B4C composite coatings were investigated by optical microscopy (OM), electron probe microanalysis (EPMA) equipped with energy dispersive spectroscopy (EDS), X-ray diffraction (XRD), hardness tester and reciprocating wear tester. The results showed that all coating composed of α-Fe, γ-Fe, (Fe, Ni) solid solution, M23(C, B)6, and M2B phases, which indicated that Ni addition into the coating had little impact on the composition of the M2B-type borides and M23(C, B)6-type carboborides in the coating. However, with the increase of Ni addition, the hardenability of the coating matrix was improved, and toughness phase of martensite was formed. Meanwhile, the morphology of strengthening phases gradually changed from chrysanthemum-like to intermittent net-like. When Ni addition was 3 wt%, the irregular block and net-like strengthening phases were uniformly distributed in the coating matrix of martensite, which made the microhardness of the coating relatively stable and the average hardness was 920 HV. Under different applied loads, non-significant variations in the coefficient of friction were observed. The wear volume of the coating with 3 wt% Ni addition was the minimum, which was only 2 × 10−3 mm3 under the applied load of 30 N, showing the best sliding wear performance. The wear morphology and elements distribution analysis suggested that the main wear mechanism of dry sliding wear of the coatings with different Ni addition were oxidative, adhesive and abrasive wear.

High-temperature erosion and sliding wear of thermal sprayed WC–Cr3C2–Ni coatings

ABSTRACT The present work focuses on high-temperature solid particle erosion and sliding wear behaviours of WC–Cr3C2–Ni coatings deposited by atmospheric plasma spray (APS) and high-velocity oxy-fuel (HVOF) processes. The high-temperature erosion behaviour and the effects of temperature on the sliding wear performance of coated specimens were comparatively studied using an air-jet erosion tester and a ball-on-disc tribometer, respectively. Unidirectional dry sliding wear has been tested up to 800 °C, whereas the erosion tests were up to 650 °C. Interestingly, in a high-temperature sliding, the wear rates of both the coatings decreased after 500 °C due to the development of tribofilm. Furthermore, erosion resistance of both coatings was observed to be more prominent at 650 °C. HVOF coating offers higher erosion resistance than APS coating due to higher hardness, lower splat cohesion, lesser degree of decarburisation, and retained oxide layer. The HVOF-deposited WC–Cr3C2–Ni coating improves the high-temperature sliding wear and solid particle erosion resistance of the base material appreciably.

Dry Sliding Friction and Wear Performance of HVOF Sprayed WC–Co Coatings Deposited on Aluminium Alloy

Dry Sliding Friction and Wear Performance of HVOF Sprayed WC–Co Coatings Deposited on Aluminium Alloy

Non-Lubricated Sliding Wear Performance of LM13 Alloy Foam and its Composite Foams Reinforced with ZrSiO4

Non-Lubricated Sliding Wear Performance of LM13 Alloy Foam and its Composite Foams Reinforced with ZrSiO4

Multiresponse Optimization of Wear Parameters of Steel-Embedded Glass-Epoxy Hybrid Composites Using Taguchi-Grey Method Optimization

Abstract In this work, Taguchi-grey relational analysis (GRA) has been used to optimize the process parameters during the tribological performance of steel-embedded glass-epoxy hybrid composites. The specific wear rate (SWR) and the average coefficient of friction (CoF) were investigated. The tribological test was planned by using Taguchi L27 orthogonal array. The tests were carried using different factors like steel volume % (0–10 %), applied load (80–100 N), and sliding distance (1,000–2,000 m) for a constant time (20 min). The optimal process parameters were obtained with Taguchi-GRA, and the influencing factor was determined with the help of analysis of variance. The results show that the most influencing factor is steel volume %, followed by applied load and sliding distance. The dry sliding wear performance was optimized to achieving minimal SWR and average CoF. Steel volume 10 %, sliding distance 1,000 m, and applied load 80 N were observed as optimum parameters to achieving minimal SWR and average CoF. A confirmation test was carried out to verify the tests. The results show that the multiresponses such as SWR and average CoF were significantly enhanced through GRA. Finally, the worn surfaces of the hybrid composites were studied through scanning electron microscope (SEM). The SEM shows that the pits on the surface of the image were covered with voids and other defects. The SEM also shows that the specimen’s porosity decreases with the increasing fractional volume of steel in the composite.

Dry sliding wear characteristics of Al-7Si-0.3Mg alloy with minor additions of magnesium at high temperature

ABSTRACT In this paper, effect of minor additions of magnesium content in the form of master alloys on the high-temperature dry sliding wear behaviour for A356 alloy has been reported. Alloy composition, normal pressures and sliding distances on A356 alloy at constant temperature of 300°C was studied. The cast alloys and worn surfaces were characterized by SEM/EDX microanalysis. The results indicate that the wear rate of A356 alloy increases with an increase in normal pressures and sliding distances in all the cases and decreases when 0.7% Mg is added to A356 alloy. The decrease in wear rate after the addition of Mg is mainly due to changes in microstructure which lead to improvement in mechanical properties. Further, worn surface study indicates that the formation of iron-rich oxide layer between the mating surfaces during sliding improves sliding wear performance.

Multi response parameters optimization of ZA-27 nanocomposites

In this study, Taguchi-Grey relational analysis was used to investigate and optimize wear parameters such as sliding speed, reinforcement of Gr and reinforcement of Al2O3, and their effect on dry sliding wear performance of ZA-27 nanocomposites. Nanocomposites were synthesized via hot pressing process with pre-processing mechanical milling. Sixteen experimental tests were performed based on design of experiments which was created with the help of Taguchi L16 orthogonal array. Grey relational analysis (GRA) was applied for determination of optimal combination of parameters in order to improve tribological characteristics. Optimal combination of factors, obtained with Taguchi Grey relational analysis was sliding speed of 100 rpm, reinforcement content of 1 vol.% Gr and reinforcement content of 4 vol.% Al2O3. Validation of results was done by using Artificial Neural Network (ANN). Developed model had overall regression coefficient 0.99836, and output values showed good correlation with experimental results. Based on this research, it can be observed that nanocomposites with reinforcement of Gr and Al2O3 can be potentially employed in many industries as a good substitute for the base alloy. In addition, as a result of the analysis of the worn surfaces, it was determined that with the increase of the Al2O3 ratio, the hard Al2O3 nanoparticles turned the dominant wear mechanism into abrasive. Also, it was determined that the Gr nanoparticles appeared on the abrasive wear lines.

Influence of Test Conditions on Sliding Wear Performance of High Velocity Air Fuel-Sprayed WC-CoCr Coatings.

Sliding wear performance of thermal spray WC-based coatings has been widely studied. However, there is no systematic investigation on the influence of test conditions on wear behaviour of these coatings. In order to have a good understanding of the effect of test parameters on sliding wear test performance of HVAF-sprayed WC–CoCr coatings, ball-on-disc tests were conducted under varying test conditions, including different angular velocities, loads and sliding distances. Under normal load of 20 N and sliding distance of 5 km (used as ‘reference’ conditions), it was shown that, despite changes in angular velocity (from 1333 rpm up to 2400 rpm), specific wear rate values experienced no major variation. No major change was observed in specific wear rate values even upon increasing the load from 20 N to 40 N and sliding distance from 5 km to 10 km, and no significant change was noted in the prevailing wear mechanism, either. Results suggest that no dramatic changes in applicable wear regime occur over the window of test parameters investigated. Consequently, the findings of this study inspire confidence in utilizing test conditions within the above range to rank different WC-based coatings.

Effect of process parameters on sliding wear performance of red brick dust-filled glass–epoxy composites

This research is focused on the study of the tribological properties of epoxy composites reinforced with red brick dust and glass fiber. Wear tests are conducted on a pin-on-disk apparatus. The wear rate and coefficient of friction are measured after tribological tests. The relative effect of process parameters such as sliding velocity, normal load, filler content on specific wear rate, and coefficient of friction is also examined using the Taguchi model and analysis of variance technique. Furthermore, an innovative optimization approach is adopted by combining grey relational analysis with the metaheuristic firefly algorithm to obtain the desired response values. A nonlinear regression model is generated to cater to the relationship between the grey relational grade and the process parameters. This model is further employed in the firefly algorithm to move the firefly to the neighboring brighter and attractive firefly. The most influencing factors for wear rate and friction coefficient are sliding velocity and normal load, respectively. This work not only opens up an opportunity for value-added utilization of waste material such as red brick dust but also the proposed metaheuristic approach can be customized and applied for any multi-response optimization problem.