Wear Studies Research Articles

Influence of ultrasonic agitation on the abrasive wear characteristics of Al-Cu/ 2 vol% Grp composite

In the present study, the abrasive wear behavior of Al–4.4 wt% Cu composite reinforced with 2 vol% graphite particle (Grp) has been investigated. In the preparation of composite, Ultrasonic Treatment (UT) is provided in the composite melt for the uniform distribution of reinforcement particles. Two bond abrasive wear tests are conducted for composites treated with ultrasound and without UT and base alloy. The results of abrasive wear studies indicate that at 5 and 10 Newton (N) loads, the composite with UT has a higher coefficient of friction (COF) and wear resistance than that of the base alloy (Al–4.4 wt% Cu). Whereas, at 15 and 20 N load, the value of COF and wear resistance is lower for the composite. Two abrasive wear mechanisms micro-plowing and micro-cutting have been observed during the wear tests of base alloy and composites. The analysis of worn-out sample surfaces at higher load reveals that softened material layer due to localized elevation in temperature between two contact surfaces during wearing acts as a tribolayer in base alloy while in composites both softened material layer and graphite layer have worked together as tribolayer.

Simulation and experimental study of tool wear in high-speed dry gear hobbing

Simulation and experimental study of tool wear in high-speed dry gear hobbing

Study of wear and micropitting in rolling/sliding contacts operating under boundary lubrication conditions

Rolling contact fatigue is a common failure mode in gears and bearings. However, this failure mode is getting greater attention due to the increasing tendency to use lower viscosity lubricants to reduce losses. Though several types of research have been done over the past decades, there are still scopes for further investigations. This study aims to study the effect of the slide to roll ratios (SRR), surface roughness and surface treatment on wear and pitting behaviour under realistic contact conditions. Fatigue and wear damages were quantified by studying the surface topography alteration at different contact cycle intervals.It was found that under boundary lubrication, initiation of micropitting took place in almost all test runs. However, once the adhesive wear mechanism activated at a higher contact cycle, the initially formed micropitted area started to wipe off. Moreover, for an extended test period and high sliding, wear volume is almost similar irrespective of SRR. Later, a surface treatment was studied, which was found effective in delaying the micropitting initiation by improving the tribological parameters compared to the untreated samples.

Wear studies on Al-Si automotive alloy under dry, fresh and used engine oil sliding environments

Wear studies on Al-Si automotive alloy under dry, fresh and used engine oil sliding environments

Effect of ultrasonic vibration treatment on microstructure and dry sliding wear characteristics of LM25 aluminum alloy

Grain refinement studies on Aluminum alloys with the addition of silicon, and magnesium alloys have fascinated considerable attention in the last five decades. Aluminum alloy properties of castings predominately depend on the grain structure formation that takes place inside the material meanwhile the solidification process. In the current investigation, a device has been designed and established to induce high-frequency ultrasonic vibrations to the molten metal at the time of solidification. This paper outlines Ultrasonic frequencies of varied were 10 to 50 kHz in the step of 10 kHz. The amplitude of the experiment was kept constant at 15 V for the entire findings. From the studies, it is found that the size of the grains has been reduced by 40% from coarse to fine equiaxed grains. Hardness value was noted with increased by 57.5% as well as Wear properties of treated LM25 alloy in dry sliding conditions have substantially improved. Wear studies has been carried out using standard pin on disc machine with various altered speeds. The study aims to validate that there are grain refinement and considerable improvement in the wear-resistant properties of the treated alloy.

Study on wear behavior of low nickel austenitic stainless steel by using ball on disc

Austenitic stainless steels have wide applications in various industries due to its good corrosion characteristics and their surface strength. A variety of procedures are used to enhance the surface characteristics. Wear studies are critical in all of the toughest materials. Surface damage was studied in terms of material-removal methods such plastic deformation and brittle fracture. This paper investigated the specific wear rate of Low Nickel ASS. The parameters selected for wear testing like sliding speed, load, time duration and types of ball. Six numbers of experiments were conducted for measuring specific wear rate, mass loss and coefficient of friction were highlighted in this paper. A comparison study was made to know the effect of wear parameters like sliding speed, load, time duration and types of ball on specific wear rate and coefficient of friction. It was seen that with increasing of load and sliding speed of disc the specific wear rate of the material significantly increasing.SEM analysis was also made on worn surface to know the behaviour of wear in the sample.

Friction stir processed Al 7075 matrix composites with addition of SiC coated graphene nanoplatelets

Friction Stir Processing (FSP) is a surface modification technique that has been commonly used while preparing surface composites. Through FSP, the surface properties such as strength, hardness, wear, and corrosion resistance could be enhanced by adding discontinuous reinforcements in the base alloy. The present experimental investigation involves nano reinforcements i.e graphene nanoplatelets (GNP) and SiC coated GNP was reinforced into Al 7075 and fabricated nano surface composite via Friction stir processing (FSP). A nano SiC granular and layered coating over GNP was obtained from FESEM studies. The Surface morphology, tensile strength, microhardness, and wear studies were explored. The hardness and ultimate tensile strength values of FSP'ed Al 7075, GNP, and SiC coated GNP in Al 7075 were 96.2, 128.4, 139.3 HV, and 344.8, 383.2, and 417.5 N/mm2 respectively. The hardness and ultimate tensile strength significantly increased by 44% and 21%. In similar lines, the specific wear rate also decreased 80% compared to other samples due to its lubricant property. X-RD analysis affirms the existence of Al, SiC, GNP phases that match with the lattice planes. Microscopic studies revealed the presence of SiC particles on GNP as a form of coating and also dispersed uniformly in Al 7075 composites.

Titanium Boride and Titanium Silicide Phase Formation by High Power Diode Laser Alloying of B4c and Sic Particles with Ti: Microstructure, Hardness and Wear Studies

Titanium Boride and Titanium Silicide Phase Formation by High Power Diode Laser Alloying of B4c and Sic Particles with Ti: Microstructure, Hardness and Wear Studies

CFD and experimental study of slurry erosion wear in Hydro-machinery

Hydropower plants which are fed from the tributaries originating from Himalayan ranges face a serious problem due to presence of slurry erosion phenomenon which led to material degradation or failure, sometimes it results in operational failure and economic loss. The main objective of the present work is to show that one can use computational fluid dynamics (CFD) to predict the slurry erosion behaviour and particle impact profiles on hydraulic machinery. To develop the slurry erosion model, Eulerian-Lagrangian based approach is used to simulate the multiphase flow phenomenon i.e. flow behaviour and liquid–solid interaction. For considering the viscosity effect, K-epsilon (k-ε) turbulence model having realizable and scalable wall function is used which simulate the mean flow characteristics for turbulent flow conditions. Furthermore, to track the motion of the particles, the Lagrangian frame of reference was used along with Eulerian formulation for continuous phase. The results obtained from the developed CFD model were in good agreement with the experimentally obtained results.

Initiation of Caries or Erosive Tooth Wear Lesions from the Host Standpoint.

Dental caries is initiated by an unbalance between periods of demineralization and remineralization, and the consequence is localized loss of minerals right under the enamel surface of certain teeth that, if left to progress, may lead to irreversible loss of structure. One approach proposed to overcome the limitation of simply counting the number of teeth or surfaces affected by caries was to characterize the initial loss of minerals from the dental enamel in the laboratory as a way to phenotype individuals for genetic studies of dental caries or erosive tooth wear. This chapter discusses the results of these original studies.

Wear and corrosion behaviour study of LM0 alloy

The current work investigates the wear and corrosion behaviour of plasma melting and sand casting LM0 alloy. LM0 alloy was prepared by both plasma melting and sand casting techniques. A comparative study of optical, hardness, density, corrosion, and wear of plasma melting and sand casting alloy samples was carried out. For the corrosion behaviour study, alloy samples are held on Seawater for 2-weeks, and weight loss/gain and corrosion rate in each week was calculated.Pin-on-disc wear testing machine conducted dry sliding wear tests at applied load 10–20 N, with varying sliding velocity 0.94-1.88 m/s for 5 min. Mass loss and wear rate variation with the normal load and sliding velocity were studied in the experiment. It is noticed that finer microstructure in plasma melting and coarse microstructure in sand casting samples were obtained from optical image analysis. Higher hardness and lower density of sand casting sample than plasma melting alloy sample. But sand-casting sample shows higher wear resistance and lower corrosion resistance than the plasma melting sample. The worn surfaces and surface corrosion products morphology was analyzed by SEM analysis to examine the wear and corrosion mechanism. The abrasive wear and pitting corrosion phenomena get from the experimental study.

Comparison of novel TiN coated and uncoated carbide tool in CNC green machining of AISI H13 to minimize tool wear

To compare the tool wear in green machining (dry turning) of AISI H13 tool steel using novel TiN coated and uncoated carbide tools. The work material chosen for the study is AISI H13 tool steel of dimension 25 mm diameter and 50 mm length. The type of cutting tool selected for the turning operation is novel TiN coated and uncoated carbide tool. The designation of the cutting tool used is CNMG120408. Three input parameters are considered, cutting speed (m/min), feed rate (mm/rev), depth of cut (mmm) and each varied at three different levels for conducting L9 experimental study. Two groups of experimental study are selected (novel TiN coated and uncoated) with 27 samples per group. The sample size is calculated with 80 % of total pretest G power. In total, 54 samples were taken for the study of tool wear. The testing set-up of tool wear in carl zeies microscope. The experimental study was conducted in the green machining (dry turning) environment. The Average of tool wear (microns) The novel TiN coated carbide tool is lesser tool wear and uncoated carbide tool is higher tool wear are recommended. All the results obtained were analysed for its significance by SPSS software and the graphs were plotted and the level of significance was found to be 0.048 (p < 0.05). The samples machined with novel TiN coated carbide tool gives good results compared with uncoated carbide tool to minimize Tool wear.

Analysis of suitability of WC tool for joining Inconel 601 alloy by electric assisted friction stir welding

The paper focus on the study and analysis of tool wear of Tungsten carbide tool for joining high strength material by Electrically Assisted Friction Stir Welding. The tool material selected for the experiment is Tungsten Carbide and base material is Inconel 601 plates. Certain parameters have been considered for the experiment such as tool speed, welding speed and current supplied. An additional electric current of about 4 V DC is supplied considering the EAFSW process. The feed rate for the experiment is about 10, 20 and 30 mm/min. The paper focuses to study the use of electric current for hybridization of FSW process and utilize the hybrid process to join high strength material by WC tool. A comparative study has been done to analyse the mechanical property of Inconel 601 joined by FSW and EAFSW and the tool wear in both the cases has also been studied. An improvement in UTS by 21.62 percent has been observed in EAFSW process than FSW process.

Optimization of dry sliding wear parameters of Al 7075 MMC’s using Taguchi method

Composite materials have established a great deal of awareness from researchers and manufacturers owing to their development in mechanical and tribological properties for a very long time. The enormous part of composites and MMCs research has been translated into realistic engineering materials.In the current study, fly ash and silicon carbide (SiC) particulates reinforced AA7075 matrix composites was evaluated experimentally. This study targets towards optimize dry sliding wear parameters during wear studies Al 7075 MMC using the Taguchi method of experimental design. The Taguchi L9 design is elected for the experiment design. The input variables such as applied load (AL), sliding distance, (SD) and sliding speed (SS) are selected and to verify the effect on response of wear rate (WR) and coefficient of friction (COF). Wear rate, according to Taguchi's analysis, is more sensitive to load, whereas COF is heavily influenced by sliding velocity.

An experimental study on abrasive wear behaviour of WC-12Co and WC-20Cr₂C3-7Ni coatings

Wear is a critical problem and common in several mechanical components, and it reduces the service span of the machine. To prevent the wear is a challenging job, especially in adverse working conditions. Coating of hard metals prevents the components from wear and increases the machine's service life. This current work studied experimentally the abrasive wear behaviour of HVOF sprayed WC-12Co and WC-20Cr₂C3-7Ni coatings. X-ray diffraction (XRD) and scanning electron microscopy(SEM) was used to characterize corresponding coatings for phase identification and microstructural investigation. Vickers hardness and a pin on the disc tester were used for microstructure and abrasive wear study. The Silicon carbide abrasive media was used as a counter surface and mounted on the circular disc by a suitable adhesive. SEM images with 3-D morphology were used to identify worn-out surface wear mechanisms. The result indicates that WC-12Co coating possesses a comparatively dense microstructure due to a strong Co binder. The WC-12Co coatings display higher microhardness and wear resistance due to dense microstructure. WC-12Co coating reveals 39 % & 38% minimum weight loss than WC-20Cr₂C3-7 N coating at both 20 N and 40 N load WC-12Co coating shows a higher Coefficient of friction. Cutting and delamination were identified as main wear mechanisms.

Abrasive wear study of marble dust reinforced Al7075 alloy surface composites: developed by friction stir processing

Abrasive wear study of marble dust reinforced Al7075 alloy surface composites: developed by friction stir processing

Optimization and prediction of hardness, wear and surface roughness on age hardened stellite 6 alloys

Growing demand for Stellite 6 alloys due to its attractive properties such as superior strength, toughness, wear resistance, fracture resistant characteristics, and their exceptional resistance to corrosion has made them applicable in industrial as well as commercial applications, such as aerospace industries, nuclear waste storage, automobile industries and surgical implantation. However, in spite of these applications, automotive part manufacturers mainly (Bearing Materials) are looking for a comprehensive study, such as mechanics of friction and the relationship between friction and wear. Hence in this paper, an attempt has been made to study the tribological behavior such as wear characterization and surface roughness of age hardened Stellite 6 alloys. The main objective of the research is to determine the favorable tribological conditions for improving wear resistant properties and surface roughness on age hardened Stellite 6 alloys. Hence two body wear study and surface roughness study during Wire Electric Discharge Machining (WEDM) of age hardened Stellite 6 alloys based on Analysis of Variance (ANOVA), Taguchi's Design of Experiment (TDOE), Response Surface Methodology(RSM) and Desirability Functional Analysis (DFA) have been used to achieve this goal. From the study it is observed that optimum values for improving hardness, wear and surface roughness values can be easily achieved with less time and cost by adopting the said techniques. •From microstructural observation, as the peak current increases there is larger amount of dendritic carbides and cracking of carbides due to high plastic deformation resulting in thermal softening of Stellite 6 alloy during wire electric discharge machining resulting in better surface roughness values. The second-order model for hardness, wear and surface roughness using response surface methodology can be adopted for predicting for hardness, wear and surface roughness in any experimental domain.

Abrasive Wear Study of Marble Dust Reinforced Al7075 Alloy Surface Composites: Developed by Friction Stir Processing

Abrasive Wear Study of Marble Dust Reinforced Al7075 Alloy Surface Composites: Developed by Friction Stir Processing

Erosion wear performance of HVOF and cold spray coatings deposited on T-91 boiler steel

Erosion wear in boiler tubes in coal based boilers is one of the serious problem and often results in downtime. After studying the literature, it was observed that thermal spray coatings are one of the effective solutions in reducing the erosion wear of boiler tubes. In this research work, the comparative erosion wear study of uncoated, HVOF coated and Cold spray coated samples of T-91 steel in simulated coal fired boiler conditions were performed. The Ni powder coatings were deposited on the substrate and impacted at 30°, 60° and 90° impingement angles with alumina erodent employing an air jet erosion tester. The erosive wear with respect to weight loss was maximum at 30° impingement angle, that was reduced at an impingement angle 60° and minimum at an impingement angle of 90°. This is erosive wear behavior of ductile materials. The erodent discharge rate was fixed at 2 g/min and air temperature at 800 °C. The cold spray coatings can reduce the weight loss from 40 to 60%.

Effect of Silicon Carbide and Alumina Reinforcement of Different Volume Fraction on Wear Characteristics of AL 7075 Hybrid Composites Using Response Surface Methodology

This study investigates the wear performance of Hybrid composite of Aluminium Al 7075 (SiC/Al2O3). The Reinforcements used for the Hybrid composite preparation are Silicon Carbide (SiC) and Aluminium Oxide (Al2O3). Reinforcements are added in 5%, 10% and 15% in volume percentage in to aluminium alloy for composite preparation. The wear performance of the developed composites was analysed using dry sliding test apparatus. The effect of wear study parameters such as load, sliding distance, sliding velocity on the response of wear rate were predicted. This study revealed that Wear rate was influenced by the load significantly. The addition of reinforcement in hybrid composite increases the wear rate up to 10% of addition and reduces the wear rate at 15% of addition. Scanning Electron Microscope (SEM) study displays the wear mechanism clearly. This study concludes that the introduction of reinforcements into the aluminium enhances the wear confrontation of the composites considerably. The developed composite may be used in high wear prone zones effectively.