Three-body Abrasive Wear Behavior Research Articles

Mechanical property analysis and dry sand three-body abrasive wear behaviour of AZ31/ZrO2 composites produced by stir casting

An experimental study of three body abrasive wear behaviour of AZ31/15 vol.% Zirconium dioxide (ZrO2) reinforced composites prepared by stir casting has been carried out. Microstructural analysis of the developed composites was carried out and found out that the microstructure of the composites revealed a uniform distribution of ZrO2 particles with refinement in the grain size of the matrix from 70 to 20 µm. The alterations in the microstructure led to an enhancement in both hardness (68–104 HV) and tensile strength (156–236 MPa) due to Orowan strengthening, quench hardening effect and better bonding. Response surface methodology was applied to formulate the three-body abrasive wear test characteristics such as load, speed, and time. Three body abrasive test results were utilized to generate surface graphs for different combinations of wear test parameters revealed an increase in specific wear rate. The specific wear rate was observed to increase with increase in speed up to a certain level and then started to decrease. The lowest possible specific wear rate was obtained for an optimized load of 20 N and a speed of 190 ms−1. Scanning electron microscopic examination of wear-tested samples showed higher specific wear rate at higher loads with predominantly abrasion type material removal. In conclusion, this study makes a substantial contribution to the field by elucidating the complex relationships among microstructure, mechanical properties, and the three-body abrasive wear behavior of AZ31/ZrO2 composites. The determination of optimal wear conditions and the insights gained into wear mechanisms provide valuable information for designing materials, implementing engineering solutions, and advancing the creation of wear-resistant components across a range of industries.

Experimental investigations on the influence of natural reinforcements on tribological performance of sustainable nanocomposites: A comparative study with polymer technology

Sustainable polymer-based nanocomposites are gaining consideration as a potential alternative to conventional composites in tribological applications. The research aimed to study the influence of reinforcements on the tribological response of sustainable polymer-based nanocomposites. In this work, nine different nanocomposites were developed by the recycling of waste plastics of three different types with incorporation of coconut fibers, jute fibers and nano-sized particles of rice husk ash. Three-body abrasive wear behaviour at five different conditions of loads and speeds were investigated. The wear of the composites increases invariably with the applied loads and speeds, and were in the ranges of 0.0154–0.2212 (cm3) and 0.02207–0.4398 (cm3), respectively. The comparative analysis of the three-body abrasive wear at the conditions of speeds has suggested the reinforcement of coconut fibers with low-density polyethylene for optimum tribological performance, whereas reinforcement of rice husk ash showed an excellent wear resistance for high-density polyethylene and polypropylene composites. The observations for three-body abrasive wear under the considered loads has suggested the incorporation of coconut fibers with low-density polyethene and polypropylene composites, whereas rice husk ash is a suitable reinforcement with high-density polyethene for optimum tribological performance. The rolling behaviour of the nanoparticles has considerably enabled the tribological performance of nanocomposites at extreme conditions of loads and speeds. The research indicated a great potential for natural reinforcement in nanocomposites and will promote the expansion of sustainable polymer-based nanocomposites for tribological applications.

Comparative study on three body abrasive wear behaviour of natural compliant thermoplastic composite under dry and lubricated conditions

This experimental study investigates the three-body abrasive wear behavior of jute/natural rubber flexible green composite under both dry and lubricated conditions. The composite material is prepared using a layering and compression method. A three-body abrasion tester is used to conduct the wear testing under various loads. The use of a lubricant further enhances the wear resistance of the composite, reducing the wear rate and friction coefficient. Mass loss of Jute/Rubber/Jute, Jute/Rubber/Rubber/Jute and Jute/Rubber/Jute/Rubber/Jute in lubricated wear condition is 44.44%, 15.87% and 29.96% less compared to dry wear condition. Wear mechanisms of the composite material are analyzed using scanning electron microscopy (SEM), revealing the presence of fiber breakage, and adhesive wear. Overall, this study provides valuable insights into the abrasive wear behavior of jute/natural rubber flexible green composite and its potential applications in various industrial sectors.

Strengthening mechanism and three-body impact abrasive wear behavior of the hot-rolled air-cooling martensitic wear resistant steel

The microstructure, mechanical properties and three-body impact abrasive wear behavior were investigated. The results indicated that martensite transformation occurred even under air-cooling, and fully martensitic structure consisted of lath martensite and a small amount of twinned martensite was obtained. And the martensite auto-tempering occurred during the subsequent air cooling process, resulting in precipitation of fine ellipsoidal V(C, N) particles and acicular η-Fe2C cementite in the matrix. Meanwhile, the tensile strength, yield strength, Brinell hardness and impact energy (−40 °C) of experimental steel were 1526 MPa, 973 MPa, 454.3 HB and 28 J, respectively. The strengthening mechanism analysis showed that solution strengthening was still the dominant strengthening method even though a large number of carbides were precipitated in the matrix. The dislocation strengthening was limited due to lower dislocation density, and the hot rolled recrystallization led to considerable grain refinement strengthening. Moreover, the results of three-body impact abrasive wear tests indicated that the wear resistance of experimental steel reached a same level as commercial Hardox450 steel. The wear mechanisms of experimental steels were plastic deformation fatigue, abrasive embedded and cutting. The mass loss rates of experimental steel and Hardox450 steel were 0.0033 g/min and 0.0032 g/min under the impact energy of 2.5 J, respectively.

Effect of Ni additions on microstructure, interfacial diffusion behavior and properties of Fe-based/B4C composite coating by vacuum cladding

In order to improve the hardenability and toughness of Fe-based/B 4 C composite coatings, which were bonded on ASTM 1045 steel by vacuum cladding, nNi ( n = 0, 1, 3, 5, weight %) were added into the coatings. The influences of Ni additions on the microstructures, interfacial diffusion behavior, impact toughness and three-body abrasive wear behavior of composite coatings were investigated systematically. The results indicated that coatings were completely fused with steel substrate without micro-defects. When the amount of Ni was increased, the activity of the C atom on the coating side was enhanced, the decarburization zone near the interface disappeared, and the metallurgical bonding state of interface was strengthened. Furthermore, the increment of Ni improved the hardenability of coating and promoted the transformation from pearlite to martensite in the matrix structure of the coating. The impact toughness of the coating samples also increased with the increment of Ni additions, and reached the maximum of 4.8 J/cm 2 at 5Ni sample. The three-body abrasive wear test implied that when 3 wt% Ni was added to the coating, the mass loss was 0.14 g, which was much lower than that of other samples and exhibited the best wear resistance. The wear mechanism of coatings changed from partial plastic cutting and fatigue spalling to single fatigue spalling. • Ni addition strengthens the metallurgical bonding state of the coating interface. • The increase of Ni addition improves the hardenability of the coating matrix. • Ni addition improves the impact toughness and wear resistance of the coating.

Three-body abrasive wear behavior of rice straw fibers reinforced PLA composites

The current study focused on improving the abrasion resistance of rice straw fiber reinforced polylactic acid (PLA) composites. The effect of applied load and rice straw fiber loading on three-body abrasive wear behavior of PLA composites have been investigated. Rice straw fibers were treated with 2 wt% NaOH solution. Both the untreated and treated were produced by injection molding technique. Wear testing was performed on a dry sand/rubber wheel abrasion tester. According to the experimental results, fiber loading and applied load have a significant influence on composite wear loss. The results reveal that the abrasive wear loss of the composites decreases as fiber loading rises, whereas wear loss increases as applied normal load increases. SEM images were used to examine at the worn surfaces of the abraded samples to learn more about how the material was taken away. The treated fiber-reinforced PLA composites showed improvement in wear resistance than the untreated fiber reinforced PLA composites because the NaOH treatment of the fibers increased the fiber–matrix adhesion,

Effect of in-situ (Ti&W)C multiphase particles on three-body abrasive wear of high chromium cast iron

In this paper, the effect of in-situ (Ti&W)C multiphase particles on the microstructure and the three-body abrasive wear behavior of high chromium cast iron was investigated. The results reveal that the different W/Ti ratios in the preforms can lead to significant differences in the microstructure and properties of the composites. The best microstructure and wear resistance of the composite (M3) is achieved when the W/Ti ratio is 4/6. Under the same wear conditions, the wear resistance of the M3 composite is more than twice as high as that of the matrix material. Furthermore, the presence of (Ti&W)C multiphase particles in the microstructure improves the hardness of high chromium cast iron, promoting its transition from cutting, fatigue, and the M7C3 fracture-exfoliation wear mechanism in the abrasive wear to micro-cutting and fatigue wear.

Tribological Characteristics of High-Chromium Based Multi-Component White Cast Irons

It has been evaluated the relationship between the microstructure and three-body abrasive wear behavior of high-chromium (18 and 27 mass % Cr) based (3 mass % each of V, Mo, W, and Co) multicomponent white cast iron materials (high-Cr MWCIs). It was also compared to MWCI to determine the service life of the materials. The results indicate that the microstructure of the material is composed of mainly martensite matrix and different types of precipitated carbides. The wear resistances of both the high-Cr MWCIs are higher than MWCI owing to the higher hardness (4–18% increment in hardness), although they contain fewer carbide types. The carbide volume fraction of high-Cr MWCI increases with increase in the Cr content, but the hardness decreases, leading to a reduction in wear resistance. This is because the transition metal significantly consumes C atoms to form more eutectic carbides during solidification, which is exacerbated by the depletion of C in the matrix during heat treatment to form coarser secondary carbides. This means that increasing the addition of Cr does not always lead to an increase in the hardness or wear resistance of the material. In addition, the wear resistance of 27Cr MWCI after tempering (wear rate: 8.80 × 10−5 g/m) is higher than that after quenching (wear rate: 9.25 × 10−5 g/m) owing to the increase in the fracture toughness of M7C3 carbide. This is contrary to the case of 18Cr-MWCI; the wear resistance after tempering (wear rate: 5.29 × 10−5 g/m) is worse than that after quenching (wear rate: 5.11 × 10−5 g/m) owing to the reduction in hardness as a stress-relieving effect.

Experimental investigation on three-body abrasive wear behaviour of novel natural cellulosic pigeon pea stalk fibre reinforced epoxy biocomposites

The current research explores the possibility of reinforcing massively available, less utilised, low-cost agro-residue fibres in an epoxy matrix to create a new tribo-material. This study focuses on determining the three-body abrasive wear behaviour (volume loss and specific wear rate (SWR)) of natural cellulosic pigeon pea (PP) stalk fibre reinforced epoxy composites. Further, abrasive wear characteristics of untreated and treated E/PP20 (20 wt.% PP stalk fibre-reinforced epoxy) composites were analysed using Taguchi and ANOVA techniques. Untreated and treated biocomposite specimens were developed using the hand lay-up (open mould) technique. At 11.77 N, 23.54 N, and 47 N loads, the SWR of untreated E/PP20 composite was reduced by almost 5.03%, 3.68%, and 22.30% compared to epoxy specimens. Results of the untreated E/PP20 composite showed that the applied load was the main contributing parameter (54.72%), followed by sliding distance (21.82%) and sliding speed (15.31%). Results of the treated E/PP20 composite showed that the applied load was the main contributing parameter (48.96%), followed by sliding speed (26.24%) and sliding distance (20.78%). The regression model predicted the SWR with a pooled error ranging from 2.37% to −17.77% for untreated composite and 9.87% to −11.49% for treated composite, respectively. The alkali-treated E/PP20 composite exhibited better abrasive resistance than the untreated E/PP20 composite. Scanning electron microscopy images of the treated composites showed good fibre adhesion with the matrix. In addition, the surface of the treated composite showed no fibre pullout or ploughing compared to that of the untreated composite. Surface topography revealed the formation of more craters on the surfaces of the untreated composites and small-sized dispersed craters on the treated composites.

Effect of abrasive particle size on the tribological behavior of thermal sprayed WC-Cr3C2-Ni coatings

In order to improve the wear performance of ball mill liners, two types of WC-Cr3C2-12Ni coatings with different Cr3C2 contents were prepared based on high- velocity oxygen fuel (HVOF) spraying technology. The three-body abrasive wear behavior of the WC-10Cr3C2-12Ni (W10N) and WC-30Cr3C2-12Ni (W30N) protective coatings under different particle sizes was systematically evaluated. Results show that the phase composition, microstructure, and mechanical properties of WC-Cr3C2-12Ni coatings were influenced by Cr3C2 content. A large amount of WC phase with good dispersion and fine morphology must be maintained to improve the wear resistance of the coatings. The friction coefficient of both coatings was the lowest when the abrasive particle size was 12.0 µm, but it was still lower than under the no-particle condition. In addition, the friction coefficient of the W30N coatings fluctuated when the particle size were 1.5 and 4.0 µm. The primary wear mechanisms of the two coatings without particles were oxidation wear and fatigue wear, respectively, and the microstructure unevenness and low WC volume fraction led to serious wear of the W30N coatings by preferential removal of the binder phase and pull-out of the WC. The wear mechanisms of the coatings after adding small to large particles were as follows: abrasive particles protected the coatings; rounded the WC grains; and planed the coating to exfoliate in layers. By contrast, the wear resistance of the W10N coatings was obviously superior to that of the W30N coatings. Importantly, the particle size influenced the counter-balls more than the coatings. This study provides potential applications for the surface protection and life extension of ball mill liners.

Study on the three body abrasive wear behaviour of EN8-steel before and after coating of wear resistance material

The effects of aluminum, zirconium, and fly-ash mixture additions on three-body abrasive wear behaviour of EN8- steel have been systematically investigated using a threebody abrasive machine and SiO<sub>2</sub> as abrasive.The coating material is preferred by using 49% aluminum and 49% zirconium is mixed by using 2% fly-ash, the fly ash works as a binder between aluminum and zirconium. Investigate the worn surface of EN8-steel specimen before and after coating of Al<sub>2</sub>O<sub>3</sub>, ZrSiO<sub>4</sub> and fly-ash mixture. The Al<sub>2</sub>O<sub>3</sub>, ZrSiO<sub>4</sub> and fly-ash coated working specimen will give less wear rate in grams compared to working specimen without coating. It clearly shows that using Al<sub>2</sub>O<sub>3</sub> and ZrSiO<sub>4</sub> will reduce the wear rate and increase life of EN8 steel.

Effect of Solidification and Hot Rolling Processes on Wear Performance of TiC-Reinforced Wear-Resistant Steel

As a commonly reinforcing phase in wear-resistant materials, TiC is often added into wear-resistant materials to improve the wear resistance. The independently developed stepped molds with variable thicknesses were used to prepare the TiC-reinforced steels with the same composition though melt solidification processing to study the effect of the solidification rate on the particle size and wear performance. The effect of the hot rolling compression ratio on the particle size and wear performance was also studied. The length and aspect ratios of the particles in heat-treated TiC-reinforced steels with different billet thicknesses and rolling compression ratios were measured. With the increasing in the billet thickness and the decreasing in the rolling compression ratio, the length and aspect ratio of the particles increased in heat-treated TiC-reinforced steels, and the hardness decreased slightly. The three-body abrasive wear behavior of the TiC-reinforced steels was conducted using a standard dry sand rubber wheel wear testing procedure, and the modeling of the wear mechanism was established. The particle size is the main factor affecting wear resistance when the hardness of TiC-reinforced steels is similar. When the particles size is moderate, about 2–6 μm, the particle can break the sand tip and hinder the sand tip from sliding on the surface. In this manner, the mass loss decreased and the wear resistance improved. The large particles will be broken easily by the abrasive, and the small particles are removed easily by the abrasive in the wear process. So, the large and small particles cannot effectively prevent the damage of the abrasive to the matrix, and they have less of an effect on improving wear resistance.

Experimental study on two-body and three-body abrasive wear behaviour of jute-natural rubber flexible green composite

The use of laboratory testing has become more significant to assess abrasion resistance in flexible reinforcement of armour and car structural components. In this study, compliant composite with constituents as woven jute fabric and natural rubber encapsulated in an NR-based B stage cured prepreg were tested for wear due to abrasion under two- and three-body conditions. Flexible composites are fabricated in three different configurations namely Jute/Rubber/Jute, Jute/Rubber/Rubber/Jute and Jute/Rubber/Jute/Rubber/Jute. The present study makes use of abrasive paper with a grit size of 60 and silica sand with size 250 μm as the abrasive medium for two- and three-body abrasion tests, respectively, and the specific rate of wear is calculated. Though the wear trend of the composites follows a similar pattern in the case of two- and three-body wear, the mechanisms governing the wear are found to be different. The morphology of the worn surface is studied with the aid of a scanning electron microscope.

Experimental investigation of three-body abrasive wear behavior of rice husk filled polylactic acid (PLA) composites

Investigation of three-body abrasive wear behavior of rice husk-filled Polylactic acid (PLA) composites of different weight percentages of 90/10, 80/20, and 70/30 and compared with the pure PLA. The experiments were carried in accordance with the ASTM G65 by using a rubber wheel abrasion tester (RWAT). The experiments were conducted for a load of 9.81, 29.46, and 49.65 N at an abrading distance of 300 m using 106microns abrasive dry Silica sand particles as a third body. The results of the experimental study revealed that the weight loss increases with an increase in applied load and wear resistance increases with an increase in fiber content in PLA composites. The greater wear resistance occurred at 30 wt% of rice husk fiber in the composite. With the help of a Scanning Electron Microscope (SEM), the worn surfaces are analyzed.

Investigation on influence of SiCp on three-body abrasive wear behaviour of glass/epoxy composites

The present study present the influence of SiCp incorporation on three-body abrasive wear behavior of glass/epoxy composites. The investigations was carried out using dry sand rubber wheel abrasive wear test apparatus. 2k factorial design of experiment was used to capture the experimental data. The parameters considered are abrading distance, load and speed. The wear volume loss found to increase with the increasing values of wear parameters. The applied load has exhibited significant effect on volume loss. Incorporation of SiCp contributed to enhance wear resistance of glass/epoxy composites. The linear regression was also presented in the study to correlate abrasion parameters with wear volume loss. SEM image analysis of abraded surface revealed the occurrence of ploughing, micro-cutting, matrix removal and fiber breakage.

Effect of titanium binder addition on the interface structure and three-body abrasive wear behavior of ZTA ceramic particles-reinforced high chromium cast iron

The effects of Ti alloy binder addition on the wettability, interface microstructure, and three-body wear behaviors of ZTA ceramic particle-reinforced composites were investigated systematically. With binder addition from 5% to 15%, molten Cr26 can wet the ZTA ceramic surface, with a wetting angle of only 17.7°. Oxygen and iron atoms diffused into the transition layer to form a metallurgical bonding interface, which enhanced the interface bonding strength and brittleness. A combined supporting effect of the Cr26 matrix on the ZTA ceramic particles and protecting effect of the ZTA ceramic particles on the matrix during wear resulted in an improvement in wear resistance. The brittleness interface harmed the wear resistance at a higher load (2 kg and 3 kg). This indicates the ZTA ceramic particles has positive influence on the wear resistance of composites.

Effect of reinforcement and applied load on three-body dry sand abrasive wear behavior of A356 bottom ash metal matrix composites

In the present study, effect of reinforcement and applied load on three-body dry sand abrasive wear behavior of A356-bottom ash metal matrix composites was carried out. The composites were fabricated using liquid metrological technique. The obtained as-cast specimens were heat treated at solutionizing temperature of 530 °C for 6 h followed by ice quenching with ageing time of 2 h. The sand abrasive wear tests were conducted at room temperature using silica sand of 200 µm as an abrasive medium as per ASTM standard G 65–81. Speed of 200 rpm, time of 30 min was kept constant for all the tests and wt% of reinforcement (2, 4, 6, 8, 10 wt%) and load of (2, 4, 6, 8, 10 N) was varied for five levels. The obtained results revealed that, the wear rate is affected from heat treatment and varying wt% of reinforcement and applied load. The wear resistance increases with the increase in percentage of reinforcement and decreases with the increase in the applied load for the given speed and time. Further, worn surfaces and wear mechanism was analyzed by using scanning electron microscope.

Effect of stacking sequence on the tribological behaviour of jute-glass hybrid epoxy composite

In the present work, an attempt has been made to study the three body abrasive wear behaviour of laminate hybrid composites consisting jute fiber/glass fiber reinforced with epoxy resin. The composites samples with different stacking sequence like S1 (GJJJJJJJJG), S2 (GJGJGGJGJG) and S3 (JGJGJJGJGJ) with glass (G) and jute (J) were fabricated using hand layup technique. The three-body abrasive wear behaviour of the designed hybrid composite was carried out as per ASTM G65 standards. The results indicate that the S2 composite exhibits higher wear resistance among the developed composites. The scanning electron microscope (SEM) study was performed for the worn surfaces of the composites to find out the wear mechanism.

Development of Temperature-controlled and Humidity-controlled three-body Abrasive Wear Testing Machine based on MLD-10 Dynamic Abrasive Wear Testing Machine

In order to simulate engineering machinery (such as mining machinery, feed pellet machine, building machinery and so on), which existence of different degrees of high temperature and humid corrosion three-body abrasive wear behavior in the laboratory environment. In view of the current three-body abrasive wear testing machine cannot simultaneously take into account the composite conditions characteristics of the three-body abrasive wear behaviour, high temperature and humidity, and make the optimization design, based on the MLD-10 dynamic abrasive wear tester. It includes corrosion and wear groove, fluid medium, temperature measuring and controlling device, stirring device, etc. A three-body abrasive wear testing Machine that can control temperature and humidity. Subsequently, the simulated working condition test of the ring die of feed pellet machine were carried out. The test results show that the wear appearance of the test sample is basically consistent with that of the real ring die of feed pellet machine. It indicates that the developed testing machine can simulate the high temperature and humid three-body abrasive wear behavior, and has good reliability and applicability.

Study of the three-body impact abrasive wear behaviour of a low alloy steel reinforced with niobium

In order to improve the wear resistance of steel, a new Nb-added reinforced low-alloy wear-resistant steel was developed, and the wear behavior of the three-body impact abrasive was systematically studied under the impact energy of 0.5J, 2.5J, 4J, 5J. Tensile testing, scanning electron microscopy (SEM), transmission electron microscopy (TEM) and nanoindentation were used to characterize the mechanical properties, microstructure evolution and wear mechanism of steel. The experimental results show that NB05 (0.05 wt%-Nb) steel with smaller size lath martensite has higher strength performance and better impact wear resistance than NB0 (0 wt%-Nb) steel. During three-body impact abrasive wear tests, the corrected wear rate was less under higher impact energy for both steels, and the NB05 steel owned less wear rate than NB0. The main strengthening mechanisms of the wear layer were newly formed martensite twins, niobium precipitates, high density dislocations and the formation of nanoscale grains for the NB05 steel. The wear mechanism of the wear layer is mainly reflected in buffering, lubrication and protection of debris.