Wear Behavior Research Articles

Wear behaviour of borided α, α+β and β Titanium alloys

This study aims to compare the wear properties of borided biomedical-grade titanium alloys, namely Cp-Ti, Ti-6Al-4V and Ti-45Nb, from basic classes each possessing α, α+β and β crystalline structures, respectively. The work also focuses on identifying the wear mechanisms that occur during tribological testing. Wear tests were conducted on surface treated samples under conditions that yielded maximum thickness and hardness values. A pin-on-disk tribometer with reciprocating motion, using a WC-Co ball as the counterface, was employed for dry sliding wear tests. Wear resistance was evaluated through wear track measurements and weight loss methods. Morphological features, microstructure of tested surfaces and also the debris generated were also analysed. At loads up to 12 N, mild polishing wear with shallow scratches and no detectable weight loss was observed across all titanium alloys. The Ti-45Nb alloy exhibited the most severe wear at 17 N due to the thinner boride layer, higher surface roughness, lower hardness and adhesion strength, resulting in premature degradation. Above 17 N, signs of delamination, microcracks, and chipping appeared to some extent in Cp-Ti and Ti-6Al-4V alloys, primarily ascribed to fatigue wear. However, no weight loss was recorded across all tested loads, indicating superior wear resistance.

Effect of AA 6351-ZrB2 in-situ composition on dry sliding wear performance at elevated temperatures

Abstract The dry sliding wear behavior of AA 6351 aluminium alloy composites in-situ reinforced with synthesized ZrB2 at elevated temperatures were investigated aiming at practical engineering applications. A low-cost, reactive system of KBF4 and K2ZrF6 was reacted with the molten AA 6351 matrix at 850 °C to form ZrB2 particles within the AA 6351 matrix. Uniaxial Strength and Elastic Moduli of ZrB2–SiC Composites with Various ZrB2 Contents (0 wt.%, 3 wt.%, 6 wt.%, and 9 wt.%) at 100 °C and 200 °C according to the method of the ASTM G99-95a standard. The addition of ZrB2 increased wear resistance dramatically, and the 9 wt. % ZrB2 composites instead of their unreinforced counterpart at 100 °C and 200 °C and/or which are 45–38% lower than that of unreinforced alloy. After the solutionizing and artificial aging, the wear resistance can be additionally increased by approximately 15–20% due to the precipitation hardening (fine Mg2Si particles formation) and a stronger matrix-particle interfacial bonding. Reinforced composites exhibited enhanced load-bearing capacity, increased thermal stability, decreased adhesive and abrasive wear. The wear resistance observed in these composites is consistent with strong scientific theory that ceramic particle reinforcement improves mechanisms of load transfer and crack deflection, suggesting that AA 6351- ZrB2 composites are well suited to aerospace brake system and automotive friction lining applications, where improved wear resistance translates to service life extension and reduced maintenance costs. Optimizing the size and uniformity of the ZrB2 particles and the process conditions could yield more significant benefits for high-temperature wear-sensitive applications.

Discrete Element Modeling of Fracture Behavior and Stress Analyses in Thermal Barrier Coatings During Wear Tests

Abstract Thermal barrier coatings (TBCs) are extensively used in various industrial applications due to their high-temperature thermal insulation and environmental protection when applied to the surfaces of engine components. Wear and frictional behaviors are important when the TBCs are subject to foreign object contact. To characterize the wear performance of TBCs, this study presents an improved discrete element method (DEM)-based model to investigate the wear mechanisms induced by friction at the microscopic level. The studied TBCs consist of a ceramic top layer, a metallic bond coat, and a high-temperature nickel superalloy as the substrate, with the assumed thicknesses of 0.25 mm, 0.15 mm, and 0.8 mm, respectively. The simulation results indicate that the wear of the coating occurs in four stages: initial microcrack formation stage, particle detachment and small pit formation stage, extensive detachment and increased pit formation stage, and intensified extrusion and surface damage stage. The growth trend of crack and bonding failure energy resembles an “S” shape. The calculated coefficients of friction show a good agreement with experimental data in terms of normal force dependence. Using the Hertzian contact theory, the DEM shows that the maximum stress-induced crack formation was greatest at the contact edge. The maximum tensile stress, maximum compressive stress, and maximum shear stress increase with contact load. The shear stress distribution is entirely confined within the coating and did not significantly affect the coating substrate.

Effects of Al2O3 Doping on Microstructure and Wear Behavior of Plasma-Sprayed CoCrAlTaY-Al2O3 Cermet Coatings

Effects of Al2O3 Doping on Microstructure and Wear Behavior of Plasma-Sprayed CoCrAlTaY-Al2O3 Cermet Coatings

Frictional and Particle Emission Behavior of Different Brake Disk Concepts Correlated with Optical Pin Surface Characterization

Brake wear emissions can be reduced by altering the surface of brake disks. A parametric study using a gray cast iron and a laser-cladded brake disk was performed in a pin-on-disk experiment with integrated optical pin surface characterization and particle emission measurement. Significant differences in the friction, wear and emission behavior are present. The high wear-resistance of the laser-cladded disk led to a reduction of 70% of the particle number emission relative to the gray cast iron disk, but the coefficient of friction was unstable. The surface of the pin used with the gray cast iron showed an initial large debris extension and protruding patches that were removed at high braking energies, exposing white patches and creating holes. These observations correspond to known processes from the plateau theory. The surface of the pin used with the laser-cladded disk showed a topography dominated by holes with almost no protruding patches. The braking condition did not influence the pin surface, implying that the disk and not solely the pin surface might be governing the friction process, and therefore challenging the applicability of the plateau theory to laser-cladded disks. To further study this aspect, a segmentation method was developed for the pin surface images and topographical data to extract and quantify different features on the pin, such as debris, patches, holes and the tribolayer. The correlation of the surface coverage ratios of the feature classes with the braking conditions (speed and applied pressure), the coefficient of friction and the emissions confirmed the differences between the gray cast iron and laser-cladded brake disk.

An Experimental Investigation of the Impact of Additive Concentration on the Tribological Performance of Castor Oil Lubrication in Piston Ring–Cylinder Liner Contact

This experimental study investigates the critical role and impact of additive concentration in enhancing the tribological performance of castor oil as a biolubricant for agricultural tractor engines. Friction and wear are major contributors to reduced engine efficiency, highlighting the need for effective lubrication strategies. While biolubricants like castor oil offer environmental benefits, they often require additives to achieve optimal performance. However, the concentration of these additives is crucial, as an imbalance can negatively impact the lubrication system, leading to a higher coefficient of friction, increased wear, and reduced engine efficiency and lifespan. This study examines the effects of varying concentrations of a mixture of propyl gallate (PG) and ionic liquid (IL) additives on the tribological performance of castor oil. The tribological behaviour of lubricated top compression piston ring and cylinder liner samples was evaluated under simulated engine conditions using a Bruker UMT Tribolab test rig, in accordance with the ASTM G181 standard. The experimental results revealed an influence of additive concentration on the coefficient of friction and wear behaviour. This emphasises the importance of optimising additive formulations to minimise engine wear and friction. Notably, a 0.5% volume concentration of the additive mixture led to a remarkable 34.8% reduction in the average coefficient of friction (COF) and a lower wear rate.

Machining Performance and Wear Behavior of TiVN-Coated SiAlON Tools in Sustainable Machining of Hardened AISI-D3 Steel under Dry and Hexagonal Boron Nitride-Mixed Nanofluid Minimum Quantity Lubrication Conditions

Machining Performance and Wear Behavior of TiVN-Coated SiAlON Tools in Sustainable Machining of Hardened AISI-D3 Steel under Dry and Hexagonal Boron Nitride-Mixed Nanofluid Minimum Quantity Lubrication Conditions

Wear behaviour of deep cryogenically treated coated tool during end milling of XH67MBTHO

XH67MBTHO is a Ni-based superalloy which finds usage in high temperature applications of aero engines. However, attributed to some of their inherent properties like strain hardening and poor thermal conductivity, tool life characteristics are adversely affected during the machining operations. The use of conventional TiAlN coated tools can address the tool wear issues faced during machining of similar Ni-based alloys. However, severe coating delamination, and significant adhesion wear mechanisms could negatively influence the effectiveness of the tools at dry lubricating conditions. The current study investigates the influence of a sustainable manufacturing technique through DCT (Deep Cryogenic Treatment) and its impact on coated tool inserts to address the tool wear issues under dry machining conditions. The DCT aids in the formation of η (eta) phase carbides, β-phase densification etc. Hence, the tool substrate develops significant wear resistance and fracture toughness in withstanding the contact stress at the machining interface. Notch wear, micro-crack formations, and built-up layer generations were observed to be major wear mechanism, and for treated tool (TT) it was less severe. Furthermore, the maximum reduction in average flank wear widths for treated tool was observed to be 26%, while the cutting force and surface roughness values were found to be reduced by 27%, and 24% respectively compared to untreated tool (UTT).

A computational study on wear behavior in piston ring-cylinder liner assemblies

The interaction between piston rings and cylinder liner, constituting a pivotal frictional pair within an internal combustion engine, profoundly impacts both engine efficiency and longevity. This study models the wear process of engine components, specifically the dry sliding wear of 2D piston ring-on-cylinder liner interactions, specifically under lubrication-free conditions, in a uniflow scavenged two-stroke engine using finite element method (FEM) in ANSYS APDL using the differential Archard wear model. The k − ε turbulence model is employed to simulate in-cylinder pressure in an engine cycle, showing minimal discrepancies from experimental data. The wear model incorporates material properties, contact mechanics, and operational parameters, employing advanced finite element method to simulate real-world conditions accurately. Key variables such as material hardness and contact pressure are examined to determine their influence on wear depth. The simulation results indicate that wear is significantly affected by the surface hardness of the interacting materials. The liner experiences more wear than the piston ring due to its lower hardness and higher wear coefficient. The developed model is validated against Hertz contact pressures, demonstrating high accuracy and reliability. In other words, the FEM results for contact pressure closely matched the predictions from the Hertz analytical solution. This study introduces integrating OpenFOAM simulation outputs as input for ANSYS APDL, enabling a more comprehensive and accurate wear analysis. Additionally, the wear simulation is conducted on a real large two-stroke engine, enhancing the practical relevance of the findings. This approach provides deeper insights into the wear behavior of piston ring–liner interactions under real-world operating conditions, offering a significant advancement over conventional modeling techniques.

Tribological study on the effect of surface texturing on scuffing resistance and wear behavior under lubricated conditions

Purpose Scuffing is a severe form of adhesive wear that can lead to catastrophic surface damage in tribological systems. This paper aims to investigate the failure mechanism of scuffing and to propose an effective surface engineering strategy to enhance the anti-scuffing performance of frictional components. Design/methodology/approach Friction and wear experiments were conducted under oil-lubricated conditions to monitor the scuffing behavior. The surface morphology and tribological parameters before and after scuffing were compared. Based on the scuffing criterion, linear velocity and load were selected as key variables. The PV value curves were obtained to determine the critical scuffing point. A surface texture was then applied to improve tribological performance. Findings The results revealed that scuffing occurred more easily with increasing velocity and load. The PV value effectively indicated the critical point of scuffing. Surface texturing improved lubrication and wear resistance, delaying scuffing under severe conditions. Practical implications The research in this paper can evaluate the performance of materials under friction and wear conditions, determine the critical point at which scuffing occurs and be applied in engineering to optimize process conditions and predict the failure behavior of materials. Originality/value The originality of this paper proposes a textured surface design to reduce scuffing risk. The texture enhanced lubrication and load capacity, providing a practical approach to improve material durability in mechanical systems. Peer review The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-11-2024-0426/

Effect of Liquid CO2 on Wear Behaviour of TiAlN Hard Coating at Elevated Temperatures

PVD hard coatings improve the wear and frictional properties in metal cutting and, therefore, extend the lives of cutting tools. Cutting fluids, including the novel use of liquid carbon dioxide (LCO2), are crucial for reducing tool wear and enhancing machining efficiency. This experimental research is focused on ball-on-disc wear tests of TiAlN hard coatings in environmental, N2 and CO2 atmospheres. In the latter case, the experiments were also performed by adding LCO2 directly into the contact zone. In order to achieve the same temperatures as real cutting conditions, tests were performed at 250 °C, 500 °C and 700 °C, in addition to room temperature. Results show that the TiAlN coating had the highest wear rate in room-temperature tests, regardless of the atmosphere. The wear significantly dropped with the test temperature. It was the lower in the CO2 atmosphere at all temperatures than in all gas-only atmospheres. When LCO2 was introduced to the contact, the wear was at its highest at 500 °C, which is the opposite of all other gas-only atmospheres, where it was at its lowest. In all tribological LCO2 tests, we noticed increased friction coefficient fluctuations. In all gas-only atmospheres, adhered material was observed on the wear tracks, but in LCO2, wear debris was not detected either on the disk or on the ball.

Wear behaviour of high entropy alloys CrFeNiAl0.3Ti0.3 and CrFeNiAl0.3Ti0.3–Ag roll bonded with steel

Abstract This study explores the feasibility of cladding CrFeNiAl0.3Ti0.3 and CrFeNiAl0.3Ti0.3–Ag high entropy alloys, produced via hot-press sintering (HPS), with commercial mild steel using the hot roll bonding (HRB) method. The bonding interface characteristics, mechanical properties, and tribological performance of these laminated composites were systematically evaluated. Microstructural analysis revealed that both high entropy alloys formed good metallurgical bonds with mild steel, exhibiting a straight interface free of visible cracks and oxidation products. Tribological investigations demonstrated that hot rolling significantly enhanced wear resistance, with specific wear rates decreasing by 70–82%. After hot rolling, the specific wear rate was reduced to (7.08–8.37) × 10–5 mm3/Nm for CrFeNiAl0.3Ti0.3 and (6.12–7.05) × 10–5 mm3/Nm for CrFeNiAl0.3Ti0.3–Ag across a temperature range from room temperature to 900 °C, compared to their pre-rolling values. These findings highlight the potential of hot roll bonding for integrating high entropy alloys with conventional materials, offering promising prospects for applications requiring high wear resistance and thermal stability. Graphical abstract

Fretting wear behavior of electroplated chromium coatings on TC6 alloy at room and high temperature

Abstract This study explored the performance of chromium coatings in protecting titanium alloys against fretting wear at varying temperatures. The hardness (H) and elastic modulus (E) of the coatings, electroplated on titanium alloy surfaces, were measured at 25°C, 150°C, and 250°C. Fretting wear tests revealed that as temperature increased, the wear mechanism transitioned from abrasive to adhesive and oxidative wear. Wear volume decreased, and fretting wear resistance improved. The findings suggest that at higher temperatures, fretting wear behavior is influenced by thermal softening and oxidation. Therefore, static mechanical properties (H and E) do not fully predict fretting wear resistance in complex conditions.

Investigation on the Dry Sliding Wear Behavior of LM 25 Alloy Amalgamated with Novel Combination of Modifiers

Investigation on the Dry Sliding Wear Behavior of LM 25 Alloy Amalgamated with Novel Combination of Modifiers

Microstructure, Mechanical Properties, and Wear Behavior of an Improved Rock-Breaking Cutter Ring Steel Used on Tunnel Boring Machine

Microstructure, Mechanical Properties, and Wear Behavior of an Improved Rock-Breaking Cutter Ring Steel Used on Tunnel Boring Machine

Mechanical property evaluation and wear optimization of LM13 MMC reinforced with AlTiVZrCrMo high entropy alloy.

Mechanical property evaluation and wear optimization of LM13 MMC reinforced with AlTiVZrCrMo high entropy alloy.

Influences of the metastability of austenitic stainless steels on the wear behavior in a radial shaft seal system

Influences of the metastability of austenitic stainless steels on the wear behavior in a radial shaft seal system

Microstructure evolution and wear behavior at room and high temperatures of Mo2C particle reinforced CoCrFeNiMn high-entropy alloys composite coatings prepared by induction cladding

Microstructure evolution and wear behavior at room and high temperatures of Mo2C particle reinforced CoCrFeNiMn high-entropy alloys composite coatings prepared by induction cladding

Evaluation of wear, corrosion, and biocompatibility of a novel biomedical TiZr-based medium entropy alloy.

Evaluation of wear, corrosion, and biocompatibility of a novel biomedical TiZr-based medium entropy alloy.

Experimental and numerical investigation of the Ti-Ni-Cu coating on AZ91D magnesium alloy by laser surface-modification: The microstructure, wear and corrosion behavior

Experimental and numerical investigation of the Ti-Ni-Cu coating on AZ91D magnesium alloy by laser surface-modification: The microstructure, wear and corrosion behavior