Wear Damage Research Articles

Implementation of Risk Management in Asset Management Governance Towards Optimizing Asset Utilization at Public Service Agency State Universities (Case Study of UPN Veteran Yogyakarta)

This study aims to analyze the application of risk management in asset governance at UPN Veteran Yogyakarta to achieve optimal asset utilization. As a Public Service Agency State University (PTN-BLU), UPN Veteran Yogyakarta faces various challenges in asset management, including budget constraints, lack of consistent monitoring, and the unavailability of formal risk evaluation standards. Qualitative descriptive research methods are used to gain in-depth understanding through interviews with asset managers and field observations. The results show that the implementation of risk management can have a significant impact on the efficiency of budget allocation, which includes more appropriate budget distribution based on priority needs and risks. Risk management also has the potential to extend the useful life of assets, with risk mitigation measures taken on assets that show signs of wear or early damage, thus preventing major repair costs due to serious damage. This research highlights that a technology-based monitoring system is an indispensable aspect to support the effectiveness of risk management in asset management. The implementation of structured risk assessment procedures helps in determining asset maintenance priorities, so that the assets that are most critical to the sustainability of campus operations receive greater attention. With the implementation of this comprehensive risk management, optimization of asset utilization can be achieved, which in turn supports the stability and sustainability of UPN Veteran Yogyakarta's operations as a quality higher education institution.

Neural network-enhanced internal leakage analysis for efficient fault detection in heavy machinery hydraulic actuator cylinders

This work presents a method for detecting internal leakage faults in hydraulic actuator cylinders using signal analysis and a supervised artificial neural network classifier. An artificial leakage is introduced into the hydraulic cylinder actuator, and a signal-based fault detection method is employed to process and transform the signals for internal leakage detection. The analysis focuses on extracting features from the pressure signal, particularly the peaks, which include information such as location, height, and width. After the neural network has undergone the training process, it is deployed for the purpose of categorizing fault levels into three distinct categories: “a healthy system,”“a system with a low fault,” and “a system with a high fault.” The proposed technique utilizes pressure difference signals from the cylinder chambers and extracts features from the peak signals to reduce dimensionality. The extracted features are then used for supervised training of an artificial neural network using a feed-forward algorithm. The trained network is capable of predicting the leakage class of unknown datasets. This method offers advantages such as reduced computational cost through feature extraction and dimensionality reduction, and it is capable of detecting multiple leakage classes. This study introduces a notably efficient approach, predicated on artificial neural networks, for the identification of internal leakage faults in hydraulic cylinders, with specific emphasis on faults arising from component wear and seal damage. The practical value of this research lies in its potential to significantly improve the reliability and efficiency of hydraulic systems used in heavy machinery. By utilizing neural networks for internal leakage detection, this research addresses a critical issue that can lead to costly downtime and maintenance in industrial operations.

An Experimental Assessment Using Acoustic Emission Sensors to Effectively Detect Surface Deterioration on Steel Plates

Acoustic emission (AE) testing is used for the continuous evaluation of structural integrity and the monitoring of damage evolution in structural components and materials. During operation, the environmental and loading conditions of metal structures can result in corrosion and surface wear damage. The early detection of surface degradation flaws is crucial, as they can serve as local stress concentration points, leading to crack initiation and failure. In this work, the effectiveness of AE in monitoring corrosion and surface wear flaw formation was experimentally evaluated. AE sensors were installed on steel test plates during the artificial induction of corrosion and surface wear in order to detect and record the generated AE signals. Corrosion-related AE signals typically exhibit low amplitude, count, and energy values. The direct detection of active corrosion can be challenging in noisy environments, but it can be carried out under certain conditions using dedicated AE sensor groups. Surface-wear-related AE signals exhibit high amplitude, energy, and count values, with long duration values that are associated with wear and grinding conditions. It was found that AE sensors can be utilised to detect corrosion and surface degradation events. The effectiveness of the AE method in detecting surface degradation in noisy environments can be improved by implementing a filtering methodology. This will limit the recording of noise-related signals that can mask out actual surface degradation AE events.

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.

Analysis of fatigue damage of hot rolling work rolls coupled with wear effect

During the hot rolling process, the work roll experiences cyclic contact stress due to the deformation of the strip steel, as well as thermal stress from periodic heating and cooling. The surface failure of the work roll results from the combined effects of wear and fatigue damage. This study proposes a comprehensive approach to analyzing coupled wear and fatigue damage using a method based on the Manson-Coffin equation, modified slope formula, and the Miner criterion. Finite element models were developed to simulate simplified heat transfer and thermal coupling, taking into account the actual rolling parameters and high-temperature material properties of the work roll. The evolution of the physical field of the work roll during the rolling process was analyzed. The analysis of these models revealed that the maximum strain on the work roll occurred at the rolling exit and was predominantly influenced by temperature. The effects of rolling speed and temperature on work roll strain varied, with fatigue damage being significantly reduced when wear was considered compared to scenarios where wear was not accounted for, under the same number of cycles.

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.

Performance assessment of agricultural waste based eco‐friendly brake friction composites

AbstractThere has been growing interest in using sustainable and eco‐friendly products to produce engineering materials. For this purpose, composite material applications obtained from agricultural wastes are gaining popularity. This study examines the synergistic effect of rice husk and rice stalk wastes on the fade and recovery performance of brake friction composites. Brake friction materials were developed using rice husk and rice stalk separately and in two different weight percentages as a 5–10 ratio in the formulation. For comparison purposes, a reference brake pad using copper as a substitute and a commercially available brake pad were used. Various physical, mechanical and thermal properties were analyzed. The tribological behavior of friction composites was evaluated on the Krauss test device in line with the ECE R90 procedure. The worn surface properties were analyzed using scanning electron microscopy. Tribo test results of friction composites were taken as criteria for performance optimization. While the importance weight of the criteria was determined by AHP, the VIKOR method was used in the sorting of alternatives. The experimental results have revealed that rice husk‐added friction composites had a good coefficient of friction value with better fade and recovery performance compared to rice stalk‐added ones. Increasing the amount of rice husk and rice stalk in the formulation tended to decrease the fade performance; however, it has increased the wear rate and recovery properties. Optimization results have shown that the brake friction composite containing 5 wt % rice husk ranks first in meeting the desired tribological criteria.Highlights Cu‐free rice husk and rice stalk‐added friction composites were developed. Fibrous structure in the matrix developed the contact plateaus. Rice husk‐based tribo‐layer protected the composite from further wear damage. The addition of agro‐waste to friction composites exhibited good potential.

Fabrication of FeCoNi alloy film via friction-assisted selective area electrodeposition

Nowadays, carbon neutrality target has been receiving a growing attention in academia and industry. In many industry applications, the wear and fatigue damages of bearing components are the frequent failures affecting machine operation. The maintenance and replacement of damaged bearings cause enormous cost in the aspects of consumptions of energy and materials. In this study, a novel technique of friction-assisted electrodeposition (FAED) is firstly demonstrated for surface remanufacturing of worn bearing races. By using the FAED technique, FeCoNi alloys with nanocrystalline were successfully deposited on the selective surface zone. The surface morphology, microstructure feature as well as mechanical properties of the deposited FeCoNi film were quantitatively characterized. The results have indicated that friction load and electrodeposition time have a remarkable effect on the microstructure of the film and its surface finish. The cross-section exhibited a uniform distribution of Fe, Co and Ni. Meanwhile, typical amorphous and polycrystalline features were observed within the deposited film. Additionally, the as-deposited layer shows desired mechanical properties, including hardness, complex modulus and friction coefficient, matching with those of the GCr15 substrate. Scratch test results showed that a good bonding strength between the coating and the bearing steel was achieved. Moreover, the role of friction in the electrodeposition process has been analyzed. This work provides a new route to achieve selective area electrodeposition of alloy films on bearing steel, which can be further developed for metal surface repairing.

Progressive Tooth Wear Against Resin-Based Restorative Composites.

The composition and properties of resin-based composite materials could affect tooth wear and lead to clinical problems. Therefore, the study objective was to characterize human tooth wear behavior against a bulk-fill restorative (BF) compared to a conventional resin composite (RC) and a CAD/CAM resin nano ceramic (RN). Square-shaped specimens of each material were prepared and sub-divided according to the number of testing cycles (n=8): 100,000, 250,000, and 500,000 cycles. An occlusal wear test was performed using a chewing machine with 49 N, 2 Hz, in 37°C distilled water. Human premolar cusps were used as antagonists. Micro-CT and laser scanner were used to scan antagonists and specimens, respectively. Wear volume was assessed using a software and the wear pattern was examined with SEM. Softening in solvent analysis was performed by measuring the materials' Knoop microhardness (KHN) before and after immersion in ethanol. Wear volume data were analyzed with two-way ANOVA and Student-Neuman-Keuls test (α=0.05). For tooth and specimen wear volume, there was statistical significance for material and number of cycles, but not for the interaction between factors. BF resulted in less tooth (p=0.008) and specimen (p=0.030) wear than RN and RC, which were similar (p⟩0.05). Volume loss increased from 100,000 to 500,000 cycles. BF showed the lowest microhardness (KHN1); and %ΔKHN similar to RC, but greater than RN. BF induced less volume loss to the tooth than RC and RN, while presenting greater wear resistance. The tooth wear pattern and damage progression were mild for all materials. Resin composites show favorable wear behavior, leading to low volume loss and mild structural damage of the tooth. Regular bulk-fill resin composite stands out for its efficient restorative technique, low wear susceptibility and reduced capacity to wear down the tooth.

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.

Fabricating ultra wear-resistant surfaces on titanium alloy by combining laser-induced modification with abrasive belt grinding

A novel method combining laser-induced modification and abrasive belt grinding (LM&BG) was proposed to prepare wear-resistant surfaces of titanium alloys. Comprehensively investigated the evolution mechanism of material modification and wear resistance of LM&BG samples. It was found that an oxide-ceramic-modified layer with increasing hardness (10 times) was formed by laser modification on the titanium alloy, mainly composed of TiO2, with the two phases Rutile-TiO2 and Anatase-TiO2. Moreover, the surface roughness after abrasive belt grinding of the modified layer is less than Ra0.1, with a uniform subsurface microstructure. Interestingly, the wear modes of the modified layer shifted from adhesive and oxidative wear to brittle microdetachment, significantly reducing the coefficient of friction, material wear, and subsurface damage, thus improving the wear-resistant capability.

Investigations into rubbing wear behavior of honeycomb land against labyrinth fin with periodic-cell model

The periodic-cell model was proposed to simulate the successive contacts between the labyrinth fin and multiple honeycomb cells. With the experimental data, the finite-element-analysis (FEA) method with the periodic-cell model was validated. The effects of incursion parameters (i.e. incursion depth, incursion rate and sliding velocity) on the contact force, frictional temperature, material loss, and worn geometry of the honeycomb seal during the incursion process were studied. With the predicted worn geometry, the sealing performance degradation in the honeycomb seal was analyzed. The results showed that the proposed periodic-cell model has an excellent accuracy in predicting the wear behavior of honeycomb seal in rubbing events. The contact force between the honeycomb liner and labyrinth fin is pronounced especially at low sliding velocity and high incursion rate conditions, which increases the possibility of wear damage in the rotor part. At low sliding velocity and low incursion rate conditions, the frictional heat transferring to rotor part is increased, which increases the thermal stress near the contact region of the rotor part. As the clearance gap of honeycomb seal increases from 0.6 mm to 0.9 mm in the rubbing event, the leakage rate is increased by about 12%, and the carry-over effects downstream of the worn cells are increased.

Wheel tread temperature assessment and its impact on rolling contact fatigue under long-term braking conditions

To analyze the temperature rise of the wheel tread under braking conditions and its impact on the rolling contact fatigue (RCF) of the wheels, this paper proposes a numerical analysis method based on thermodynamics, material mechanics, and wheel-rail contact mechanics. This method has features of simplicity and fast computing speed. The study shows that the temperature rise of the wheel tread is mainly affected by the thermal friction between the brake pad and the wheel tread. The effects of track gradient, braking speed, and ambient temperature on wheel tread temperature rise are 16 °C/‰, 9.4 °C/km h⁻¹ , and 10 °C/°C, respectively. Therefore, reducing the gradient of the track, locomotive braking speed, and braking duration can help reduce the wheel tread temperature, thereby slowing the development of RCF of the wheels. The study shows that the value of RCF considering the temperature rise of the wheel tread is about 1.55 times that without considering the temperature rise, while the value of wear damage is reduced by 23 %. Therefore, when analyzing wheel damage, the comprehensive effects of RCF, wear, plastic flow, and temperature are recommended to be considered from different angles to provide a basis for reducing wheel damage.

Peridynamic study on thermomechanical damage of the rail during wheel idling

Wheel idling is an extreme sliding contact scenario that accelerates rail failure. Using temperature-dependent elastoplastic materials, a peridynamic (PD) model for wheel-rail contact was developed to investigate the thermomechanical damage behavior of rails during wheel idling. Numerical simulations of loading and unloading during wheel idling under different loads were performed, and the results of contact stress, temperature, plastic deformation, and material damage were obtained and analyzed. During loading, the temperature of the rail surface increases rapidly to over 1200 °C, which is well above the austenitization temperature. The intense thermal softening caused by high temperatures deteriorates the wheel-rail contact relationship and leads to a surge in plastic deformation. The softened surface material was continuously removed by the contact load, leading to severe wear damage, and the wear depth increased significantly with the load and idling time. The wear coefficients for the Archard wear model were derived using the wear results from the PD model. During unloading, the surface material cools rapidly at a rate of 1400°C/s through heat transfer into the rail, undergoing martensitic transformation and forming a brittle and hard white etching layer. The thickness of the WEL decreases as the wear depth increases.

Impact and tangential composite fretting wear of Zr-4 alloy tubes under random loading conditions

The fuel rod casing tube is a crucial component in pressurized water reactor (PWR) nuclear power plants. Flow-induced vibrations in the circulating water can result in complex alternating fretting wear between the casing tube and the positioning lattice frame. Existing research on fretting wear has primarily focused on unidirectional wear, with limited investigation into composite fretting wear under complex working conditions. This study conducted impact and tangential composite fretting wear tests on Zr-4 alloy tubes under varying constant and random impact loads to examine fretting wear behavior. The findings show that the peak friction coefficients in the impact and tangential composite fretting wear tests were consistent across the three constant load conditions, with higher peak friction coefficients observed under random load conditions and a longer time required to reach these peaks during micromotion tests. Comparative analysis revealed that random impact and tangential composite fretting wear caused the most severe damage. Under constant load conditions, wear damage became more severe with increasing load, transitioning from oxidized and adhesive wear to a peeling layer as the load intensified in the impact and tangential composite fretting wear tests.

Laser-assisted Belt Grinding with Creep Feed for Enhanced Surface Integrity and Abrasive wear Reduction

Creep feed belt grinding (CFBG) is a vital machining technique used for intricate curved parts like aero-engine blades and flaps. CFBG effectively removes material by using larger depths of cut and lower feed rates, but high loads can lead to severe belt wear and thermal damage defects in the process. Laser-assisted processing technology can mitigate tool wear and enhance machining quality. This research compared and analyzed belt wear behavior and its impact on the surface integrity of titanium alloys in laser-assisted creep feed belt grinding (LCFBG) and CFBG processes. The following conclusions were drawn: The local thermal effect of the laser softened the material, reduced the grinding force. The wear pattern of the abrasive grains changed from abrasive fracture and stripping to steady abrasive wear. The effective life of the belt increased by about 33 %. In addition, due to reduction in grinding force, the thermo-mechanical coupling effect caused by material removal is reduced, and the grinding temperature is lowered. As a result of the reduction in grinding force and temperature, the mechanical and thermal stresses are reduced, the oxidation reaction on the surface of the titanium alloy is weakened, and the residual stress is lowered, leading to an improvement in surface quality.

Microstructure and properties of novel nano-lamellar Al27Nb18(CrZr0.5)xTi55−1.5x eutectic high-entropy alloy coatings on Ti-6Al-4V alloy

The serious wear damage caused by low surface hardness and poor wear resistance of titanium alloy severely limits its further application in engineering field. In this work, novel eutectic high entropy alloys (EHEAs) were designed by means of infinite solution strategy combined with mechanical assistance to explore the application of EHEAs in the field of surface protection coating. Three types of EHEA coatings were achieved through the adjustment of the Cr and Zr element proportions on Ti-6Al-4V alloy by laser cladding. The microstructure was eutectic structure composed of Laves and BCC/B2 phases with superlattice structure. A significant presence of stacking faults, Lomer-Cottrell locks and other defects is observed within the BCC/B2 phase, which contributes to the enhancement of both microhardness and nano-hardness. Al27Cr25Ti18Nb18Zr12 coating showed excellent wear resistance and minimal volume loss, which are 0.340 (65.38 % of the substrate) and 6.71 × 10−5 mm3/N·m (16.89 % of the substrate). Notably, the three alloys exhibit interesting selective corrosion behavior, which is mitigated by the presence of a nano-lamellar eutectic structure that limits pitting propagation.

Investigation of Failure Mechanisms in Oil-Lubricated Rolling Bearings under Small Oscillating Movements: Experimental Results, Analysis and Comparison with Theoretical Models

Bearing life calculation is a well-researched and standardized topic for rotating operation conditions. However, there is still no validated and standardized calculation for oscillating operation, only different calculation approaches. Due to the increasing number of oscillating rolling bearings, for example, in wind turbines, industrial robots, or 3D printers, it is becoming more and more important to validate one of these approaches or to formulate a new one. In order to achieve this goal, the damage mechanisms for oscillating operating conditions must first be analyzed in more detail by means of experimental investigations. The open question is whether fatigue is the relevant damage mechanism or whether wear damage, such as fretting corrosion or false brinelling, dominates. The present work therefore shows under which oscillation angle and frequency fatigue occur in oil-lubricated cylindrical roller bearings.

Research on the wear resistance and impact resistance of modified rubberized concrete

Rubber can improve the ductility and durability of concrete and reduce compressive strength. Tests were conducted to investigate the mechanical properties, wear resistance, and impact resistance of modified rubberized concrete (MRC) by mixing basalt fibers (BF), curing agent, and epoxy resin mixture. The results showed that the epoxy polymer improved the flowability of the rubberized concrete. The BF changed the failure mode of the rubberized concrete and enhanced the mechanical properties. When the curing agent-epoxy resin ratio was 4:8, the wear rate of BF6E8C4 after 120 times was 4.59 kg/m2, which was 70.02% and 3.77% less than that of BF2E8C4 and BF4E8C4. The impact strength of BF6E8C4 was increased by 256% and 409% compared with the BF2E8C4 and BF4E8C4, respectively. By analyzing the mechanism of the synergistic modification of BF and epoxy polymer, it was found that the synergistic work of BF and epoxy polymer could make the internal structure of concrete denser. At last, the wear damage and impact damage models of MRC were established, and the coefficient of determination exceeded 0.92.

Assessing wire EDM as a novel approach for CFRP drilling: performance and thermal analysis across lay-up configurations

Conventional drilling of carbon fibre–reinforced plastic (CFRP) presents significant challenges due to the material’s abrasive nature and anisotropic properties, leading to tool wear, delamination, and surface damage. To address these challenges, this study pioneers the use of wire electrical discharge machining (WEDM) to evaluate the drilling performance of thick CFRP lay-up configurations mainly unidirectional and multidirectional, marking the first application of WEDM for CFRP drilling. The study evaluates material removal rate (MRR), delamination factor (DF), and surface damage while employing an analytical solution to estimate surface temperature and heat conduction in the laminates. An eight-full factorial experimental design was employed, involving variations in ignition current (3 A and 5 A) and pulse-off time (4 µs and 8 µs). The findings revealed that the multidirectional lay-up achieved an MRR of 2.85 mm3/min, significantly outperforming the unidirectional lay-up’s MRR of 0.95 mm3/min, representing a 300% increase at 5 A and 4 µs. However, the increase in discharge energy led to surface damage such as delamination, frayed fibres, and irregular circularity, especially evident in the unidirectional lay-up. For delamination, the multidirectional lay-up had the highest top DF of 1.4 at 5 A and 6 µs, while the unidirectional lay-up achieved the peak bottom DF of 1.24 at the same levels. While none of the parameters significantly affected the responses, the current exhibited the highest contribution ratios. Analytical predictions of the thermal distribution indicated a 45-µm delamination length at the laminate surface and depth, aligning closely with experimental predictions of 30–50 µm.