Wear Process Parameters Research Articles

Synthesis of a novel AlBeSiTiV light weight HEA coating on SS316 using atmospheric plasma spray process

High Entropy Alloys (HEAs) are currently a subject of significant research interest in the fields of materials science and engineering. They are rapidly evolving due to their exceptional properties, and there is considerable focus on expanding their application potential by developing HEA coatings on various substrate materials. This area of study holds promise for advancing technology and innovation in diverse industries. In this study, a novel equiatomic AlBeSiTiV Light Weight HEA was synthesized via mechanical alloying and was sprayed on the substrate SS316 by the thermal spray process. The microstructural characterization revealed that synthesized HEA had a major FCC phase and the average coating thickness was observed to be 150 μm. The average microhardness was measured to be 975 ± 13 HV for the coating which was five times than the substrate. The coated samples' wear resistance was found out using a pin-on-disc apparatus by varying the wear process parameters and Taguchi's L27 Orthogonal Array was used to interpret the parametric influence on wear rate. ANOVA and regression analysis revealed applied load to be the most significant factor followed by distance and velocity. The major wear mechanisms observed were adhesion abrasion and oxidation, and the formation of tribolayer was observed at higher velocity and distance.

Study on the Wear Behaviour of Aluminium foam Reinforced Glass Fibre Epoxy Composites

Hand layup was used to fabricate the glass fibre reinforced aluminium foam epoxy composites in this study. On the manufactured materials, dry sliding wear experiments were performed. The effect of wearprocess parameters such asapplying load (kg), speed (m/s), and sliding distance (m) on specific wear rate (Ws) was investigatedand the obtained results were compared with neat glass fibre reinforced epoxy composite in this work. The outcome of these results showed that specific wear rate (Ws) of glassfibre epoxy composite containing aluminium foam decreased as compared with neat glass fibre reinforced polymer composites. Experimental results showed that a minimum wear rate of 10.1 �m was attained for the sliding velocity (1.5 m/s), Applied load (2 kg), and sliding distance (1000 m) in the fabricated composite laminates. It was observed thatthe resistance to wear in glass fibre reinforced aluminium foam composite was mainly due to the bond strength between aluminium foam and epoxy.

A Machine Learning Approach to Predict Properties of Wood Products during Milling

Abstract The wood industry seeks innovative methods to improve process monitoring and adaptive control by modeling workpiece characteristics. This study proposes a sensor fusion approach that integrates data from airborne sound, cutting forces, power consumption, and acoustic emissions while milling diverse wood-based products. The objective of this research is to accurately predict workpiece attributes, such as the density of the wood products to achieve strength grading and the roughness of the machined surfaces to identify tool wear or unsuitable process parameters. To accomplish this objective, machine learning regression was employed by training a model on the predictors chosen through supervised univariate feature ranking. Individual linear regression models per workpiece type depended heavily on the material, where the validation R2 values ranged from 0.1 to 0.99, due to presplitting in the case of samples machined across the fiber and porosity in the case of particleboard samples. A validation R2 of 0.99 could be achieved for the collective modeling of density based on all the collected samples, with samples machined against the fiber being excluded. Surface roughness could be predicted with a validation R2 of 0.91 by excluding samples machined across the fiber and particleboards.

Dry sliding wear characteristics of Al7075 alloy‐reinforced with SiC and cenosphere particles

AbstractAluminum metal matrix composite (AMMC) is employed in all engineering applications, most notably as a substitute for conventional metals in the fields of defense, automotive, and aerospace. AMMC should have a wide variety of structural, mechanical, thermal, wear, and corrosion qualities that may require mutually exclusive features at an optimal level to achieve this. The current research focuses on the stir casting process for producing SiC and cenosphere reinforced Al7075 alloys. The response surface method's (RSM) face‐centered central composite design (CCD) was used to design the number of experimental trials, and a response surface technique was enforced to forecast the optimum combination of processing variables in the wear process. The SiC reinforcement improved the wear resistance of Al7075‐SiC‐cenosphere composites substantially. Overall, the experiments show that Al7075‐6 wt% SiC‐5 wt% cenosphere has excellent tribological properties. The hybrid Al7075/SiC/Cenosphere composites were shown to be effective, fit, and suitable in the ideal wear process parameters (load of 10 N, sliding distance of 1000 m, and sliding velocity of 1.5 m/s) for lowering wear rate (0.38035 × 10−3 mm3/m) at 6wt% SiC reinforced composite. This suggests that the combination of SiC and cenosphere improves the wear resistance of AMMC.

Tribological Behavior of Ni-P Electroless Coating of Inconel 625 with Multiwall Nano Carbon Tubes

An attempt was taken to study the wear rate of coated Inconel 625 using 0.3 gm of multiwall carbon tubes (MWCNT).The coating was carried out by the Ni-P electroless coating method. The Ni-P-MWCNT coating was prepared by using nickel phosphorous solution. The sliding wear test was conducted using pin on discs tribometer. The wear rate behavior was investigated at various levels of pin on discs tribometer factors, and a predictive model was developed using regression equations. The wear test experiment was carried out based on the L27 orthogonal array. The wear process parameters load, sliding velocity, and sliding distance were chosen. It was observed that the rate of wear increased as the load increases, whereas increase in sliding velocity and sliding distance reduces the rate of wear. The developed regression model was validated with the measured wear rate. The percentage error was observed within 0.99%.

Mechanical and tribological properties of aluminium based metal matrix composites: An overview

This paper presents a comprehensive review of open literatures to segregate the effects of composite fabrication process parameters, reinforcement types and its contents on mechanical and tribological properties of the developed metal matrix composites (MMCs). Effects of various wear factors (i.e. load, sliding speed and sliding distance) on wear rate (WR) and coefficient of friction (COF), along with different dominating wear mechanisms are emphasized. Outcomes of the review revealed that increase in stirring time affects the mechanical properties adversely, whereas increase in ball milling time improves these. Incorporation of ceramic and carbonaceous reinforcements in Al alloy improves its mechanical and wear resistance properties. Effects of wear process parameters on WR and COF depend upon the types of matrix-reinforcement combinations, reinforcement content and test conditions.

Tribological Behavior of AA-6063 Cast Using In Situ Microwave Process by Taguchi Method and ANFIS Model

Abstract Tribological behavior of AA-6063 casted by microwave casting process was investigated. In this work, sliding wear analysis has been done on in situ cast developed through the novel technique. The in situ cast of AA-6063 was developed using microwave irradiation. Sliding wear process parameters such as normal load, sliding velocity, and sliding distance are optimized through the Taguchi technique. L9 orthogonal array and signal-to-noise (S/N) analysis are used to obtain the optimum process parameters for wear-rate (WR) as the selected response. After optimization, a confirmatory test was performed using the analysis of variance (ANOVA). Scanning electron microscopy (SEM) images, energy-dispersive X-ray spectroscopy (EDS) images, and frictional characterization were used to study the mechanism of wear. By using the experimental data, an adaptive neuro fuzzy inference system (ANFIS) model has been developed and which was further tested using average wear-rate.

Taguchi 방법에 의한 주석 분말로 충전된 폴리프로필렌 복합재의 마찰 특성 분석

The tribological behavior of polypropylene polymer composites filled with Tin powder as fillers was studied using a pin-on-disc wear test rig at dry sliding conditions. The influence of wear process parameters like materials type (MT), applied load (AL), and sliding speed (SS) on the coefficient of friction (CoF) and specific wear rate (SWR) were investigated. A plan of experiments based on Taguchi technique performed to acquire data in a controlled way. An orthogonal array and analysis of variance (ANOVA) employed to investigate the influence of process parameters on the wear of these composites. The results showed that Tin powder

Dry sliding wear analysis of vacuum die‐casted hybrid aluminum nanocomposites using the DOE Taguchi method

AbstractThis study focuses on the impact of wear process parameters on the sliding wear behavior of titanium oxide (TiO2) and yttrium oxide (Y2O3) reinforced pure aluminum (Al) hybrid nanocomposites. The optimization of wear test parameters for hybrid aluminum matrix nanocomposites (HAMNCs) was examined with the design of experiments Taguchi method. The HAMNCs were manufactured by a vacuum die casting technique using a unique double‐layer feeding method. Initially, mechanical characterization as tensile and hardness of HAMNC samples was performed to identify the optimum reinforcement. The nanocomposites at 5‐wt.% TiO2 + 5‐wt.% Y2O3 (HAMNC1) showed excellent tensile strength and microhardness of 127.6 MPa and 75.43 BHN, respectively, than the other configurations of HAMNCs. The three levels of machine process parameters as load at 5, 10, 15 N, sliding velocity at .5, 1, 1.5 m/s and sliding distance at 200, 400, and 600 m are selected to identify optimum process parameters of HAMNC1 that possess ultimate wear properties. The results derived from optimization were further predicted using ANOVA and regression equations for individual influences. The improved grain size observed in the wear surface morphology of HAMNC1 was performed using field emission scanning electron microscopy.

Microstructure, mechanical and wear behavior of LM24/SiC/MoS2 hybrid composites produced via liquid metallurgy process

Silicon carbide (SiC) and Molybdenum disulphide (MoS2) has been expected broad contemplation is a potential strengthening particulate for metal matrix composites (MMCs) to enhance the mechanical and wear behaviors. The purpose of this study is to process and investigate the mechanical characteristics of LM 24/SiC/MoS2 composites. These composites were fabricated via the stir casting process from the prepared arrangements of LM 24/SiC/MoS2 with various weight proportions. The following proportions are pure LM 24, LM24-3wt%SiC-1wt%MoS2, LM24-6wt%SiC-1wt%MoS2 and LM24-9wtSiC-1wt%MoS2. The scanning electron microscope (SEM) utilized to inspect the micrographs on processed composites. The SEM micrographs interpret identical dispersion of SiC with LM 24. The influence of SiC weight percentage on the physical properties like density, relative density & porosity and mechanical properties like tensile, compression, hardness, impact and flexural strength and tribological behavior were investigated. The processed LM24-9wt%SiC-1wt%MoS2 composites compose the enhanced mechanical properties. The wear performance was studied throughout the pin on disc device with various wear process parameters. These parameters are load, Sliding velocity and distance. Finally, these parameters are framed via the L16 orthogonal array and to attain the minimum wear rate and coefficient of friction from the optimal process parameters by Grey Relational Analysis (GRA). The optimal parameters for wear rate and coefficient of friction are LM24-9wt%SiC-1wt%MoS2 and followed by the wear parameters namely load 15N, sliding velocity 2 m s−1 and sliding distance 1600 m, respectively. The ANOVA outcomes uncovers that the load is the most significant parameter for wear rate and coefficient of friction.

Optimization and analysis of dry sliding wear process parameters on cellulose reinforced ABS polymer composite material

PurposeThis study aims to the optimization using three factors and three-level parameters (sliding speed [rpm], sliding distance [m/s] and load [N]) of design matrix were adapted to Box–Behnken design using design expert v8.0 software. Based on the parameters, to develop the linear regression equation and to find the significant considerable wear process parameters based on output responses like wear loss (WL) and coefficient of friction (COF) value of polymer matrix composites (PMC) specimen of Acrylonitrile-butadiene-styrene (ABS)/cellulose composite (80 wt% of ABS and 20 wt% of cellulose).Design/methodology/approachThe fabrication of the ABS/cellulose composite sample was carried out by the simple hands-on stir process method. As per the American Society for Testing and Materials G99 standard, the sample was made by the molding process. The wear analysis was made by multi tribotester TR25 machine and validated the developed model by using statistical software design expert v.8.0 and numerical tools like analysis of variance. The surface morphology [field emission scanning electron microscopy (FESEM) analysis] of the sample was also observed using the Quanta FEG-250 FESEM instrument.FindingsThe parameters like sliding speed, sliding distance and load are independently affected the COF value and WL of the 80% of ABS matrix and 20% cellulose reinforced composite material. The regression equations were generated by the coefficient of friction value and WL, which predicted the minimum WL of 80% of ABS matrix and 20% of cellulose reinforced composite material. The worn surface analysis result exposes the worn path and equal distribution of reinforcement and matrix on the surface of composite material.Originality/valueThe literature survey revealed a small number of studies available regarding wear analysis of ABS matrix and cellulose reinforced composite materials. In the present work, to fabricate and evaluate the wear performance of PMC (80% of ABS and 20% of cellulose) depends on the WL and COF value. The maximum and minimum COF value (µ) of 80% of ABS and 20% of cellulose composite material is 4.71 and 0.28 with the optimized wear process parameter by 1,000 mm of sliding distance, 0.25 (m/s) of sliding speed and 9 N of load.

Optimization and effect of load, sliding velocity, and time on wear behavior of AA8011- 8 wt.% fly-ash composites

This research work was undertaken to study the effect of dry sliding wear process parameters such as load, time, and sliding velocity on the wear rate and coefficient of friction of AA8011 with 8 wt.% fly-ash composites. The response surface methodology was used to determine the most important criteria to maximize the wear rate and minimize the coefficient of friction. The experimental procedure was designed based on second-order rotatable central composite design. The optimization studies were carried out on dry sliding wear process parameter with multi-response characteristics, including the wear rate, coefficient of friction, based on multi-criteria decision-making using the TOPSIS approach. Sensitivity analysis was used to identify the important criteria and classify them by their order of importance in model validation. A confirmation test was carried out to validate the results, and the obtained optimal parameter levels were found to be very close to an ideal solution.

On the wear behavior of AA6061 alloy and in-situ AA6061-TiB2 composite subjected to Equal Channel Angular Pressing

This paper reports the effect of annealing and Equal Channel Angular Pressing (ECAP) on the wear behavior of AA6061 alloy and in situ AA6061-5 wt.%TiB2 composite. The in situ AA6061-5 wt.%TiB2 composite was prepared through aluminothermic reduction reaction process using potassium hexafluorotitanate (K2TiF6) and potassium tetrafluoroborate (KBF4) salts as precursors in an AA6061 alloy melt. The in situ AA6061-5 wt.%TiB2 composite and AA6061 alloy were subjected to annealing followed by the ECAP process to refine the grain structure. The wear test was carried out on both the materials (AA6061 alloy and in situ AA6061-5 wt.%TiB2 composite) in annealed and ECAP processed conditions using steel as a counter face material. The wear testing was carried out for different wear process parameters like load (20, 30 and 40 N), sliding velocity (0.5, 1, and 1.5 m s−1) and test temperature (25 °C, 100 °C and 200 °C). The ECAP processed AA6061 alloy displayed superior wear resistance than the ECAP processed AA6061-5 wt.%TiB2 composite. The AA6061 alloy subjected to 6 passes exhibited the highest wear resistance at room temperature (25 °C) for the applied load 30 N with a sliding velocity of 0.5 m s−1. Shallow grooves and a slight plough appeared on the worn surface of the AA6061 alloy. The AA6061-5 wt.%TiB2 composite showed ultra-mild wear mode. The Analysis of Variance (ANOVA) test results helped to identify the contribution of every factor to the wear behavior of both the materials. In the AA6061 alloy and AA6061-5 wt.%TiB2 composite, the number of passes and the applied load were respectively the most influencing factors.

Mechanical and Sliding Wear Performance of AA356-Al2O3/SiC/Graphite Alloy Composite Materials: Parametric and Ranking Optimization Using Taguchi DOE and Hybrid AHP-GRA Method

The novelty of this research work lies in (i) designing and fabrication of hybrid AA356-Al2O3/SiC/Graphite alloy composite materials via semi-automatic stir casting method as per the standard industrial procedure. The ceramic particulates Al2O3/SiC were reinforced in a complementary manner (0–8 wt.%, in the step of 2%) along with constant 3 wt.% of graphite bringing about five alloy composite specimens namely SA-08, SA-26, SA-44, SA-62, and SA-80 respectively. The prepared specimens were explored for any synergistic effect of ceramic combinations on physical (density and void content), mechanical (tensile strength, flexural strength, impact strength and hardness), and sliding wear performance adopting ASTM standards. Simultaneously, optimization of sliding wear process parameters (like sliding velocity, sliding distance, normal load, etc.) using the Taguchi design of experiment and Grey Relational Analysis techniques were explored. Further, surface micrographs were analyzed to understand the underlying wear mechanisms and elemental presence/dispersion over the worn-out surfaces. Thereafter, the ranking of compositions was analyzed using a hybrid AHP-GRA material selection method for optimal selection and recommendations. It has been found that both Taguchi and GRA techniques were effective in parameter optimization and gives an attuned outcome. Composition, SA-44 hybrid alloy composite, having the equal presence of both the ceramic particulates tend to optimize the overall performance criteria. The results of ranking obtained by hybrid AHP-GRA analysis attunes to the subjective analysis.

Effect of heat treatment on mechanical and tribological properties of aluminum metal matrix composites

LM25 aluminum alloy reinforced with 10 wt% of TiB2, WC, and ZrO2 were squeeze cast to investigate the effect of T6 heat treatment on tribo-mechanical properties. Among all, WC-reinforced composite achieved superior mechanical properties at the aging time of 8 h. Microstructural examination performed on all composites and alloy concluded that the presence of WC in T6 LM25 caused reduction of α-Al dendrite size, exhibiting superior properties for this composite. X-ray diffraction analysis conducted on alloy and WC-reinforced superior composite revealed formations of phases, which improved their mechanical properties. Energy-dispersive X-ray spectroscopy analysis quantified the actual intensity of WC presence in the superior composite along with its other constituents. Response surface methodology model developed for wear test of the superior composite involves parametric range like applied load (10–50 N), sliding velocity (1–4 m/s), and sliding distance (500–2500 m). Analysis of variance along with regression analysis proved that, statistical analytical model developed good relationship between the actual wear rate and process parameters. Response surface plots represented the linearly increasing wear trend with respect to load and sliding distance. Wear rate dropped initially and raised later on along with velocity. Scanning electron microscopy exhibited the surface deformation prevailing on the composite surface at high load.

Statistical Analysis of Dry Sliding Wear Process Parameters for AZ91 Alloy Processed by RD-ECAP Using Response Surface Methodology

The main objective of this paper is to study the influence of wear testing parameters on the weight loss of AZ91 magnesium alloy which was developed via rotary die-equal channel angular pressing (RD-ECAP) method through the different number of passes. The AZ91 sample was pressed up to 16 passes in order to decrease the grain size to 10 μm. After RD-ECAP processing, significant grain refinement was found, which yielded a refined grain size after 16 passes and enhanced mechanical properties and wear resistance. Dry sliding wear experiments with a ball on disc apparatus at room temperature were conducted, following RD-ECAP processing. The response surface methodology (RSM) was used to optimize and compare the wear resistance of the RD-ECAP alloy and the as-received alloy. Analysis of the wear mechanism and the worn surfaces of AZ91 samples was performed using scanning electron microscope. RSM analysis showed that increased applied load, sliding speed and sliding time in all cases decreased wear resistance. On the other side, wear resistance in AZ91 magnesium alloy was improved by the increase in the number of passes of RD-ECAP. The three empirical models were validated by conducting confirmation tests and certified that the proven empirical wear models are reliable for wear applications as a predictive tool.

Optimization of Wear Process Parameters on 17-Cr Ferritic ODS Steel

The main aim of this article deals with the wear behavior of mechanically alloyed 17-Cr oxide dispersion strengthened (ODS) Ferritic steel consolidated through Vacuum Hot Pressing (VHP) at temperature level of 1170 °C under pressure level of 60 MPa with 60 minutes as holding time and with rate of cooling of 50 ˚C /min and a vacuum level of 10-3 torr. The persuade of wear process parameters were investigated based on the load applied, sliding velocity and sliding distance at a temperature of 350°C on dry sliding track of 17-Cr Ferritic oxide dispersion strengthened steel (Fe-17Cr-0.35Y2O3 -1.5ZrO2 -4Al (%wt). Wear test was conducted in a dry atmosphere using a pinon-disc wear testing machine. Wear behavior of 17-Cr Ferritic ODS steel was analyzed by using Taguchi approach. To examine the process parameter during high temperature wear rate analysis of variance and signal to noise ratios were used. During the wear analysis sliding distance was found to be influential parameters of wear rate for 17-Cr Ferritic oxide dispersion strengthened steel succeeded by functional load and sliding velocity. The regression model was found to calculate the rate of wear for 17-Cr Ferritic oxide dispersion strengthened steel.

Optimization of Dry Sliding Wear Parameters of Titanium Alloy using Taguchi Method

The present work focuses on the study of mechanical and tribological properties of Ti-3Al-2.5V titanium alloy. The most influencing process parameters of wear process are investigated in this work. Taguchi technique was used to carry out the experiments. The results indicate that load, sliding distance and sliding velocity were the process parameters which make significant contribution in wear properties. The optimal wear process parameters were found using the regression equation developed by the taguchi method.

Optimization of wear process parameters on 16-Cr Ferritic ODS steel through Taguchi approach

Abstract Dry sliding wear was performed on a pin on disc wear testing machine by varying the process parameters such as applied load, sliding velocity and sliding distance which were performed on 16-Cr Ferritic ODS steel at high temperature (350 °C). Taguchi approach was used to analyze the process parameters for high temperature wear behavior using Signal-to-Noise ratio and analysis of variance. It was found that sliding velocity was the most significant parameters of wear rate followed by applied load and sliding distance. Regression model was obtained to find wear rate and conformation test was conducted to verify the experimental results.

Synthesis of Al LM25/TiB2 in-situ composites and investigation of its adhesive wear behavior

Aluminum/titanium diboride (TiB2) in-situ metal matrix composite was produced by reaction between aluminum alloy and potassium hexafluoro titanate (K2TiF6) and potassium tetrafluoro borate (KBF4) salts. Aluminum titanate and aluminum diboride formed during reaction process resulted in formation of TiB2. Energy Dispersive X-Ray analysis was carried out in order to confirm the presence of titanium and boron. Microstructure analysis of composite specimen showed uniform distribution of TiB2 in aluminum matrix. The composite was tested for sliding wear behavior using pin-on-disc tribometer by considering load (10N, 20N, 30N), sliding velocity (1.5m/s, 2.5m/s, 3.5m/s) and distance (750 m, 1250m, 1750m) as parameters. A Taguchi’s L27 orthogonal array was used to optimize process parameters to obtain maximum wear resistance. Analysis of Variance technique was used for statistical analysis for finding parameters having maximum significance with respect to wear rate and Signal-to-Noise ratio was employed to determine their level of influence. Results clearly concluded that load (69.23%) has primary effect on wear rate followed by sliding distance and velocity. Regression model was developed to find relation between wear rate and process parameters. Confirmation tests were conducted and percentage error was found to be less than 10. Scanning Electron Microscopic studies carried out on worn surfaces revealed severe delamination at high loads.