Wear Properties Research Articles

Wear properties of Al6061/SiC + B4C + TiC hybrid composites produced by vacuum infiltration method

Abstract In the study, hybrid metal matrix composite (HMMC) structures were produced by vacuum infiltration method (VIM) using Al6061 alloy and varying amounts of SiC, B4C, and TiC ceramic powder pairs. Age-hardening processes were applied to these HMMCs. After heat treatment, wear behavior was examined under different loads using the pin-on-disc test method. All Al6061 hybrid composites exhibited better wear performance than unreinforced Al6061. In the wear tests of composite samples, the lowest volume loss and therefore the highest wear resistance were obtained in Al6061 3 wt.% B4C + SiC composites under 5 N force. The lowest wear resistance due to the highest volume loss was determined in Al6061/1 wt.% TiC + B4C composites under 15 N force. Abrasive and adhesive wear characteristics were observed in field emission scanning electron microscopy(FESEM) images of worn surfaces. Additionally, wear debris, smearing, and deep grove formations were determined on the surface. In the EDS analysis performed on the worn surface, O and Fe elements were found in addition to the elements that are likely to be in the structure (such as Al, B, C, Ti, Si, and Mg). The wear tests caused the formation of oxide layers on the sample surfaces.

Investigations on Microstructure, Mechanical, and Wear Properties, with Strengthening Mechanisms of Al6061-CuO Composites

Metal matrix composites (MMCs) reinforced with Copper Oxide (CuO) and Aluminum (Al) 6061 (Al6061) alloys are being studied to determine their mechanical, physical, and dry sliding wear properties. The liquid metallurgical stir casting method with ultrasonication was employed for fabricating Al6061-CuO microparticle-reinforced composite specimens by incorporating 2–6 weight percent (wt.%) CuO particles into the matrix. Physical, mechanical, and dry sliding wear properties were investigated in Al6061-CuO MMCs, adopting ASTM standards. The experimental results show that adding CuO to an Al6061 alloy increases its density by 7.54%, hardness by 45.78%, and tensile strength by 35.02%, reducing percentage elongation by 40.03%. Dry wear measurements on a pin-on-disc apparatus show that Al6061-CuO MMCs outperform the Al6061 alloy in wear resistance. Al6061-CuO MMCs’ strength has been predicted using many strengthening mechanism models and its elastic modulus through several models. The strengthening of Al6061-CuO MMCs is predominantly influenced by thermal mismatch, more so than by Hall–Petch, Orowan strengthening, and load transfer mechanisms. As the CuO content in the composite increases, the strengthening effects due to dislocation interactions between the matrix and reinforcement particles, the coefficient of thermal expansion (CTE) difference, grain refinement, and load transfer consistently improve. The Al6061-CuO MMCs were also examined using an optical microscope (OM), energy-dispersive spectroscopy (EDS), X-ray diffraction (XRD), and scanning electron microscopy (SEM) before and after fracture and wear tests. The investigation shows that an Al6061-CuO composite material with increased CuO reinforcement showed higher mechanical and tribological characteristics.

Influence of Cooling Rate on Primary Silicon Size in Hypereutectic Al–Si Alloy Fabricated by Laser Powder Bed Fusion

Herein, the effects of cooling rate on primary silicon (Si) phases in laser powder bed fusion (PBF‐LB/M) processed hypereutectic Al–Si alloy are investigated. These alloys are particularly in demand for automotive and electronic applications, thanks to their excellent wear and thermal properties. Nevertheless, when processed by conventional methods like casting with comparatively lower cooling rates, the coarse primary Si phases are responsible for increasing brittleness and inducing crack propagation. The refinement of the primary silicon phases is aimed to be achieved through the PBF‐LB/M process, which offers a high cooling rate. The primary Si phases are observed under three different thermal substrate plate conditions—untempered, with cooling and heating, and additionally with varying volume energy density. Furthermore, the impact of primary Si size on the hardness of the fabricated samples is evaluated. The findings show that a faster cooling rate has a notable effect on refining the primary Si size. Then, hardness is directly affected by the primary Si size, with larger Si resulting in decreased hardness.

Microstructural, mechanical, and wear properties of ultrasonic assisted stir casted A356 Alloy/AlN composite

The ultrasonic-assisted stir-casting method has effectively prepared A356 alloy/AlN composites. The ultrasonic treatment and integration of AlN particles are shown to greatly enhance the mechanical and wear characteristics of the matrix via grain refinement. By incorporating 9 vol.% of AlN reinforced particles, the average grain size of A356 alloy was decreased from 36 μm to 10 μm. Additionally, the hardness and tensile strength experienced a respective rise of 60.6% and 32%. With an increase in the volume percentage of AlN particles, it is found that both the wear rate and the friction coefficient decreased. It is also observed that the A356 alloy displayed severe wear, whereas the composites exhibited moderate wear.

Review of Surface Treatment Technology for Improving Wear Resistance of Magnesium Alloys

Background: As the lightest metal structural material in engineering, magnesium alloy has excellent mechanical properties, such as high specific strength, high specific stiffness, good damping performance, and good machinability. It is widely used in the fields of precision parts, automobiles, aerospace, and military. However, poor friction and wear performance are significant magnesium defects of the alloys, which make its use limited in some areas with high working conditions, so it is essential to improve the wear resistance of the magnesium alloy surface. Objective: The aim of this study was to summarize the technology of improving the wear resistance of magnesium alloy in recent year. The influence of different surface treatment technology for enhancing friction and wear properties was also analyzed, which could provide a reference for related scholars and researchers. Method: In this paper, the literature related to friction and wear properties of magnesium alloys in recent years were reviewed, the principles of various surface treatment technology of magnesium alloys were explained, and the advantages and disadvantages of each technology were analyzed. Results: Based on the literature analyses related to the wear resistance of magnesium alloys, the problems existing in the surface treatment technology for improving the wear resistance of magnesium alloys are summarized, and future development directions are put forward. Conclusion: Among the technologies to improve the wear resistance of magnesium alloys, the combination of various techniques can better meet the working demands. The environmentally friendly and efficient manner has a good prospect for development.

Tensile Fracture Behavior and Friction and Wear Properties of TiB2 Particle Reinforced Al-Si Matrix Composites

Tensile Fracture Behavior and Friction and Wear Properties of TiB2 Particle Reinforced Al-Si Matrix Composites

Corrigendum to: “Recent Patents of Micro-arc Oxidation Technology”

A typographical error appeared in terms of repetition of sentences in the manuscript titled “Recent Patents of Micro-arc Oxidation Technology”, 2024; 18(6): e300423216386 [1]. <p> Original: Liu et al. [90] provided a method for micro-arc oxidation of electrolytes and reducing the brittleness of microporous ceramic film. By adding chitin nanowhiskers and Nacetylated chitosan into the electrolyte, the toughness of the ceramic film is improved, and bending brittleness and fragmentation are prevented. <p> Li et al. [91] provided an electrolyte for micro arc oxidation self-lubricating composite ceramic coating. The friction and wear properties of the composite ceramic coating were improved by adding nano additives and micro MoS2 powder into the conventional electrolyte. <p> Liu et al. [90] provided a method for micro-arc oxidation of electrolytes and reducing the brittleness of microporous ceramic film. By adding chitin nanowhiskers and Nacetylated chitosan into the electrolyte, the toughness of the ceramic film is improved, and bending brittleness and fragmentation are prevented. <p> Li et al. [91] provided an electrolyte for micro arc oxidation self-lubricating composite ceramic coating. The friction and wear properties of the composite ceramic coating were improved by adding nano additives and micro MoS2 powder into the conventional electrolyte. <p> Corrected: Liu et al. [90] provided a method for micro-arc oxidation of electrolytes and reducing the brittleness of microporous ceramic film. By adding chitin nanowhiskers and Nacetylated chitosan into the electrolyte, the toughness of the ceramic film is improved, and bending brittleness and fragmentation are prevented. <p> Li et al. [91] provided an electrolyte for micro arc oxidation self-lubricating composite ceramic coating. The friction and wear properties of the composite ceramic coating were improved by adding nano additives and micro MoS2 powder into the conventional electrolyte. <p> The original article can be found online at https://www.eurekaselect.com/article/131347

Influence of nanodiamond on compressive and dry-sliding wear behaviors of Al2O3–Al interpenetrating-phase composites

In this research, the effects of nanodiamond (ND) addition at different loadings on the compressive and wear properties of the interpenetrating phases hybrid aluminum/alumina (Al/Al2O3) composite were investigated. The samples were fabricated in a two-step process. First, the Al2O3-ND preforms were fabricated via the replica method. Second, the squeeze casting route was employed to infiltrate the molten pure Al. The ceramic preforms were made by immersing a polyurethane foam with 17 ppi pores in a slurry containing α-Al2O3 powder (1 μm), ND particles (0–10 vol%), and natural egg white. After sintering at 1500 °C for 4 h, the preheated preforms were infiltrated with molten Al. The microstructural evaluations of the preforms and composites revealed a proper distribution of the ND particles in the preform, as well as the formation of the ND agglomerates at higher volume percentages. Also, the hardness of the samples enhanced with an increase in the ND loading, reaching a maximum of 263.8 Vickers for the 10 vol% ND-loaded composite. The compressive strength of the samples enhanced up to 3 vol% ND addition and then decreased due to the agglomeration. The wear test results indicated that the best behavior was related to the 3 vol% ND-loaded composite. Embedding the 3 vol% ND decreased the weight rate and friction coefficient of the interpenetrating phases hybrid Al/Al2O3 composite by 16 % (from 8.2396×10−3 to 6.9269×10−3 mm3/m) and 12 % (0.8165 to 0.7238), respectively. The study of the worn surfaces of the samples after wear testing revealed that the dominant wear mechanisms were abrasive and adhesive for the higher and lower volume fractions of the ND, respectively.

Effect of Pulse Electrodeposition Mode on Microstructures and Properties of Ni-TiN Composite Coatings

Mild steel is a kind of material commonly used in the chemical industry and to manufacture machinery, farm tools, and other parts in order to improve the surface performance of the parts and prolong their service life. The Ni-TiN composite coating was fabricated through ultrasonic electroplating using a Ni-based sulfamic acid bath with added nano-TiN particles. The effects of three distinct current modes, direct current (DC), positive pulse current (PC), and positive–negative pulse current (PNPC), on various aspects of the coating, including surface morphology, TiN content and distribution, interface bonding strength, microhardness, friction and wear properties, as well as corrosion resistance, were investigated. The findings demonstrated that, in comparison to DC electroplating, PC electrodeposited Ni-TiN composite coatings yielded finer grains, smoother surfaces, reduced surface cracks, increased interface bonding strength, and enhanced corrosion resistance. Furthermore, PNPC electrodeposited Ni-TiN composite coatings showed higher interface bonding strength than those of PC electrodeposited Ni-TiN coatings and had the densest structure, leading to the best corrosion resistance. Pulse current electroplating enhanced the incorporation of nano-TiN particles, with a higher deposition rate observed in positive–negative pulse current electroplating compared to positive pulse current electroplating. Furthermore, the PNPC electrodeposited coating displayed improved microhardness and demonstrated the best friction and wear properties, while the DC electroplated coating displayed the least favorable performance in these aspects.

Achieving precise graphenization of diamond coatings below the interfacial thermal stress threshold

Abstract Diamond coatings possess numerous excellent properties, making them desirable materials for high-performance surface applications. However, without a revolutionary surface modification method, the surface roughness and friction behavior of diamond coatings can impede their ability to meet the demanding requirements of advanced engineering surfaces. This study proposed the thermal stress control at coating interfaces and demonstrated a novel process of precise graphenization on conventional diamond coatings surface through laser induction and mechanical cleavage, without causing damage to the metal substrate. Through experiments and simulations, the influence mechanism of surface graphitization and interfacial thermal stress was elucidated, ultimately enabling rapid conversion of the diamond coating surface to graphene while controlling the coating's thickness and roughness. Compared to the original diamond coatings, the obtained surfaces exhibited a 63–72% reduction in friction coefficients, all of which were below 0.1, with a minimum of 0.06, and a 59–67% decrease in specific wear rates. Moreover, adhesive wear in the friction counterpart was significantly inhibited, resulting in a reduction in wear by 49–83%. This demonstrated a significant improvement in lubrication and inhibition of mechanochemical wear properties. This study provides an effective and cost-efficient avenue to overcome the application bottleneck of engineered diamond surfaces, with the potential to significantly enhance the performance and expand the application range of diamond-coated components.

AlZn-Matrix Cast Composites Reinforced with Ti Aluminides

Doping high-zinc aluminium alloys with Ti builds in-situ composites reinforced with ternary aluminides Ti (Al,Zn)3 with a significantly grain-refined matrix. In a series of studies, Ti was introduced with Al-6 wt% Ti (AlTi6) and Zn-4 wt% Ti (ZnTi4) master alloys in amount to contribute about 3 wt% Ti in the examined alloys. The alloy microstructure has been studied using light microscopy, SEM / EDS and XRD measurements. The observed significant refinement of the alloys matrix should lead to improvement in ductility, while the in-situ reinforcement should improve tensile strength and wear properties.

MoS2/Ti Co-deposited Coatings and Their Fretting Wear Properties at Elevated Temperatures

Abstract Fretting wear refers to the damage phenomenon experienced by the mechanical components undergoing micro-amplitude relative slip at their contact region due to vibration. Titanium alloys find their extensive application in aerospace industry components such as splines and dovetail joints, where they experience fretting wear phenomenon. This research work investigates the effect of MoS2/Ti co-deposition coatings with varying Ti content, deposited on TC4 titanium alloy substrate using magnetron sputtering. Fretting wear tests were conducted at room temperature, 100 °C, and 200 °C, using a specially designed fretting test fixture with a ball-on-flat contact configuration, mounted on a servo-hydraulic fatigue testing machine. The results indicated that the coating becomes denser with an increase in the Ti content. The coating exhibited the highest hardness and better anti-fretting wear performance at room temperature. However, the effect of Ti content on the fretting wear behaviors changed at elevated temperatures. At the highest Ti content coating, excessive oxide particles were found at the worn surface at elevated temperatures, inducing an abrasive effect and localized cracks. However, coatings with moderate Ti content (9.62 at. %) effectively protected the substrate from significant wear at room temperature and maintained a low coefficient of friction at high temperatures without failure.

Electrophoretic deposition of polyetheretherketone/polytetrafluoroethylene on 316L SS with improved tribological and corrosion properties for biomedical applications

Introduction316L stainless steel (316L SS) has poor wear and corrosion resistance compared to that of the Cp-Ti and Ti-6Al-4V implants [when studied under a physiological environment using phosphate-buffered saline (PBS)]. However, 316L SS implants are cost-effective. Their wear and corrosion properties can be improved by depositing biocompatible coatings.MethodIn this research work, a polymer coating of polyetheretherketone (PEEK) and polytetrafluoroethylene (PTFE) was deposited at optimized parameters (20 V for 3 min) on 316L SS via electrophoretic deposition (EPD). We compared the performance between of the PEEK coating and hybrid PEEK/PTFE coatings for biomedical applications. The PEEK/PTFE coating was sintered at 350°C for 30 min.Results and DiscussionScanning electron microscopy (SEM) analysis revealed that the PEEK/PTFE coating showed a uniform coating with a uniform thickness of ∼80 µm. Fourier transform infrared (FTIR) spectroscopy analysis confirmed the presence of bonds attributed to the PEEK and PTFE coatings. The PEEK/PTFE coating exhibited adequate average surface roughness (Ra) of 2.1 ± 0.2 µm with a high value of contact angle of 132.71 ± 3, indicating the hydrophobic nature of the PEEK/PTFE coating. Scratch tests evaluated that the PEEK/PTFE coating demonstrated a 7 N load, which indicated the good adhesion between the coating and 316L SS. Furthermore, the PEEK/PTFE coating demonstrated good wear resistance, capable of withstanding a 7 N load under dry conditions, and showed a specific wear rate of ∼0.0114 mm3/Nm. Electrochemical analysis conducted using the phosphate-buffered saline (PBS) solution demonstrated that the corrosion rate of 316L SS was reduced from 0.9431 mpy to 0.0147 mpy by depositing the PEEK/PTFE coating. Thus, the developed coatings present suitable wear and corrosion resistance and are thus considered for potential orthopedic applications.

Shrouding Gas Plasma Deposition Technique for Developing Low-Friction, Wear-Resistant WS2-Zn Thin Films on Unfilled PEEK: The Relationship Between Process and Coating Properties

In this study, tungsten disulfide–zinc (WS2-Zn) composite films were generated on polyether ether ketone (PEEK) disks by an atmospheric pressure plasma jet (APPJ) equipped with a shrouding attachment. The friction and wear properties of the WS2-Zn coatings were intensively investigated by using a rotational ball-on-disk setup under dry sliding and ambient room conditions. In order to gain more information about the lubrication mechanism, the coating areas as deposited and the worn areas (i.e., in the wear track) were analyzed with a scanning electron microscope (SEM) with regard to their chemical composition in depth by energy-dispersive X-ray spectroscopy (EDS). X-ray photoelectron spectroscopy (XPS) was conducted to obtain precise chemical information from the surface. The results indicated that WS2-Zn coatings significantly improved the tribological properties, exhibiting a coefficient of friction (COF) of <0.2. However, the tribological performance of the coatings is strongly dependent on the plasma process settings (i.e., plasma current, dwell time of the powder particles in the plasma jet), which were tuned to reduce the oxidation by-products of WS2 to a minimum. The COF values achieved of the dry lubricant films were significantly reduced in contrast to the uncoated PEEK by a factor of four.

Influence of Al2O3 and h-BN on Wear and Corrosion Performance of IN625 Nickel-Based Coating

IN625 offers high-temperature oxidation resistance, wear resistance, and stable chemical properties. To improve the corrosion and wear resistance of the Q345B steel surface, two types of metal matrix composites (IN625 + 1% Al2O3 and IN625 + 1% h-BN) were applied to the substrate surface using the laser cladding process. This study analyzed the hardness, electrochemical corrosion, friction, and wear properties of both the laser-clad specimens and the substrates. The results show that (1) the hardness and wear resistance of the fusion-coated coating were significantly improved compared with the base material. Notably, the hardness increased by 19%, and the coefficient of friction decreased by 41% compared with the IN625 + 1% h-BN coating. Furthermore, the hardness and wear resistance of the IN625 + 1% h-BN coating were superior to those of the IN625 + 1% Al2O3 coating, attributed to the formation of eutectic compounds such as NiB and Ni2B in the dendritic region. (2) The corrosion resistance of the IN625 + 1% Al2O3 coating exceeds that of the IN625 + 1% h-BN coating and is also superior to that of the substrate. This improvement is primarily attributed to the addition of Al2O3, which enhances solid solution strengthening within the dendritic crystals of the fused-coating layer, reduces the percentage content of inclusions, and elevates the corrosion resistance of the coatings.

Mechanical and Wear Properties of AL2024 T3 Reinforced Composites with TIB2 & MOS2

Mechanical and Wear Properties of AL2024 T3 Reinforced Composites with TIB2 & MOS2

The effect of multi-step cycles on the surface properties of Ni-TiO2 coatings produced by pulse current electrodeposition

ABSTRACT In this study, the Ni-TiO2 coatings were deposited on copper substrates by pulse plating. The effect of multi-step current cycles on the metallurgical properties of produced coatings was investigated. The results showed that the values of applied currents within the periods significantly affect the surface properties of all coatings. Using the negative current cycles, the surface morphologies completely changed from regular and compact to irregular, compared to the deposits that did not have a negative cycle in the coating process. Also, the surface roughness increased by 1.5 times in the best case. Applying the 8-step cycle increased the percentage of TiO2 content inside the Ni-TiO2 layer from 13.13 vol.% to 31.58%. The corrosion and wear analysis results showed that the coating applied by a 4-step cycle with a 90-second off time has the best properties. Therefore, the corrosion and wear properties were not necessarily directly related to the participation percentage of TiO2 particles. Compact morphology with high current efficiency, wide distribution of TiO2 particles (6.31 vol.%) with minimal agglomeration, low coating roughness (Ra = 0.32 µm), high hardness value (436 Vickers), and the participation of (111) plane in the preferred texture improved the corrosion and wear behaviour of the optimal coating.

Engineering the Atomic Interface of Refractory‐Metal‐Reinforced Copper Matrix Using Direct Ink 3D Printing

Herein, 3D printing involving metallic materials with substantially distinct melting temperatures and their immiscibility presents a formidable challenge. Nevertheless, it may be possible to overcome this challenge using the direct ink writing (DIW) method within such immiscible systems. In this article, a successful fabrication of Cu‐based composites utilizing the additive manufacturing process that is DIW technique, followed by a post‐sintering process, is presented. The secondary addition to the Cu–matrix includes tantalum (Ta), tungsten (W), and niobium (Nb). The rheological properties of the composite inks are also analyzed for the DIW technique. The underlying reasons behind the increased mechanical, wear, and thermal properties are assessed through experimental and molecular dynamics simulations. Microstructural analysis is conducted using optical and scanning electron microscopes. Mechanical, electrical, thermal, and wear properties are evaluated at ambient temperature, and comparisons are established with DIW‐processed pure Cu. Elemental mapping through energy‐dispersive spectroscopy and high‐resolution transmission electron microscopy confirm the distribution of W, Ta, and Nb particles within the composite. The 3D printing of immiscible alloy components opens new avenues for exploring novel material properties, mixtures, and composite materials, thus fostering the development of innovative materials.

Influence of silica and alumina nanoparticles on the wear and mechanical behavior of Indian almond fiber reinforced natural composites

Natural composites are valued for their lightweight, cost-effectiveness, and environmental benefits, but they often fall short in performance compared to conventional materials. To enhance their properties, nanoparticles are added. This study focused on natural composites made from Indian almond fiber, with alumina and silica nanoparticles incorporated. The scope of this research was to develop the Indian almond based materials as industry ready by enhancing its strength with nano-fillers. Four composites were created: C0 (Epoxy/Indian almond), C1 (Epoxy/Indian almond/Silica), C2 (Epoxy/Indian almond/Alumina), and C3 (Epoxy/Indian almond/Silica/Alumina), using a resin-to-fiber ratio of 70:30 and 3 wt% nanoparticles. The inclusion of nanoparticles improved composite performance, with C2 demonstrating superior mechanical and wear properties. Specifically, C2 achieved high tensile strength (84 MPa), flexural strength (122 MPa), impact strength (7.31 kJ/m2), and hardness (86 shore D), along with smallest wear and friction coefficient. HIGHLIGHTS Natural fiber based material was prepared by means of Indian almond fiber in addition to epoxy resin Silica and alumina nano-additives were added for further strengthening of composite Indian almond/Silica/Alumina composite’s functioning was investigated Indian almond/Alumina composite exhibited better tensile, flexural and impact strengths Indian almond/Alumina composite showed high hardness, slightest wear plus low friction coefficient

Tribological Behavior and Cold-Rolling Lubrication Performance of Water-Based Nanolubricants with Varying Concentrations of Nano-TiO2 Additives

This study aimed to investigate the effect of water-based nanolubricants containing varying concentrations (1.0–9.0 wt.%) of TiO2 nanoparticles on the friction and wear of titanium foil surfaces. Water-based nanolubricants containing TiO2 nanoparticles of varying concentrations were prepared and applied in friction and wear experiments and micro-rolling experiments to evaluate their performance regarding friction and wear properties. The findings indicated that the best results were achieved with a 3.0 wt.% TiO2 nano-additive lubricant that significantly improved the tribological properties, with reductions in the COF and wear of 82.9% and 42.7%, respectively, compared to the dry conditions without any lubricant. In addition, nanolubricants contribute to a reduction in rolling forces and an improvement in the surface quality of titanium foils after rolling. In conclusion, nanolubricants exhibit superior lubricating properties compared to conventional O/W lubricants, which is attributed to the combined effect of the rolling effect, polishing effect, mending effect and tribo-film effect of the nanoparticles.