Wear Rate Of Material Research Articles

Optimization of Material Removal Rate and Wear Rate in EDM Machining of Inconel 625 Using a Novel Nano Al-Ni Composite Electrode: A Response Surface Methodology Approach

The electric discharge machine is a novel machining technique. When the tool and the work item do not communicate. Components composed of difficult-to-machine hard materials. In the current experimental inquiry, the process factors that influence the machining concert process and its effectiveness are explored. The response table for each set of machining limitations is used in conjunction with the response surface methodology in the research to determine the appropriate levels of machining factors. The work's machining input parameters are optimized for maximum material removal rate (MRR) and reduce the electrode wear rate (EWR) when electro-discharge machining Inconel 625 using the tool Nano Al-Ni composite electrode. Another analysis of variance is to identify the factors causing the different answers mentioned above. EDAX was also used to investigate the material composition of the workpiece. Machined workpiece surfaces were evaluated using scanning electron microscopy to assess surface accuracy and microstructural characteristics (SEM). The following conclusions may be drawn from this work. The MRR parameter that is most affected is pulse off time. As pulse-off time lengthens, MRR increases. According to the response graph, the greatest MRR value that can be attained under the ideal parameters of Ip = 8A, T-ON = 50μs, and T-OFF= 100μs is 0.0115 g/min. The magnitudes of MRR range from 0.0091 to 0.044 g/min. Impact of T ON and T OFF: Higher EWR is 0.0022 g/min is seen in runs with T ON = 70 μs and T OFF = 100 μs.

Experimental Analysis of Wear Rate and Frictional Coefficient of Various Steel Material

This research study focuses on experimentally investigating the wear rate and frictional coefficient of different steel materials using a pin-on-disk testing machine. The tribological properties of steel materials play a crucial role in determining their performance and reliability in various applications. The objective of this study is to assess and compare the wear characteristics and frictional behavior of multiple steel materials under controlled testing conditions. The experimental setup involved employing a pin-on-disk testing machine, where a steel pin was brought into contact with a rotating steel disk. To ensure consistency, the pin and disk specimens were fabricated from various steel materials with uniform dimensions and surface finish. Several test parameters, such as load, sliding speed, and duration, were carefully selected to mimic real-world operating conditions. Throughout the experimental runs, the frictional forces and wear rates were continuously monitored and recorded. The wear rate was quantified by measuring the weight loss of the pin and disk specimens after each test run. Additionally, the frictional coefficient was calculated by dividing the frictional force by the applied load. By comparing these parameters among the tested steel materials, the researchers aimed to identify variations in their tribological performance. The results obtained from the experimental investigation indicated significant disparities in the wear rate and coefficient of friction among the tested steel materials. Certain steel materials exhibited lower wear rates and frictional coefficients, suggesting improved tribological properties compared to others. The observed differences in wear patterns and frictional behavior were thoroughly analyzed to gain insights into the underlying mechanisms responsible for the performance variations.

Influence of pore structures on friction and wear properties of iron-based oil-containing composites under dry and self-lubricated sliding conditions

This study successfully prepares iron-based oil-containing materials with connected porous structures using TiH2 and nylon 66 short fibers as pore-forming agents. The dehydrogenation of TiH2 can produce large pore cavities and the nylon 66 short fiber with a highly regular shape has a unique advantage in pore channel production. Compared to the iron-based specimen without the pore-forming agent, the oil content of the iron-based specimen with the two pore-forming agents increases by 33.86 %. The tribologica23ee3l properties of the iron-based oil-containing materials under dry and self-lubricated sliding conditions are evaluated using the MM-200 ring-block sliding tribometer and the HDM-20 end-face friction and wear tester, respectively. Special emphasis is given to the effect of pore structures on wear patterns. The results showed that the material's surface is subjected to significant shear failure under dry sliding conditions, leading to the closure of pores due to plastic deformation during the initial sliding. The connected pore structure is a non-dense region, allowing shear damage to occur in the deeper subsurface of the matrix and increasing the material's wear rate. Under self-lubricated conditions, the connected pore structure facilitates the rapid release of lubricating oil, improves the initial lubrication state, and delays pore closure. As compared with dry friction, the wear rate can be reduced by two orders of magnitude under self-lubricating conditions. At a sliding speed of 0.46 m/s, an appropriate load (about 900 N) can enhance the material's ability to continuously and rapidly supply oil.

Nanosecond laser-assisted fabrication of Ti6Al4V surfaces with gradient wettability and robust cross-linked microstructures

Abstract Surfaces with gradient wettability outperform singular superhydrophobic surfaces in terms of self-cleaning efficiency, anti-contamination properties, and fluid manipulation. These attributes offer extensive application potential across various industrial and scientific domains. This study introduces and employs nanosecond pulsed laser ablation to create wettability gradient surfaces on Ti6Al4V alloys, featuring robust cross-linked frame microstructures. Experimental results demonstrate that by varying the ridge width (w), associated with the liquid-solid contact fraction, we can achieve varying wettability and mechanical durability in these cross-linked frame microstructures. Wettability tests indicate static contact angles ranging from 150.7° to 105.45°. Furthermore, the sandpaper linear abrasion test illustrates a decrease in material wear rate with an increase in w. Under similar test conditions, the proposed surfaces demonstrate superior mechanical durability compared to two other prevalent wettability surface structures. The proposed surfaces, efficiently and eco-friendly produced through nanosecond laser fabrication, hold tremendous potential for diverse applications.

Abrasion Wear Resistance of Precipitation-Hardened Al-Zn-Mg Alloy.

The heat treatment of aluminum alloys is very important in industries where low weight in combination with high wear resistance, good strength, and hardness are important. However, depending on their chemical composition, aluminum alloys are subjected to different mechanical and thermal treatments to achieve the most favorable properties. In this study, an Al-Zn-Mg alloy was heat-treated including solution annealing at 490 °C for 1 h with subsequent artificial aging at 130, 160, and 190 °C for 1, 5, and 9 h. The hardness (HV1) and abrasive wear resistance with three different abrasive grain sizes were measured for all samples. The highest hardness was measured for the samples artificially aged at 130 °C/5 h, 227 HV1, while the lowest hardness was measured for the samples aged at 190 °C/9 h. The highest and the lowest wear resistance was also observed for the same state, i.e., artificially aged at 130 °C/5 h and 190 °C/9 h, respectively. The critical abrasive grain size was detected for some samples, where a decrease in wear rate was observed with an increase in the abrasive grain size from the medium value to the largest. The Response Surface Methodology (RSM) was applied to demonstrate the influence of the input parameters on the material wear rate.

Influence of Post-processing and Build Direction on the Wear Behaviour of Laser Powder Bed Fused Maraging Steel

Abstract Present study investigates the effect of post processing (heat treatment: solutionising at 850°C for 2 hr with aging at 490°C for 3 hr and cryogenic treatment at -196°C for 24 hr) and the effect of build direction (along the build direction (BD) and perpendicular to the build direction (PBD)) on the wear behavior of maraging steel fabricated by Laser powder bed fusion (LPBF). The results are also compared with conventional hot-forged samples. The pin on disc equipment was used to conduct the wear experiments with an EN31 steel disk as the counter body. Heat treatment decreased the wear rate of LPBF material by 54.78% and 83.84% in BD and PBD, respectively. This is due to the restriction of grain expansion by the Ni-based precipitants in age hardening treatment. The cryogenic treatment further decreased the wear rate of LPBF material by 87.84% and 90.9% in BD and PBD, respectively. This significant reduction can be attributed to the change of phase to martensite, as confirmed through microstructure and X-ray diffraction (XRD) analysis. Moreover, hot forged material also obtained a reduced wear rate after heat and cryogenic treatments. The highest wear resistance was found with the LPBF cryo-treated BD sample due to increased hardness from 388 HV to 640 HV. The worn surface of test samples was examined by using scanning electron microscopy (SEM), energy dispersive X-ray (EDX), 3D profilometer, and XRD analysis. Oxidation wear, adhesive wear, and abrasive wear are the predominant wear mechanisms identified using SEM.

Tribological Performance and Enhancing Mechanism of 3D Printed PEEK Coated with In Situ ZIF-8 Nanomaterial.

Polyether ether ketone (PEEK) is esteemed as a high-performance engineering polymer renowned for its exceptional mechanical properties and thermal stability. Nonetheless, the majority of polymer-based lubricating materials fail to meet the contemporary industrial demands for motion components regarding high speed, heavy loading, temperature resistance, and precise control. Utilizing 3D printing technology to design and fabricate intricately structured components, developing high-performance polymer self-lubricating materials becomes imperative to fulfill the stringent operational requirements of motion mechanisms. This study introduces a novel approach employing 3D printing technology to produce PEEK with varying filling densities and conducting in situ synthesis of zeolitic imidazolate framework (ZIF-8) nanomaterials on its surface to enhance PEEK's frictional performance. The research discusses the synthetic methodology, characterization techniques, and tribological performance evaluation of in situ synthesized ZIF-8 nanomaterials on PEEK surfaces. The findings demonstrate a significant enhancement in frictional performance of the composite material under low-load conditions, achieving a minimum wear rate of 4.68 × 10-6 mm3/N·m compared to the non-grafted PEEK material's wear rate of 1.091 × 10-5 mm3/N·m, an approximately 1.3 times improvement. Detailed characterization and analysis of the worn surface of the steel ring unveil the lubrication mechanism of the ZIF-8 nanoparticles, thereby presenting new prospects for the diversified applications of PEEK.

Experimental design on high-speed sliding wear

This paper recounts research that develops, conducts, and analyzes an experimental design characterizing wear rates of various materials sliding at high speeds along an AISI 4340 steel rail. The work supports Holloman Air Force Base’s engineering of a more wear-resistant rocket slipper for their high-speed test track. A design of experiments approach is used to systematically identify and evaluate potential slipper attributes that mitigate wear based on a heat transfer model. Results include recommendations of slipper materials that theoretically perform similar to or better than the baseline Vascomax®C300 maraging steel as well as statistical evaluation of the finite element analysis heat transfer model of the Air Force Research Laboratory’s pin-on-disk rig.

The effect of sand on the wear of anodized aluminum

PurposeThe purpose of this paper is to use a wear test to determine the effect of sand on the wear rates of materials typically used in aerospace applications. Once a repeatable wear test has been established, it can be used to test any combination of materials or coatings. The effectiveness of several different test methods will also be evaluated, including the sample height, surface roughness and mass difference. In addition, the current work will observe the differences between applying sand before the samples are brought into contact or after. The wear rates obtained from these tests could also be used to predict the wear of other components in similar abrasive particulate environments.Design/methodology/approachA modified block-on-flat wear test of anodized aluminum on hard coat anodized aluminum was used to study this. The experiments were performed with and without sand to study the effects of the sand. Two methods of adding sand were also evaluated. Weighing and profilometry were used to study the differences between the tests.FindingsWear rates have been calculated based on both the change in the masses of the samples and the change in the height between the upper and lower samples over the course of each test. The wear rates from the change in the masses are repeatable with and without sand, but the results for the change in height show no repeatability without sand. In addition, only in the presence of sand do the trends for the two methods agree. The wear rate was found to be non-linear as a function of load and therefore not in agreement with Archard’s Wear Law. The wear rate also increased significantly when sand was present in the contact for the duration of the test. The sand appears to change the wear mechanism from an adhesive to an abrasive mechanism. Black wear particles formed both when there was sand and when there was not sand. The source of these particles has been investigated but not determined.Originality/valueThis work has not been previously published and is the original work of the authors.

Machinability and surface morphology investigations of multiwall carbon nanotube reinforced aluminium 7075 metal matrix composite during electrical discharge machining: A grey relational approach

AbstractMultiwall carbon nanotube buttressed aluminium 7075 metal matrix composite was synthesized through an amended liquid metallurgy method, which consisted semisolid stirring, ultrasonic treatment and squeeze casting. Aim was to investigate its machinability and surface morphology during electrical discharge machining. Variable machining factors were peak current, pulse‐on time and gap voltage, whereas the responses under investigation were electrode wear rate, material removal rate and average surface roughness. Results revealed electrode wear rate, material wear rate and average surface roughness increased on increasing peak current and pulse‐on time, but all these responses behaved inversely with the increase of gap voltage. Average surface roughness reduced by around 44 % on reducing the peak current from 10 A to 4 A and increasing gap voltage from 55 V to 80 V at constant pulse‐on time of 300 μs; however, it increased by around 25 % on reducing the gap voltage from 80 V to 55 V and increasing the pulse‐on time from 100 μs to 300 μs at constant peak current of 10 A. Significance of the process parameters were verified, regression models were developed and morphology of the machined surfaces was studied. Finally, multiple response optimization was conducted following grey relational approach.

Real-time wear rate prediction and analysis: Gradient-weighted class activation mapping (Grad-CAM) in 1D convolutional neural network bridges experiments and neural networks

In this study, we propose a one-dimensional convolutional neural network (1D-CNN) for predicting wear rates using friction coefficient data. The model achieves high prediction accuracy for both training and testing sets, surpassing other machine learning methods. To ensure model reliability, we employ the Grad-CAM method, calculating importance scores correlating well with wear severity assessed by surface roughness (Ra) and wear track topography. The 1D-CNN model promises a precise, quantitative assessment of wear severity compared to traditional classification-based approaches. Furthermore, the model exhibits robust generalization abilities and potential as a base model for predicting wear rates of other materials, broadening its applicability in the tribology field.

Friction behavior of polycrystalline diamond compact and the evolution of the friction film under different matching materials

The friction and wear behavior of polycrystalline diamond compact (PDC) and the evolution of the friction film under nano‑molybdenum disulfide (MoS2) lubricating additives after leaching cobalt were investigated under different friction pairs (SiC, ZrO2, and Al2O3). The results showed that the friction coefficient and wear rate of different matching materials and PDC after leaching cobalt in a solid–liquid lubrication environment are related to the amount of friction film formed on the sliding interface, the evolution behavior, and the filling effect of lubricating additives on the friction interface. Different matching materials and PDC after leaching cobalt will undergo dissimilar chemical reactions during the sliding process, and different wear mechanisms are obtained.

Wear properties and microstructural characteristics of mild steel cladded with AISI 316L stainless steel using constant current gas metal arc welding process

The main objective of this study is to investigate the microstructure and wear resistance of AISI 316L austenitic stainless steel (ASS) cladding deposited over mild steel (MS) of grade IS 2062 using constant current (CC-GMAW) gas metal arc welding process. The microstructural features of cladded region were analyzed using optical microscopy (OM). The wear rate of cladded specimens was studied using pin-on-disc method and the morphology of wear surfaces was studied using scanning electron microscopy (SEM). The microhardness distribution of cladded region was analyzed and correlated to the wear performance of cladded specimens. The results showed that CC-GMAW cladded surface exhibited greater hardness and wear resistance compared to mild steel substrate. The overlay region of CC-GMAW clad showed the evolution of dendritic structure and columnar grains. The CC-GMAW cladding showed martensite laths and widmanstätten ferrite plates microstructure in the HAZ region closer to interface. The wear rate of CC-GMAW cladding increases with increase in load from 1.5 kg to 5.5 kg. It showed 422.85% and 423.58% increase in material weight loss and wear rate at higher loads. The materials weight loss of CC-GMAW cladding increases from 0.0082 g to 0.0517 g with increase in speed from 150 rpm to 550 rpm. The wear rate of CC-GMAW cladding increases from 3.66 × 10-5 g/m to 10.94 × 10-5 g/m with increase in temperature from 27 °C to 200 °C.

Study on wear behaviour of aluminium-based piston alloy using different coatings

The wear rate of a piston in an engine determines how long it can run and how much power it can produce. The wear rate of lightweight piston materials used in medium cars was examined. The piston itself was used to cut the plates after it had been formed in an aluminium alloy. It was then successfully prepared for coating with hard anodizing and tin coating after being trimmed to a diameter of 90 mm. There are a number of wear tests, including the pin on the disc test, slurry abrasion test, scratch test, and erosion test to analyse the wear rate. The coating's substance and intended applications determine which wear test is used. Slurry erosion and corrosion tests for the coating are favoured for usage on automobiles. But the pin on disc and scratch tests are frequently carried out in cases where the coating is applied dry. In the current investigation, only one variable load (30 N, 40 N, and 50 N) and sliding speed (500 rpm) was chosen for the wear test. Sliding distance (1200 m) was treated as a constant. Under dry conditions, a pin-on-disc machine was used to test the wear of the coatings and soft materials. SEM analysis was used to examine the surface morphology of the coating's worn surfaces. It was discovered that as the load grew, the coating's wear rate also did. It was discovered that as the load was raised, the coating's co-efficient of friction decreased. With the aid of an optical telescope, the microstructure of the coating's worn surfaces was also inspected, although no evidence of a change in the microstructure owing to frictional heat was discovered. It was discovered that the coating's micro hardness decreased away from the wear track at the coating's cross section. Using a SEM, adhesion, deformation, and microcutting were the main wear mechanisms seen.

Tribological behaviour of HVOF-sprayed Ni-based self-lubricating composite coatings

ABSTRACT In the current investigation, the tribological behaviour of HVOF sprayed Ni-based self-lubricating composite coatings on cast iron substrate, which is a commonly used material for cylinders, was studied. Four different combinations of coatings materials, namely, Ni–10Mo–10Al, Ni–10Mo–10Al–10graphite, Ni–10MoS2–10Al and Ni–10MoS2–10Al–10graphite were deposited on a cast iron substrate. Then, the mechanical, morphological and tribological properties of the coated and uncoated samples were analysed by performing microhardness measurements, a scratch resistance test, a wear test (pin on disc), XRD and SEM/EDS. Results showed that among all coatings, Ni–10MoS2–10Al–10graphite coated cast iron sample has the highest microhardness of about 349.4 HV 111% higher than the substrate material and lowest average wear rate of about 1.1 × 10−4 g s−1.

High‐Stress Abrasive Wear Analysis of in Situ TiC‐Reinforced Zinc–Aluminum Composites Using Integrated Taguchi–TOPSIS Method

This study involves the preparation of in situ TiC‐reinforced zinc–aluminum alloy (ZA‐37) composites and analysis of their high‐stress abrasive wear behavior. The wear rate, friction coefficient, and frictional heating of the composites are investigated using a pin‐on‐disk wear tester. The experiments are carried out based on a plan created using Taguchi's technique. TOPSIS methodologies are used to determine the effects of applied load, abrasion distances, TiC contents on wear rate, coefficient of friction, and frictional heating throughout the wearing process. The results reveal that the composite with 10 wt% TiC exhibits the highest level of wear resistance among all samples. It is found that ploughing, microcutting, and delamination were the dominant wear mechanisms in general. However, in the optimum combination, mild abrasion and microploughing prevail. As per TOPSIS analysis, the reinforcement content affects the wear rate of test materials the most followed by applied load and abrading distance. Under the optimal combination of parameters, the in situ TiC composite has the potential of replacing the conventional gray cast iron utilized in bearing applications.

Influence of Axle Load on the Wear of Railway Wheel Material

This study investigated the influence of axle load on the wear rate of railway wheel material. Excessive wear of wheel/rail materials and reduced service life of the wheel/rail system might be caused by the increase in axle load and traffic volume. Two kinds of rail and wheel steels have been studied against different axle load steps, simulating them for wear performance analysis using multibody simulation software (SIMPACK) and MATLAB programming. The simulation model results are validated against the vehicle’s specifications and wear depth measured on Ethiopia—Addis Ababa Light Rail Transit (LRT), and experimental results from the literature. The result shows that the wear rate increases proportionally with the increasing of applied load and that the proportionality coefficient is 0.1393, which has a very good agreement with the experimental results from the works of literature. Likewise, the estimated total tread wear amount after a mileage of 52,000 km is 2% larger than the measured one in LRT, which is indeed an excellent result taking into account the inaccuracy of the wheel diameter gauge used to measure the wheel transversal profile. In normalized UIC 50 kg/m rail and S1002 wheel profile, the wear rate increases linearly from 5110.02, 9997.87, and 18990.17 mm3/km on 11, 21, and 30 tones applied load, respectively. Apparently, on the hardened UIC 60 kg/m and S1002 wheel profiles, the wear rate has been improved by 14.5%, 10.8%, and 7.5% on 11, 21, and 30 tones applied load, respectively, in comparison to normalized rail/wheel match. Briefly, the wheel wear rate is highly influenced by the increasing applied load, referring proportionality coefficient of 0.1393.

Tribological Properties and Wear Mechanism of C/C Composite Applied in Finger Seal

The application of C/C composites in finger seals can effectively solve the problem of seal wear due to its excellent tribological and mechanical behaviors. However, the designable characteristics of composites, such as the density and orientation of fabric on the friction plane, have a very important influence on the tribological properties and service life of sealing materials. In order to obtain a better material design scheme for the C/C composite on the finger seal, it is necessary to conduct research on the tribological properties and wear mechanism of the C/C composite based on the working conditions of the finger seal. Therefore, a reciprocating tribo-tester was used to conduct the test by abrading the C/C composite disk with a pin made of 1045,080M46. The effects of material density, fabric orientation, and load and sliding velocity on the tribological properties and wear mechanism of the C/C composite were studied. The results show that the friction coefficient and wear rate of the composite with a perpendicular orientation (non-woven cloth perpendicular to the friction plane) were lower than those with a parallel orientation (non-woven cloth parallel to the friction plane). The tribological properties with higher density are better than those of material with a lower density. The friction coefficient of low-density material increases with the load, whereas it decreases gradually with high-density material. The wear rate increases with the load for two-density materials. With the increase in the sliding velocity, the friction coefficient decreases. The wear rate of low-density material decreases significantly, whereas it changes little with high-density material. The influence of the sliding velocity on the friction and wear properties of the C/C composite is greater than that of the load. This study provides a feasible material design idea for effectively alleviating the wear of finger seals.

Comparative study of the current-carrying tribological properties of carbon graphite composites with different hardnesses

To investigate the effect of sliding speed and electrical current on the current-carrying friction performance of carbon brushes with different hardnesses. In this paper, two carbon-graphite material samples with different hardnesses manufactured by a powder metallurgical process were prepared. And a pin-disc current-carrying friction tester was used for testing. The results showed that the difference in hardness has a noticeably different effect on the sliding contact resistance and interface temperature rise of the material. As the electric current changes, the material with low hardness exhibited good adaptability. Then, the adhesive wear occurred for all materials of different hardnesses, and it changed to abrasive wear mainly with increasing electrical current. As the sliding speed increased, the wear rate of low-hardness material dropped, while the opposite trend was observed for high-hardness material. The increased sliding speed does not generate remarkable damage to the contact surface of the high-hardness material, which demonstrated good resistance to mechanical shocks.

Statistical investigation of the machining of aluminum LM-25 /SiC metal matrix composite

In the current study, various machining variables are investigated in relation to the abrasive mix electrical discharge machining (AMEDM) performance of aluminium LM25/SiC MMC. An originality of this experiment lies in the fact that silicon carbide abrasive mix EDM has been successfully applied to aluminium LM25 grade metal with 5% SiC reinforcement. The research was conducted with aluminium LM25/SiC MMCs with abrasive mixed dielectric fluid using Box-Behnken design (BBD) of response surface methodologies (RSM). The ANOVA has been performed to identify machining parameters that significantly influenced machining performance. The purpose of this article is to provide directions for optimizing the AMEDM parameters, such as voltage, pulse rate, and powder concentration, based on the material removal rate, wear rate, and roughness of the surface. It is found that discharge current contributes significantly to the improvement of material removal rate (99.23%), surface finish (98.01%) as well as the tool wear rate (40.56%), respectively. Which enhanced the performance characteristics of abrasive mix EDM.