Mechanical Wear Resistance Research Articles

Impact of stacking sequence on mechanical and dry sliding wear properties of bamboo and flax fiber reinforced hybrid epoxy composite filled with TiO2 filler

PurposeThis study examines how different stacking sequences of bamboo and flax fibers, treated with 5% aqueous sodium hydroxide (NaOH) and filled with 6wt% titanium oxide (TiO2), affect the physical, mechanical and dry sliding wear resistance properties of a hybrid composite.Design/methodology/approachComposites with different fiber stacking arrangements were developed and tested per American Society for Testing and Materials (ASTM) standards to evaluate physical, mechanical and wear resistance properties, focusing on the impact of flax fiber mats at intermediate and outer layers.FindingsThe hybrid composite significantly outperformed composites reinforced solely with bamboo fibers, showing a 65.95% increase in tensile strength, a 53.29% boost in flexural strength and a 91.01% improvement in impact strength. The configuration with multiple layers of flax fiber mat at intermediate and outer levels also demonstrated superior wear resistance.Originality/valueThis study highlights the critical role of stacking order in optimizing the mechanical properties and wear resistance of hybrid composites. The findings provide valuable insights for the design and application of advanced composite materials, particularly in industries requiring high performance and durability.

Surface one-step modification of graphene oxide with N-cyclohexylbenzothiazole-2-sulfonamide to enhance the wear resistance of natural rubber/butadiene rubber composites

Natural rubber (NR) and butadiene rubber (BR) composites are frequently used in manufacturing tires and conveyor belts, which are susceptible to severe wear, leading to product failure and significant losses. To enhance the wear resistance of NR/BR composites, we prepared NR/BR composites reinforced with a synergy of N-cyclohexylbenzothiazole-2-sulfonamide surface one-step modified reduced graphene oxide (CZ-rGO) and carbon black N234 (CB) using a latex co-precipitation method. This study explored the effects of GO content and CZ modification on the structure, wear resistance, thermal conductivity, and mechanical properties of the NR/BR blended composites. It showed that adding 2 phr of GO resulted in excellent filler dispersion, significantly improving the tensile strength, elongation at break, tear strength, thermal conductivity, and wear resistance of the composites. The incorporation of CZ-rGO further increased the crosslinking density, vulcanization performance, and filler dispersion with enhanced mechanical properties, thermal conductivity, and wear resistance of the composites. Notably, the DIN abrasion volume was reduced to 77.88 mm³, surpassing the ISO 10247 standard for conveyor belt cover rubber in terms of wear resistance. The wear resistance of NR/BR/CZ-rGO composites is not only significantly higher than that of single NR- or SBR-based rubber composites, but also significantly higher than that of other binary rubber blend composites, and the CZ-rGO filler is simpler in composition and structure and exhibits a more prominent wear enhancement. This work provides guidance for an efficient and environmentally friendly approach to GO surface modification, as well as useful insights for the development of high wear-resistant rubber composites with excellent overall performance.

Regulation of microstructure, phase transformation behavior, and enhanced high superelastic cycling stability in laser direct energy deposition NiTi shape memory alloys via aging treatment

The remarkable mechanical properties, fatigue resistance, wear and corrosion resistance, biocompatibility, shape memory effect, and superelasticity of NiTi shape memory alloys make them applied in diverse engineering areas, including satellite antennas, oil pipelines, and vascular stents. This paper focuses on the preparation of Ni50.8Ti49.2 alloy via laser directed energy deposition (LDED) utilizing pre-alloyed powder and the heat treatment of solid solution at 950 °C for 8 h followed by subsequent aging at 350 °C, 450 °C and 550 °C for 2 h. The influence of varying aging temperature on the microstructures, phase transformation behavior and superelastic cyclic stability of them was comprehensively summarized and discussed. The martensitic transformation temperatures of NiTi alloys after aging decrease as the aging temperature increases. Specifically, NiTi alloys aged at 450 °C for 2 h exhibit excellent superelasticity and high cyclic stability. After an initial loading-unloading cycle with an 8.079 % pre-strain, the alloy achieves 100 % complete recovery. Even after 10 cycles, the recoverable strain remains at approximately 7.374 %, with a recovery rate exceeding 90 %. These outstanding properties of high superelasticity and superior cyclic stability are significantly better than most other LDED NiTi alloys. This exceptional performance is primarily attributed to the synergistic effects of the R-phase and Ti3Ni4 precipitates on the shape memory alloy.

Nano-twinned silicon in Al-Si alloys for high wear-resistance

Wear-failure is the most common damage for power transmission components in the field of engineering materials, constituting approximately one-fourth in service loss. The development of high wear-resistant Al alloys plays a crucial role in reducing energy demand and weight, and then attributes to the achievement of dual-carbon target. Here we report a novel strategy to develop outstanding wear-resistant (the coefficient of friction of 0.31) Al-10 wt%Si alloys at room temperature, based on the formation of multiple parallel {111} twins and hierarchical {111}-{111} double twins by a route of combining ultrahigh pressure solid solution and electropulsing assisted aging (HPEP), which overwhelms all values of Al alloys, even Ti alloys and high entropy alloys reported so far. The microstructure, formation process and wear-resistant mechanism of nano-twinned Si have been clarified by transmission electron microscopy observations, molecule dynamics simulations and the first principles calculations. It demonstrates that the interactive nano-twinned Si structures are mainly introduced through twin-twin collision or the phase/matrix interface prohibition of twin motion, which are effective to restrain atom separation in contrast to eutectic Si perfect crystal, resulting in homogeneous wear-loss and long operation life. Those new results provide insights towards designing wear-resistant materials with high mechanical properties.

Investigations on Mechanical Properties of Nano Particulates (Al<sub>2</sub>O<sub>3</sub>/B<sub>4</sub>C) Reinforced in Aluminium 7075 Matrix Composite

Metal Matrix Nano Composites (MMNCs) with the addition of nano-particulate reinforcements can be of significance for automobile, aerospace, and numerous applications due to their low density and good mechanical properties, better corrosion and wear resistance, low coefficient of thermal expansion as compared to conventional materials. Designing the metal matrix composite material aims to combine the desirable attributes of metals and ceramics. The present work is focused on studying the mechanical properties of aluminium alloy (7075) with Al2O3 and B4C nanocomposite produced using the stir casting technique and ultrasonic cavitation method. Different % age of reinforcement is used. An ultrasonic cavitation technique is used to achieve a uniform dispersion of nano-particulate Al2O3 and B4C in molten aluminium alloy. Tensile, Hardness, and Impact tests were performed on the samples obtained by the fabrication processes. A structural study will be carried out through a Scanning Electron Microscope (SEM) to know the distribution of Al2O3/B4C Nano particulates in Al alloy.

Process optimization and tribological behavior of Ti-48Al-2Cr-2Nb prepared by selective electron beam melting

Selective electron beam melting (SEBM) technology was utilized to fabricate TiAl alloys which possess low density and excellent high-temperature performance, to achieve lightweight design of automotive engines. The forming process of Ti-48Al-2Cr-2Nb was systematically optimized, and found that the microstructure of TiAl formed by SEBM consisted of a layer of alternating γ-band structure and duplex-like structure. As the energy density increases, grain coarsening, proportion increasing of high angle grain boundaries, and anisotropy strengthening occur successively. The forming quality of TiAl reaches its peak at an energy density of 22.5 J/mm3, at which point its mechanical properties and wear resistance also perform the best. Subsequently, in-depth friction experiments at high and room temperatures were conducted, and it was found that at room temperature, as the load increased, the friction coefficient of the samples decreased and the wear rate increased. In addition, the friction coefficient decreases from 0.54 to 0.44, while the wear rate increases from 19.90×10−5 mm3/(N·m) to 25.97×10−5 mm3/(N·m). At this point, abrasive and adhesive wear were the main wear mechanism. Under high temperature conditions, the wear mechanism of the substrate is mainly abrasive wear, adhesive wear, and oxidative wear. And the friction coefficient decreases from 0.69 to 0.49. At lower temperatures, the detached debris was filled and solidified on the wear marks under the action of the friction ring, forming a hardened layer called “enamel”, which can alleviate the negative effects of wear. Under the influence of extreme high temperature environment, the unworn surface forms a light blue oxide film due to rapid oxidation, known as the “burning blue” phenomenon. Along with the high-temperature oxidation phenomenon confirmed by EDS, the oxide layer is more prone to peeling off and forming debris. In addition, melting softening occurs inside the annular wear scar, which increases the amount of deformation under external force, ultimately leading to a significant increase in wear.

Influence of Additives on Grinding Performance of Digital Light Processing-Printed Phenol Bond Grinding Wheels

Resin bond grinding wheels are the most common grinding tools in the industry. Until now, all research on the additive manufacturing of resin bond grinding wheels has focused on commercially available acrylate resin. However, using a phenol-based bond to print resin-bond grinding wheels has been challenging for researchers and industries. In this study, a photo-curable phenol resin bond grinding wheel was introduced for the first time, offering advantages such as lower cost, high thermal resistance, and good mechanical properties. To enhance the grinding performance of the printed wheels, various additives, such as copper, glass fiber, and carbon fiber, were incorporated into the composition. Different on-machine and out-of-machine measurements, such as force, tool wear, dimensional accuracy, and optical microscopy measurements, were conducted to investigate the grinding performance of the printed wheels. The results demonstrate that printed grinding wheels have strong potential in grinding applications, which was more prominent for the bond reinforced by glass fibers, providing improved mechanical properties (up to 50%), wear resistance (up to 75%), and higher dimensional accuracy (up to 11%).

Comparative Study on the Tribological Performance of Conventional and Metal Matrix Composite Brake Pads in Automotive Applications

Abstract: This study investigates the wear and mechanical properties of aluminum alloy composites reinforced with titanium dioxide (TiO2) nanoparticles. Aluminum-based composites are increasingly favored in engineering due to their excellent properties, and incorporating TiO2 nanoparticles presents a promising method for further enhancement. The composites were produced using a powder metallurgy technique, and their mechanical performance—including tensile strength, hardness, and impact resistance—was thoroughly assessed. Additionally, wear tests under various conditions were conducted to evaluate the composites' wear resistance. The findings indicate that incorporating TiO2 nanoparticles significantly enhances both the mechanical properties and wear resistance of the aluminum alloy.

Surface mechanical rolling treatment-introduced gradient nanostructured Inconel 625 alloy with enhanced high-temperature wear resistance

Heterogeneous gradient nanostructures induced through surface treatment of nickel-based superalloys hold significant promise for enhancing wear resistance. In this study, a 700 µm ultra-thick gradient nanostructured (GNS) strengthening layer was fabricated on the surface of an Inconel 625 alloy plate via surface mechanical rolling treatment (SMRT). Subsequently, the tribological behaviors and wear resistance mechanisms of coarse-grained (CG) and GNS samples at temperatures ranging from 25 ℃ to 800 ℃ were comparatively investigated. The results indicated that the gradient nanostructures significantly enhanced the high-temperature wear resistance of the samples, which wear characterized by low coefficient of friction (COF), wear rate and thin friction layer. This enhancement was attributable to the stability and excellent hot hardness of the gradient nanostructures during friction.

Promoting grain refinement and nanocrystal generation in surface nanomachining by means of overlapping collisions

Surface nanostructuring effectively improves the mechanical properties and wear resistance of the moving parts, yet a thorough understanding of its formation mechanism remains elusive. This study examined the microstructure evolution of pure copper under various linear overlapping ratios (φ) using a self-made impact wear tester. The results revealed that high Smid factor grains activate the basal slip system to handle deformation during repeated impacts. Still, overlapping impacts can intensify plastic deformation by activating multiple slip systems and boosting dislocation proliferation. Moreover, overlapping collisions will generate Frank's incomplete dislocations, hindering dislocation slip and generating cross slip trajectories, resulting in the bending of slip-trajectories, the formation of uneven wrinkles, and the refinement of superficial grains.

Tribological Behavior and In‐Vitro Biocompatibility of a Newly Designed TiZrNbMoTa High‐Entropy Alloy

A novel Ti35Zr15Nb25Mo15Ta10 high‐entropy alloy has been designed, fabricated, and characterized as a viable substitute for the conventional Ti‐6Al‐4V alloy in biomaterial applications. Alloy design is conducted based on various parameters including mixing enthalpy (ΔHmix), omega parameter (Ω), delta parameter (δ), valence electron concentration (VEC), and biocompatibility aspects of its constituent elements with CALPHAD approach. The fabricated Ti35Zr15Nb25Mo15Ta10 alloy demonstrated a body‐centered‐cubic (BCC) solid solution phase with no evidence of intermetallics. Nanoindentation investigations exhibited high hardness of ≈5.1 GPa and a young modulus of ≈140 GPa. The alloy proposed better surface properties and tribological behaviour in comparison with the Ti‐6Al‐4V alloy in dry and wet (under PBS solution) conditions. Furthermore, the newly designed alloy revealed promising behaviour after investigation of in‐vitro biocompatibility compared to the Ti‐6Al‐4V alloy. These initial benefits of the Ti35Zr15Nb25Mo15Ta10 alloy concerning mechanical properties and wear resistance over the conventional Ti‐6Al‐4V alloy present an avenue for exploring novel orthopedic implant alloys.

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.

Effect of groove textures on wear of friction pair between groove side and scraper under different factor combinations

Three-body wear is the primary wear mechanism in friction pair between groove side and scraper. This study quantitatively investigates the effect of groove textures on three-body wear under different factor combinations through abrasive wear experiments. The results indicate that groove textures significantly reduce wear of samples. The wear reduction rate of sample reaches 41% under the optimal factor combination. Width, depth, and tilt angle of groove textures significantly influence wear loss. Among these factors, width exhibits a negative effect on the change of wear loss, while depth and tilt angle show positive effects. Additionally, there are interactive effects on the change of wear loss between width and depth, as well as width and tilt angle. The effect process of groove textures to three-body wear was qualitatively analyzed by discrete element method (DEM) simulation. Combined with wear morphologies, the wear-resistant mechanism of groove textures was explored. The results indicate that groove textures can mitigate the severity of three-body abrasive wear, reduce the contact area between particles and samples, alter particles movement and enhance wear resistance. Meanwhile, groove textures can serve as a guiding mechanism to modify particles movement and direction and transform the sliding motion of coal particles into rolling motion, converting the continuous “face-face” contact of three-body wear into intermittent “point-face” and “line-face” contacts. This study provides novel study ideas and theoretical foundations for wear-resistant designs in mining machinery and three-body wear equipment.

Investigation on mechanical and tribological properties of PTFE nanocomposites reinforced by surface-modified graphene using molecular dynamics simulations

Surface-modified nanoparticles are commonly used to improve the mechanical properties and wear resistance of polytetrafluoroethylene (PTFE). However, fewer studies have been devoted to quantitatively revealing the action mechanism of graphene (Gr) modified with different functional groups on the mechanical and tribological properties of PTFE. Herein, the effects of four functional groups (−OH, −NH2, −COOH, and −COOCH3 functional groups) on the surface of Gr nanosheets on the mechanical and tribological properties of PTFE nanocomposites are studied using molecular dynamics simulations. The results indicate that the incorporation of functional groups to the Gr surface is able to significantly improve the mechanical properties and wear resistance of the nanocomposites, and the COOH-functionalized Gr nanosheet shows the best reinforcing effect due to the synergistic effect of its own high surface roughness and strong interfacial interaction between itself and the matrix. It is also found that the friction coefficient of the nanocomposites is obviously increased by the inclusion of functionalized Gr nanosheets, and the greater the surface roughness of the functionalized Gr nanosheet, the more significant the growth of the friction coefficient of the nanocomposites. The pull-out test and confined shear simulation reveal that due to the increased interfacial shear strength and the isolation of functional groups, an inhomogeneous transfer film is formed at the friction interface, leading to a decreased anti-friction property. This study provides some guidance for the future design and development of polymer nanocomposites with excellent mechanical and tribological performance for use in extreme service conditions.

Structural, mechanical, and oxidation resistance properties of double glow plasma Ta[sbnd]W alloys

To enhance the performance of surface coatings on weaponry, TaW alloy layers with various W contents (7, 11.5, 13, 14, 14.5 and 16 at. %) were prepared on the surface of a PCrNi3MoVA gun steel substrate using double-glow plasma surface metallurgy technology. Mechanical properties, friction wear, and oxidation resistance were studied using scratch, hardness, and tribometer testers. The mechanical properties, interfacial properties, and effects on the oxidation performance of the gun steel substrate of the TaW alloy layer were calculated using first principles. The results indicated that the surface and cross-sectional microstructures of the TaW alloy layers were dense and free from obvious defects. With increasing W content, the thickness, hardness, and adhesive strength of the TaW alloy layer increased, and the coefficient of friction and wear rate decreased. The results of the calculations indicate that an increase in the W content enhances the elastic modulus of the TaW alloy and improves its brittleness, strength, and hardness. Doping with Ta and W atoms can increase the vacancy formation energy of Fe atoms in the Fe supercell, the adsorption energy of O atoms on the surface of Fe(110), and the diffusion barrier of O atoms in the Fe supercell and on the Fe(110) surface. Interdoping of Ta, W and Fe atoms at the Fe(110)/Ta-W(110) interface improved the bonding strength and stability of the interface, and the FeTa and FeW chemical bonds formed at the Fe(110)/Ta-W(110) interface ensured stable bonding at the interface. The incorporation of W into the TaW alloy layer enhanced both the mechanical and frictional properties of the alloy. It is well established that TaW alloys improve the antioxidant properties of gun steel substrates, thereby enhancing the performance of coatings on weaponry.

Determining of the effect of reinforcing microrelief guides on the efficiency of folding integrated covers

The object of research is the processes of strengthening the working surfaces of profile folding strips made of stainless steel AISI 347 and carbon steel AISI 1005 using laser formation of microrelief guides. The analytical and experimental studies are based on the technique of laser microrelief formation by pulsed laser effects. The main assumption of the study is that the use of laser microrelief formation could increase the hardness and wear resistance of the folding strips, improving the process of folding integrated covers. Analyzing the effect of different hardening methods on the mechanical properties and wear resistance of the working surfaces of folding strips is necessary to achieve this goal. A methodology for assessing microstructural changes and their impact on the mechanical properties of folding strips during laser hardening has been proposed. It has been shown that the formation of microrelief guides by laser pulse exposure reduces the thermal load on the material, increases the uniformity of hardening and wear resistance. The revealed wear rates calculated for carbon steel AISI 1005 are 0.875, and for stainless steel AISI 347 – 0.345. To improve the accuracy and efficiency of the folding process, a methodology has been devised for calculating the quantitative formation of microrelief guides on the working surface of profile folding strips. This will not only improve the wear resistance and mechanical properties of the strips but also optimize production processes. Differences in the results of hardening for stainless steel AISI 347 and carbon steel AISI 1005 were found: the hardness values for AISI 347 are 3,088–4,904 MPa at a load of 50–350 g with a deviation of 37.1 %, and for AISI 1005 – 2141–1665 MPa with a deviation of 22.3 %

A study on microstructural, mechanical properties, and optimization of wear behaviour of friction stir processed AZ31/TiC composites using response surface methodology

The primary objective of this study is to investigate the microstructural, mechanical, and wear behaviour of AZ31/TiC surface composites fabricated through friction stir processing (FSP). TiC particles are reinforced onto the surface of AZ31 magnesium alloy to enhance its mechanical properties for demanding industrial applications. The FSP technique is employed to achieve a uniform dispersion of TiC particles and grain refinement in the surface composite. Microstructural characterization, mechanical testing (hardness and tensile strength), and wear behaviour evaluation under different operating conditions are performed. Response surface methodology (RSM) is utilized to optimize the wear rate by considering the effects of process parameters. The results reveal a significant improvement in hardness (41.3%) and tensile strength (39.1%) of the FSP-TiC composite compared to the base alloy, attributed to the refined grain structure (6–10 μm) and uniform distribution of TiC particles. The proposed regression model accurately predicts the wear rate, with a confirmation test validating an error percentage within ± 4%. Worn surface analysis elucidates the wear mechanisms, such as shallow grooves, delamination, and oxide layer formation, influenced by the applied load, sliding distance, and sliding velocity. The enhanced mechanical properties and wear resistance are attributed to the synergistic effects of grain refinement, particle-accelerated nucleation, the barrier effect of TiC particles, and improved interfacial bonding achieved through FSP. The optimized FSP-TiC composites exhibit potential for applications in industries demanding high strength, hardness, and wear resistance.

Investigation on mechanical properties and wear behavior of basalt fiber and SiO2 nanofillers reinforced composites

This study explored the fabrication and evaluation of basalt fiber-reinforced composites containing silicon dioxide (SiO2) nanofillers. Hand layup followed by vacuum bagging was used to create composite specimens with mold dimensions of 300 × 300 × 3 mm³. The mechanical properties, hardness, and wear resistance of the fabricated composites were assessed according to ASTM standards. SiO2 nanofillers significantly improved the flexural properties of the composites, with a remarkable increase of 178 % and 26 % in flexural strength and modulus, respectively. Additionally, the tensile strength and modulus of the composites were also enhanced. The hardness reached a maximum of 86 at 6 wt % SiO2, and the wear resistance improved owing to the better interfacial bonding and reduced wear debris size. Wear tests revealed that SiO2 nanofillers reduced the wear rate and weight loss, which was attributed to improved interfacial bonding and reduced wear debris size. The FESEM analysis provided insights into the fracture mechanisms, showing enhanced energy dissipation and controlled crack propagation. The study concluded that SiO2 nanofillers enhance the mechanical properties and durability of fabricated composite laminates.

Optimization of Fused Filament Fabrication for High-Performance Polylactic Acid Parts under Wear Conditions

This paper investigates the impact of various manufacturing parameters on the mechanical and tribological properties of high-performance PLA (polylactic acid) parts produced using Fused Filament Fabrication (FFF). It addresses the challenges associated with optimizing additive manufacturing processes, particularly for polymer-based materials, and emphasizes the importance of understanding how factors such as build orientation, layer thickness, and infill density influence the final properties of the printed parts. This study highlights the improvements that can be achieved by incorporating reinforcements such as carbon fibers and graphene nanoplatelets into PLA, enhancing its mechanical strength and wear resistance. Experimental results show that optimizing printing parameters can significantly reduce the coefficient of friction and wear, leading to better performance in applications involving movement and mechanical stress. Key findings include the observation that higher infill densities and specific build orientations improve the fatigue life and tensile strength of PLA parts. Additionally, post-printing thermal treatments can alleviate internal stresses and enhance interlayer adhesion, further improving mechanical properties. The article concludes that with proper optimization, high-performance PLA can be a viable material for industrial applications, offering both environmental benefits and enhanced performance.

Combining Ultrafast Laser Texturing and Laser Hardening to Enhance Surface Durability by Improving Hardness and Wear Performance

Aluminum alloy 7075 is utilized widely across marine, aerospace, and automotive sectors. However, its surface wear resistance has hindered its application in certain tribological environments. Addressing this challenge, the current study examines a hybrid laser method to increase surface wear resistance by combining two techniques: ultrafast laser texturing and laser‐based surface hardening. Ultrafast laser processing is conducted using 3 W laser power, 100 kHz pulse repetition rate, 4 mm s−1 scanning speed, and three different scan patterns. After the texturing operation, laser‐based surface hardening is then performed on these textures using a continuous wave laser. The laser heat treatment is conducted using laser powers of 400 and 500 W with three different scan speeds of 1, 2, and 3 mm s−1. Microhardness evaluations show a notable increase in hardness, with the hardest sample exhibiting a 17.8% increase compared to the pristine sample. The laser‐textured and laser heat‐treated samples exhibit a significant reduction in the average coefficient of friction and wear volumes compared to samples that were laser‐textured but not laser heat‐treated. The investigated laser processing strategy offers a promising approach for surface modification, enhancing both mechanical properties and wear resistance of aluminum alloy 7075 surfaces.