Wear Resistance Of Composite Materials Research Articles

High temperature tribological properties of additively manufactured WC reinforced CuAl7–W composites

A wear-resistant composite material based on aluminum bronze with an addition of tungsten and tungsten carbide particles is developed using a combined wire- and powder-feed additive electron beam technology. The wear tests conducted under dry sliding conditions at room and elevated temperatures demonstrate a significant increase in wear resistance without any significant changes in the friction coefficient. Specifically, the composite with a particle content of 10 % exhibits an average wear rate 1.6 times lower compared to that of pure aluminum bronze, while the composite with a particle content of 20 % shows a 3.9-times wear rate reduction. The wear of the steel counterfaces during the composite sliding remains close to the values observed in a similar process for pure bronze.

Wear resistance of composite materials based on ultra-high molecular polyethylene with combined filling

Polymer composite materials (PCM) of antifriction duty with self-lubricating properties are used for the manufacture of various parts in friction units of machines and mechanisms. PCM can partially replace parts made of metals and alloys, increasing the reliability and service life of the equipment when the use of oils or external lubricants is limited or prohibited. The goal of the study is the effect of fillers (sulfenamide, sulfur, magnesium and zinc oxides) on the tribological parameters of polymer composite materials based on ultra-high molecular weight polyethylene (UHMWPE). Samples were prepared by hot pressing at a temperature of 175°C and a pressure of 10 MPa. Composites with filler concentrations 0.5 and 1 wt.% were considered (for sulfenamide, sulfenamide with sulfur, and combinations of 0.5 and 1 wt.% sulfenamide with sulfur and zinc oxide or magnesium oxide). It is shown that the introduction of sulfenamide leads to an increase in the wear resistance by six times, and the introduction of a combination of fillers of 0.5 wt.% sulfenamide, sulfur, and magnesium oxide — by 1.5 times. The friction surfaces of composites were studied using methods of scanning electron microscopy and IR-spectrometry. The formation of an oriented ordered structure in the form of clusters of wear products was revealed on the friction surfaces of composites filled with sulfenamide. In the case of combined filling, secondary structures were found on the friction surface, which visually differ from the UHMWPE friction surface. The appearance of peaks in IR spectra corresponding to oxygen-containing groups (–C=O, –COOX) was observed on the friction surface of composites with combined filling. It is shown that IR spectra of composites with mono- and binary fillers have peaks of less intensity due to the formation of secondary structures. The introduction of sulfenamide into UHMWPE, together with zinc and magnesium oxides, promotes the crosslinking of polymer macromolecules in the friction zone due to frictional heating, shear loads, and the action of a counterbody. The developed materials can be used as parts of friction units for cars and transport equipment that can withstand harsh operating conditions in a sharply continental climate.

Effect of Heat Treatment on Sliding Wear Resistance of Hybrid Aluminum Matrix Composite

Composite materials with aluminum as matrix material have a wider amplitude of large-scale applications in engineering. Some salient features of aluminum matrix composites are, low density, low thermal coefficient of performance and low weight and high strength. Among the various series of aluminum alloy, Al6061 have been widely used by researchers due to its outstanding properties particularly as they are heat treatable. Aluminum 6061 alloys have been reinforced with various particulate reinforcements such as silicon carbide, and graphite to study their friction and wear resistance properties. Adding silicon carbide particulate reinforcement improves the sliding wear resistance of composite material. However, it makes the material brittle and hard resulting in machining difficulties and rough surface finish. On the other hand, it has been found from the literature survey that the addition of graphite particulate reinforcement increases ductility and sliding wear resistance. In this context, the present article focuses on developing hybrid aluminum matrix composites by incorporating both graphite and silicon carbide. Heat treatment has been carried out to further enhance the wear resistance and strength of the composites. Vortex-stir casting was successfully utilized to fabricate Al6061-SiC-Gr hybrid composites. There was excellent bonding between the matrix and reinforcement materials as revealed by the microstructure study. The sliding wear resistance of the Al6061-SiC composite was higher than the base matrix material. Heat treatment increases the sliding wear resistance of the composite. Ice quenching results in maximum improvement. Increased content of graphite increases the sliding wear resistance of Al6061-SiC composite. Further heat treatment increases the sliding wear resistance of the hybrid composites with ice quenching resulting in maximum improvement.

Achieving exceptional wear resistance in cemented carbides using B2 intermetallic binders

Conventional strategy for designing wear-resistant composites relies on the immersion of a carbide skeleton into ductile binders to impart necessary strength and deformability but sometimes overlooks the deformation compatibility, rendering the composites vulnerable to premature wear failures. In this work, extensive binder extrusion was specifically noted on traditional cemented carbides during sliding in absence of oxides protection. To alleviate this situation, we designed the WC-CoFeAl composites with a novel B2_CoFe binder phase structure, as per the calculated phase diagrams, in comparison to the WC-CoAl and WC-Co composites that respectively incorporate a single α-Co phase and a mixture of α-Co and ε-Co phases. The WC-CoFeAl reveals an exceptional binder extrusion resistance and realizes a ≥50% wear reduction within a temperature range of 25–400 °C. Originating from the intrinsically high strength and the dynamically generated gradient nano-structures, consisting of a nano-grained surface tribolayer and an ultra-fine grained subsurface layer, the B2 intermetallic binders promote an improved deformation compatibility with the WC skeleton, which contributes to the maintenance of robust contact surfaces. The current work thus highlights the important role of deformation compatibility on the durability of cemented carbides, which offers a new thread to future development of wear-resistant composite materials.

Analysis and prediction of erosion behavior of short kenaf fiber‐based hybrid composites using response surface method integrated with neural networks

AbstractThere has been a huge demand in industries for the design and development of bio‐degradable and low‐cost wear resistant composite materials since long. In response to this, the present work includes an exhaustive analysis for the solid particle erosion characteristics of a new class of hybrid polyester composites reinforced with a natural fiber (kenaf) and filled with a construction waste (marble dust) in different proportions. The test trials on the composite samples are conducted using a DUCOM high temperature erosion test rig as per ASTM G76. The experimentation and analysis are conducted as per the L30 model of response surface method (RSM). The results revealed that the incorporation of marble dust enhanced the resistance to erosion wear of the fiber‐polyester composites and among the control factors, the contributions of striking velocity and angle of impingement towards the erosion rate are significant. A predictive model working on the concept of neural networks (ANN) is used for the prediction of erosion rates at different levels and combinations of the significant control factors. The mechanisms of erosion loss are identified from the morphologies of the worn surfaces taken using a scanning electron microscope.

ИЗУЧЕНИЕ ВЛИЯНИЯ СОСТАВА КОМПОЗИТОВ НА ОСНОВЕ СПЕЧЕННОГО ИМПАКТНОГО АЛМАЗА НА ИХ ИЗНОСОСТОЙКОСТЬ ПРИ ОБРАБОТКЕ КАРБИДА КРЕМНИЯ

The article presents the results of comparative tests on the wear resistance of composite materials (CM) sintered at high pressures and temperatures based on impact diamond (diamond-lonsdaleite abrasive — DLA) when processing silicon carbide (SiC). To assess the CM performance based on impact diamonds, a method has been developed for determining the wear resistance, based on the determination of the CM specific productivity. It is shown that for CMs based on impact diamond, it is expedient to use SiC as a binder. For CMs based on impact diamond with an additive of 40 vol.% SiC, specific productivity when machining a silicon carbide wheel is 25–30 % higher than for compositions containing dense BN phases — wBN and cBN. The decrease in the specific productivity of CM “impact diamond — cBN” relative to CM “impact diamond — SiC” is determined by the higher dispersion of crystals of dense BN phases in comparison with SiC, which generally impairs the abrasive ability of the material. In this case, the addition of a coarse fraction of impact diamond 100/63 μm to the charge composition does not lead to an increase in the specific productivity of the abrasive element as compared to CM based on DLA with a particle size of less than 40 μm. Preliminary mechanical activation of the initial charge also reduces the CM abrasive ability due to the formation of a highly dispersed structure of the material.

Tribological properties of carbon-containing composite materials prepared by high-pressure high-temperature synthesis

The composite materials (CM) based on Co, Ti-Cu, and Pt and reinforced with diamond-like carbon particles and diamonds with different component ratios have been obtained by high-pressure high-temperature synthesis (5–9 GPa, 800–1800 °C). The methods of optical microscopy, dynamic indentation, and tribological tests were used to establish the correlation between the structure and properties of the reinforcing phase and CM and to define the limits of the applicability of the CM as tribotechnical materials. Low friction coefficients (0.08–0.06) were demonstrated by the CM reinforced with a superhard (35–40 GPa) diamond-like phase obtained from ball-milled fullerites with a cobalt binder as well as by the CM with diamonds regardless of the binder type and particle size. The wear resistance of the cobalt-based CM increases with increasing hardness of the reinforcing diamond-like particles. The condition for obtaining super wear-resistant CM from metal-fullerene mixtures is the synthesis at a temperature of about 800 °C, which ensures the collapse of fullerene molecules, but limits the graphitization of the diamond-like structure.

Rigid three-dimensional networks of hafnium diboride for improving mechanical and wear properties of boron carbide

Being one of the hardest materials known in nature, boron carbide (B4C) suffers from severe degradation of mechanical properties when subjected to external pressure or shear stress, which hinders its application in metal forming and machining industries. Herein, based on the phase diagrams, a new strengthening strategy consisting of constructing three-dimensional hafnium diboride (HfB2) networks was proposed to reinforce B4C using the molten-salts method followed by spark plasma sintering (SPS). It was found that the surface amorphization and subsequent decarburization were the main wear regime of pure B4C. Incorporating hard HfB2 networks in B4C resulted in enhanced mechanical properties and reduced wear rates, as the deformation and decarburization of B4C grains were effectively restrained. The excessively high Hf contents, however, made the composites prone to severe adhesive wear following the material transfer from mating materials during the inception of sliding contact, which led to deteriorated wear performances. Thus, the optimal molar ratio of Hf to B4C was determined with the underlying wear mechanisms delineated. The presented results not only show the feasibility of B4C-HfB2 composites as tool materials but also provide a novel designing strategy employing hard networks rather than conventional compliant binders to fabricate wear-resistant composite materials.

The mechanisms behind the tribological behaviour of polymer matrix composites reinforced with TiO2 nanoparticles

In this present work, the sliding wear behaviour of hybrid polymer nanocomposites was investigated under different loading conditions and against different counterface roughness. Two different polymers matrices, epoxy and polyamide 66, with classic micro-sized short carbon fiber and graphite flakes as tribo-fillers were investigated with and without TiO2 reinforcing nanoparticles. It was found that the synergistic effect between nanoparticles and micro-sized fillers on friction and wear performance depended on the tribological system involved. In particular, for epoxy-based composites, the incorporation of TiO2 nanoparticles was only beneficial against a sufficiently rough disc but detrimental otherwise. Whilst for polyamide nanocomposites, the combination of nanoparticles and other fillers resulted in low friction and wear against both rough and smooth disks, particularly at higher applied contact pressures. When the cross-sections of the transfer films were analysed using a high-resolution SEM, it was found that TiO2 nanoparticles are only beneficial if they can blend with other wear debris to form a TiO2-enriched transfer film. The strengthened film provides the support required for other dislodged TiO2 nanoparticles to achieve the rolling effect, thus reducing friction and wear. In contrast, if TiO2 cannot effectively blend into the transfer film, TiO2 nanoparticles act as an abrasive that readily abrades away the comparatively softer film, thus exposing the polymer to fresh asperities on the steel counterface, a detrimental outcome to both friction and wear. Hence, to design high wear resistant composite materials, it is important to understanding the interactions between different tribo-fillers for particular circumstances or contact conditions.

Microstructure and wear characteristics of in-situ micro/nanoscale niobium carbide reinforced copper composites fabricated through powder metallurgy

In this work, a highly wear-resistant cooper matrix composite reinforced by in situ formed nano-NbC particles was synthesized by hot pressing mechanically alloyed Cu+Nb+C powders. The composite possesses a smaller friction coefficient and displays a wear rate (2.6 × 10−5 mm3N−1 m−1) two orders of magnitude lower than the micro-NbC reinforced Cu composites (123.5 × 10−5 mm3N−1 m−1). Such property enhancement is attributed to the hardness improvement and the solid lubricating effects induced by nanoscale niobium carbides/oxides as well as iron oxides. The oxidation and pulverization of NbC during friction have played a key role in increasing the wear resistance and their mechanisms are discussed. The findings provided a strategy for developing other wear-resistant composite materials.

Composite material based on ultra-high molecular weight polyethylene and elastomer for seals of hydraulic devices

A new wear-resistant composite material based on UHMWPE has been developed, on the basis of which it is possible to produce seals that are not inferior in their characteristics to chevron rings for hydraulic devices. To give products an additional frame structure and rigidity fibrous fillers (banavis) have been used.

Heat - and wear-resistant composite material based on copper powder for heavy duty friction pairs

This study is dedicated to the development of the copper dispersion-strengthened composite material with increased indexes of heat - and wear - resistance for heavy duty friction pairs parts and, first of all, for valve guides of high-forced internal combustion engine and plunger of the die-casting machine. As a result of the research conducted, the material was obtained containing (% wt): aluminum − 2.90; carbon − 1.20; oxygen − 0.20; copper - the rest. The developed material has the recrystallization temperature of 1000 °C and exhibits higher tribotechnical properties compared to the standard materials, in particular, compared to bronze CuA19Fe3. The tests conducted revealed that the developed dispersion-strengthened copper-based material has recrystallization temperature almost two times higher than that of CuA19Fe3 bronze, and the wear out intensity is almost four orders of magnitude lower, which ultimately provides parts made of new material a significantly higher life-time compared to the parts life-time from standard bronze.

MORPHOLOGICAL, MECHANICAL, THERMAL AND TRIBOLOGICAL PROPERTIES OF ENVIRONMENTALLY FRIENDLY CONSTRUCTION MATERIALS: RECYCLED LDPE COMPOSITES FILLED BY BLAST FURNACE DUST

ABSTRACT This study focused on developing a sustainable composite material using metallic wastes of the iron-steel industry and plastic wastes of the plastic industry in order to reduce resultant waste from the production processes of various industrial products and to sustain waste management of these industries. In this study, different amounts of blast furnace dust (BFD), which is the major iron-steel industry waste and is used as filler for recycled low-density polyethylene (LDPE), was mixed with LDPE to produce the composite material. The morphology, mechanical, vicat softening temperature thermal conductivity, hardness and wear resistance properties of BFD filled LDPE composites were assessed. The increasing of BFD in recycled LDPE improved the heat resistance, increased thermal conductivity and wear resistance of composite materials. In addition, it was found that the composite materials had sufficient mechanical properties, when mechanical tests were evaluated. These results showed that the produced composite material could be used in buildings as a floor coating material and thereby saving raw materials and resources, as well as potentially reducing environmental problems.

Effect of praseodymium addition on wear properties of Al-15%Mg2Si composites

Nowadays, aluminium metal matrix composites are widely used in various industrial applications, especially in automotive and aerospace industries. In engineering, rare earth elements (RE), such as yttrium, neodymium and cerium are widely used as alloying elements to improve the strength and wear resistance of composite materials. Therefore, this research project was done to investigate the effect of praseodymium (Pr) addition on wear behaviour of aluminium MMC of Al-15%Mg 2 Si composite. Microstructure analysis was carried out by using optical and SEM analyses. In addition, Vicker hardness and dry sliding wear tests were conducted to measure the effectiveness of Pr addition on mechanical and tribological properties of the fabricated composites. The result showed that Pr addition affected the microstructure and wear properties of aluminium composites. Pr addition with 1.0 wt% concentration gave the highest Mg 2 Si phase density of area and lowest value of wear rate with average wear rate of 2.3 mm 3 /km for 20 N applied load compared to 2.4 mm 3 /km for the base composite which indicated the positive effect of Pr addition on the wear resistance of composites.

Investigating the Effect of Chewing Force and an Abrasive Medium on the Wear Resistance of Composite Materials by Chewing Simulation

Various composite materials used as biomaterials were tested by 20-, 50-, and 80-N chewing forces in distilled water and a poppy seed medium by using a computer-controlled chewing simulation procedure. In each chewing test, steatite balls 6 mm in diameter were used as an antagonist material. The mean volume loss of worn surfaces and the surface roughness of the composite materials was measured with a contactless 3D profilometer.

Study on tribological properties of Al-TiC composites by Taguchi method

The tribological behaviour of Aluminium metal matrix composite studied by adding TiC particles. Centrifugal casting method was used for the preparation of composite specimens. The samples were prepared with varying the weight percentage of TiC particles such as 2.5%, 5% and 7.5%. The Taguchi technique was used for preparation of design of experiments by considering weight percentage, load and sliding distance as control parameters. The specific wear rate and coefficient of friction is determined with the help of Ducom made pin on disc machine. The ANOVA is applied to predict the effect of each factor over specific wear rate and coefficient of friction. The results show that the weight percentage of TiC reinforcement has significant effect on specific wear rate as well as coefficient of friction. The wear resistance of composite material is increased with increase in TiC reinforcement. The mathematical model through regression is predicted for specific wear rate and coefficient of friction.

Wear Resistance of Composite Materials Reinforced by Glass Fiber

Wear Resistance of Composite Materials Reinforced by Glass Fiber

Tribological properties of PAANa/UHMWPE composite materials in seawater lubrication

Abstract To prepare a high-performance anti-friction and wear-resistant composite material for friction sub-components in marine equipment, a modification was made by adding different amounts sodium polyacrylate (PAANa) to ultra-high molecular weight polyethylene (UHMWPE). PAANa/UHMWPE-blended powders were prepared at individual weight ratios of 0/100, 3/97, 5/95, 8/92, 13/87, and 18/82 with hot-press molding. In seawater, experiments of PAANa/UHMWPE composites sliding against GCr15 have been conducted with a ball-on-disk configuration in this study. The results show the surface hardness of composites was almost the same with the increase in PAANa proportion, however, the friction coefficient and wear scars of PAANa/UHMWPE composites/GCr15 sliding pairs firstly decrease and then increase. Scanning electron microscopy (SEM) results show that wear mechanism of the composites is mainly plastic deformation and spalling. The composites with PAANa content of 3% and 5% achieves better tribological properties than the pure UHMWPE material.

Investigation of two-body wear resistance of composite materials for biomaterial application in oral environment: the influence of antagonist material

ABSTRACTThe purpose of this study was to investigate the effect of antagonist material on two-body wear resistance of modern composite dental materials. Kalore, 3M ESPE P60, Grandio and Heliomolar dental composite materials were exposed to in vitro chewing simulation tests using different antagonist materials. The mean volume loss of the worn surfaces was measured with a non-contact 3D profilometer after chewing test procedures. As a result of the interactions between antagonist material and mean volume loss of composite materials were found to be significant. Among the tested materials highest two-body wear volume loss rate was obtained when P60 composite material was used as an antagonist. To reduce volume loss of contact-wear mechanism that the use of the harder structure of antagonist composite material should be avoided or if it is a hard fill the particles be reduced to nano size.

Comparison of Tribological Behaviour between Natural and Synthetic Fibres Composites

This work aims to study the wear resistance of composite materials that mainly differ in the fibre typologies used as reinforcement. In detail hemp, glass and carbon fibres in form of woven fabric were used. For the production of the composite materials, an epoxy resin was used as matrix, and the vacuum infusion process was adopted. In order to compare the tribological behaviour of the manufactured composites, a detailed experimental campaign, including tribological tests and microgeometrical measurements, was carried out. In particular, the tribological behaviour was studied through the pin-on-disk tests conducted at 210 mm/s as peripheral speed under 50 N as applied load testing both the composite and the single un-impregnated fabrics. These tests were followed by microgeometrical measurements in order to critically observe the wear tracks, evaluate their depth, width and volume and then to calculate the final less of volume. The tests results showed a good and interesting behaviour of composite materials reinforced with hemp fibres.