Wear Resistance Of Layers Research Articles

Diamond-like films of tetrahedral amorphous carbon deposited by anodic arc evaporation of graphite

A physical vapor deposition process using anodic arc evaporation in combination with a hollow cathode arc discharge was applied to the evaporation of graphite for deposition of hydrogen-free carbon layers. The diamond-like carbon (DLC) films deposited on 100Cr6 steel substrates were investigated by nanoindentation, Raman spectrometry, FE-SEM, AFM and spectroscopic ellipsometry. The relationships between the process parameters and the coating properties are discussed. Coatings deposited without bias voltage at substrate temperatures <200 °C are very hard (61–75 GPa) with also very high Young's modulus (588–685 GPa). The evaluation of the Raman spectra indicated a high proportion of tetrahedral sp3 bonds in the range of 70–88 %. Obviously, the vapor particle energies are high enough to achieve such high hardness values even without application of a bias voltage. The coatings proved to be completely droplet-free and have a very low surface roughness as confirmed by FE-SEM and AFM. The deposition rates in the range of 4–18 nm/s are exceptionally high for such tetrahedral amorphous carbon (ta-C) coatings, which is a good prerequisite for industrial applications. The ta-C layers with very high hardness and smooth surface are well suited as wear resistant layers.

The Preparation, Microstructure, and Wet Wear Properties of an Fe55-Based Welding Layer with the Co-Addition of 0.01 wt% CeO2 and 1.5 wt% SiC Particles Using the Plasma Beam Spraying Method

Severe erosion wear is found on valve spools, which threatens the safety and reliability of these units. The use of the plasma beam spraying surfacing method can significantly improve the corrosion resistance and sealing performance of hydraulic valve spools, reduce material waste, and reduce maintenance costs. The effects of the co-addition of CeO2 and SiC particles on the morphology, surface cracks, microstructure, precipitated phases, and wear property of plasma-beam-sprayed Fe55-based coatings on 1025 steel were investigated using OM, EDS, ultra-deep field microscopy, and a wet sand rubber wheel friction tester, respectively. The dendrite exhibited a directional growth pattern perpendicular to the substrate and the transitional states of the microstructure with the co-addition of CeO2 and SiC particles. CeO2 or SiC reduced the liquid phase diffusion coefficient DL of Cr and C and resulted in a decrease in the G/R ratio. The dendrites changed into equiaxed grains. The main phase composition of the Fe55 welding layer was Cr7C3, γ-Fe. The martensite in the surfacing layer and the carbides formed Cr7C3, which can improve the hardness of the surfacing layer. The grain boundaries consisted mainly of a reticular eutectic structure. The uniform distribution of the Cr7C3 hard phase in the Fe55+1.5 wt% SiC+0.01 wt% CeO2 resulted in a uniformly worn surface. The sub-wear mechanisms during the friction process were micro-ploughing and micro-cutting. The hardness and toughness of Fe55+1.5 wt% SiC+0.01 wt% CeO2 were well-matched, avoiding excessive micro-cutting and microplastic deformation. A low content of CeO2 could lead to the formation of equiaxed grain and effectively improve the uniformity of the microstructure. The wear-resistant layer of Fe55+1.5 wt% SiC+0.01 wt% CeO2 can effectively improve the service life and long-term sealing performance of the valve spools.

Enhancing tribological properties of 18CrNiMo7-6 through grain refinement incorporating Al2O3 particles

Wind turbine gears are critical components within the internal gearbox of the wind turbines. However, the vulnerability of gears to wear adversely affects their operational lifespan. Here, we propose a novel approach utilizing ultrasonic shot peening to incorporate Al2O3 particles onto the surface of the 18CrNiMo7–6, termed the USG treatment. The tribological test shows that the coefficient of friction and wear rate of the USG-treated sample decreased by 14.4% and 58.3% respectively, as compared to the untreated sample. Experiments and detailed analysis reveal that 18CrNiMo7–6 not only undergoes grain refinement on its surface but also forms a wear-resistant layer enriched with Al2O3. The findings here provide a new insight into the design of wear-resistant layers on gear steel surfaces.

Technology of forming a wear-resistant thermite alloy layer based on the Fe-Cr-C system by self-propagating high-temperature synthesis

The technology of forming a thermite alloy layer on the basis of Fe-Cr-C system on a metal basis by self-propagating high-temperature synthesis is offered, which allows to obtain cast functionallayers withphysico-mechanical and exploitativeproperties. The optimal technological parameters of the forming a wear-resistant layer of thermite alloy process are determined: the amount of metal filler with the maximum yield of suitable alloy, the heating temperature of the thermite charge and the mold to obtain additional heat, the temperature ranges of the melt to melt the metal base with further formation of the functional layer. Metallographic studies of the obtained wear-resistant layer of thermite allo[y showed that the zone of formation of the functional layer is characterized by the stability of the macrostructure and the positive effect of non-metallic inclusions in the form of Al2O3, which influences the formation of chromium carbides in the obtained alloy by creating the effect of inoculative modification of thermite alloy.

Corrosion and Wear-Resistant Composite Zirconium Nitride Layers Produced on the AZ91D Magnesium Alloy in Hybrid Process Using Hydrothermal Treatment

The aim of the study was to investigate the possibility of an effective improvement in performance properties, including corrosion and wear resistance of magnesium AZ91D alloy using a surface engineering solution based on zirconium nitride composite surface layers produced on AZ91D alloy in a hybrid process using hydrothermal final sealing. Research results show that the formation of a composite ZrN-Zr-Al-type zirconium nitride layer on zirconium and aluminum sublayers results in a significant increase in resistance to corrosion and wear. The decrease in chemical activity of the sealed zirconium nitride composite layer on AZ91D, expressed by the displacement of the corrosion potential in the potentiodynamic test, reaches an outstanding value of ΔEcorr = 865 mV. The results of the SIMS chemical composition analysis of the layers indicate that the sealing of the composite layer occurs at the level of the aluminum sublayer. The composite layer reduces wear in the Amsler roll on block test by more than an order of magnitude. The possibility of effective sealing of zirconium nitride layers on the AZ91D alloy demonstrated in this study, radically increases the corrosion resistance and combined with the simultaneous mechanical durability of the layers, is of key importance from the point of view of new perspectives for application in practice.

(Invited) bionic Composite Films for Biomechanical Energy Harvesting and Self-Powered Sensing Applications

Triboelectric nanogenerators (TENGs) are novel and sustainable devices for harvesting ambient energy for many technological-based applications. However, extreme friction wear of triboelectric layers severely limits their long-term electrical stability and mechanical reliability, restricting the applicability of TENGs for low-frequency mechanical energy harvesting. Herein, we report novel bionic composite (BC) films, inspired by the structures and compositions of bioskins, as wear-resistant triboelectric contact layers for TENGs. We demonstrated that the proposed BC films has superior charge transfer capability, high wear resistance, and maintained long-term stable outputs compared to commercially available films. These works provide an effective strategy to reduce material abrasion by exploiting unique characteristics of the bionic materials, and lays a foundation for effective environmental energy harvesting toward practical applications. Figure 1

Microstructure and properties of TiC–Ti5Si3 reinforced copper matrix composites

In this study, Ti5Si3 single-phase and TiC–Ti5Si3 hybrid phases reinforced copper matrix composites with different volume fractions were prepared by melt reaction. The microstructures and mechanical properties of the composites were analyzed to investigate their wear and tensile mechanisms. The wear resistance of the composite materials exhibits a non-linear behavior with increasing load, initially decreasing and then increasing, reaching its lowest point at 7.35 N. At higher loads, such as 9.8 N, the composites form a more stable and effective wear-resistant layer, exhibiting the positive impact of the reinforcing phase on wear resistance. Furthermore, as the content of the reinforcing phase increases, the brittleness of Ti5Si3 also increases, along with the expansion of the interface between the reinforcing phase and the matrix. This results in a transition of the wear mechanism from delamination wear to abrasive wear and an increased likelihood of spalling under shear forces. Therefore, the composite material achieves optimal wear resistance when the Si content is at 1%. In addition, the TiC and Ti5Si3 phases within the Cu matrix not only effectively bear the load but also impede crack propagation, resulting in a shift in the fracture mode of the composites from ductile fracture to cleavage fracture or quasi-cleavage fracture as the reinforcement content increases. Finally, hot rolling proves to be an effective method for refining the reinforcement and improving its uniformity, leading to significant enhancements in tensile strength and ductility. However, the reinforcement causes a disruption in the continuity of the matrix, resulting in a reduced elongation in the composite material with a Si content of 1% after the hot rolling process.

Improvement of the service life of mining and industrial equipment by using friction modifiers

Purpose. Enhancement of the performance, service life and sustainability of industrial vehicles, mining machinery and various equipment by reducing the friction coefficient. Methodology. Laboratory research on assessing the interaction of friction pairs under external loading, rolling, and sliding in dry friction conditions, as well as the influence of friction modifiers. Industrial experimental studies on the performance indicators of mining machinery under the influence of friction modifiers. Findings. Actual diagrams depicting changes in the friction coefficient between the contacting surfaces of disc pairs were obtained for four specific loading periods and corresponding pressures of 529, 374, 274 and 187 MPa. These measurements were taken while the discs experienced a 10 % relative slippage and cyclic load interaction during the testing of specimens, with the presence of the repair-recovery compound called “Ideal” and without it, using only dry friction. The new technologies and the new repair-recovery compound “Ideal”, developed at the Institute of Geotechnical Mechanics named by N. Poljakov of National Academy of Sciences of Ukraine, provide an exceptionally low friction coefficient of 0.04–0.005 and ensure the durability of the protective layer under dry friction before failure, reaching 80–100 thousand cycles at a specific pressure of 529 MPa. At a specific pressure of 187–374 MPa, the protective layer under dry friction provides up to 1 million cycles of interaction. Originality. The unique properties of the combination of the “Ideal” tribotechnical composition, which forms a metal-ceramic, superhard, refractory, and wear-resistant nanostructured layer on a metal base, have been established. This layer provides protection against wear, dynamic loads, thermal and oxidative degradation, and increases the service life of friction units in industrial equipment by 3–10 times. Practical value. Based on the results of experimental and acceptance tests of the “Ideal” repair-recovery compound, a decrease in friction coefficient values and an extension of the service life of highly loaded gear mechanisms in mining and industrial equipment by 1.4–2.0 times have been established. It has been found that the protective layer provided by the “Ideal” repair-recovery compound helps reduce the wear mass of friction surfaces by 20 times in the tested samples, ensuring cleanliness of lubricants in equipment and increasing their operational lifespan while saving on maintenance costs.

Preparation and characterization of wear resistant TiO layer on Ti alloy

Titanium monoxide (TiO) is golden in color, and of good chemical inertness and high hardness, making it a potential candidate for decorative and protective coatings. In this study, a TiO layer was coated on Ti alloy substrate through a combination of cathode plasma electrolysis (CPE) and comproportionation between the Ti substrate and Ti4+ from the electrolyte. The thickness of the obtained TiO layer was around 500 nm, with a hardness of 11 GPa, a modulus of 220 GPa and a critical load of 55 N. The coefficient of friction of the CPE-treated sample vs. ZrO2 ball was decreased from 0.4 to 0.6 to around 0.2 when the Hertz pressure was less than 885 MPa. The wear rate of the CPE-treated sample was reduced by ~450 times compared with that of the untreated Ti alloy. Correspondingly, the wear rate of the ZrO2 ball was reduced by ~170 times. In addition, wear resistance of the CPE-treated samples was also significantly improved for common metallic materials (such as stainless steel, carbon steel, or copper alloy) as the counterpart. The surface morphology evolution and the mechanical properties of the TiO layer can avoid the severe abrasive wear as well as adhesive wear, and contribute to the excellent antiwear effects. CPE demonstrates a technologically relevant capability, especially in forming a TiO antiwear layer on Ti alloy.

Effect of Additive Manufacturing Thickness on Microstructure and Properties of DG09 Welding Wire Wear-resistant Layer

In order to study the influence of additive manufacturing thickness of coal mining machine-guide slide shoe on the microstructure and properties of wear-resistant layers, four kinds of wear-resistant layers with different thicknesses were mainly manufactured in this paper. The influence of the cladding thickness on wear resistance was further clarified by analyzing the metallographic structure, hardness, and wear resistance of the material. The experimental results show that the thickness of the wear-resistant layer has little effect on its microstructure and wear resistance. Hardness has a great influence on wear resistance. The higher the thickness of the wear-resistant layer is, the wider the wear width of the sample is. The main wear mechanism of produced cladding is abrasive wear accompanied by oxidation wear with a certain degree of spalling wear. The experimental results have a key role in the overall use performance of the coal mining machine.

Numerical Modeling of Microstructure and Properties of Wear-resistant Layer Fabricated by Overlaying with different Wire Compositions

In order to investigate the influence of the composition in DG09 steel on the microstructure and properties of the wear-resistant layer manufactured by overlaying welding on the guide slippers of coal-cutters, the finite element method (FEM) simulations were used. After importing the physical parameters of the filler metal with different Cr and Ni contents calculated by JMatPro into the FEM software, the evolution of the temperature was simulated. The simulated results showed that the first layer melted when the second layer was welding. The microstructure and properties of the wear-resistant layer were simulated. The results revealed that reducing the Cr and Ni content increases the tensile strength and hardness of the wear-resistant layer. In addition, the microstructure of the wear-resistant layer fabricated by designed fillers was the martensite phase. The simulation results not only demonstrate that reducing the Cr and Ni content in DG09 steel can improve the mechanical properties, but also provide a theoretical basis for the design of low-cost filler metal.

Amorphous plasma sprayed coating

The plasma spraying method has wide application in many industries, including the automotive industry, due to its diversity and efficiency. The interest in this technology is increasing as it is possible to replace expensive materials with iron-based alloys and use air instead of inert gas to activate plasma. There are a number of works that have emphasized the importance of properly selected spray parameters, but they used the plasma generation gas, which is an expensive inert gas such as argon, heli, or their gas mixture with a different ratio. The objective of this paper is to study the influence of the most specific parameters that affect the quality of the wear-resistant spray layer using Fe-based powder sprayed onto the steel substrate material. The experiment design with the ANOVA analysis helped to find out the nature of the elevation of the wear resistance under the influence of the particle velocity and the related technological parameters in the process. The research results provide an experimental formula that combines the main spray parameters with the evaluation of wear resistance in relation to the traditional material group.

Research and Optimization of the Influence of Process Parameters on Ti Alloys Surface Roughness Using Femtosecond Laser Texturing Technology

One of the major disadvantages of Ti alloys is their poor wear resistance. To increase their wear resistance, before applying a wear-resistant layer, the surface of the substrate should be carefully prepared to ensure the required coating adhesion. Femtosecond laser (fs) texturing is a technology that can be used for surface texturing of Ti alloys because it enables a controlled heat input on a small surface area. The process of laser texturing is very sensitive to the choice of input parameters, such as the number of passes (P) and laser power (W), the choice of which may significantly influence the ultimate surface roughness values (Ra). It cannot be expected that by using the fs process a given default Ra value will be achieved, but it is assumed that the obtained roughness values will be within the given interval. As a result of this research with a significance level of 95% using a design of experiments (DOE) and Monte Carlo simulations, a general linear model of Ra = f (P, W) and optimal input parameter intervals (P and W) of laser texturing were obtained both for the given interval as well as for the default surface roughness value (Ra). Considering that an industrial process is involved here, a process performance capability index (Cpk) has been also defined, which shows that optimal process parameter intervals give roughness values for the given interval or given default roughness value.

Development of hard and wear-resistant SiC-AISI304 stainless steel clad layer on low carbon steel by GMAW process

In the present investigation, a successful attempt has been done to utilize conventional gas metal arc welding (GMAW) setup to develop SiC reinforced AISI 304 stainless steel (ASS) clad layer on low carbon steel (LCS) substrate. The characteristics of the clad bead like bead profile and dilution depend on the GMAW processing parameters like GMAW voltage and consumable wire feed rate (CWFR). The clad deposition at a higher voltage range (30 V) developed a defect-free, uniformly distributed fine SiC-reinforced clad layer with better clad dilution with the substrate. Further, the SiC-reinforced clad layer showed a uniform distribution of fine SiC particles in the steel matrix and also the formation of different hard intermetallics like CrSi2, Mn3Ni2Si, Fe2C, Fe5C2, and Cr7C3 in the clad layer. The SiC-reinforced clad surface showed a significant improvement in Microhardness (up to 504 HV0.5) compared to the steel substrate (180 HV0.5). The clad layer also improved the adhesive wear resistance (upto 8.7 times) and abrasive wear resistance (upto 1.7 times) of low carbon steel substrate.

Optimization Study of Annular Wear-Resistant Layer Structure for Blast Furnace Tuyere

A new tuyere small sleeve coating structure that balances the high thermal conductivity of the copper substrate with the high wear resistance of the protective layer was developed in this paper. This structure can achieve a low-carbon blast furnace by reducing the heat loss from the tuyere. The 3D model was established via Solidworks for modeling and Ansys for numerical simulation, the temperature field of the annular wear-resistant layer structure tuyere small sleeve with different widths of the wear-resistant layer was analyzed and compared with the temperature and stress field of traditional tuyere small sleeve. The results show that the design of the annular wear-resistant layer structure of the tuyere small sleeve is more effective. The new annular wear-resistant layer structure for the tuyere small sleeve results in a decrease of 24 K in the average temperature of the wear-resistant coating. The comparison of this structure with tuyere sleeves without wear-resistant coatings shows a 16.7% reduction in heat loss, improves the wear resistance of the tuyere, providing new technological ideas for low-carbon blast furnace production. Compared with the tuyere sleeve completely covered with a wear-resistant coating, the maximum thermal stress of this structure decreased from 624.98 Mpa to 427.99 Mpa, resulting in a reduction of 31.5%, which is beneficial for the service life of the tuyere sleeve. The copper surface temperature of the new tuyere small sleeve is in a safe range when the temperature is below 2273 K.

Inverse Thermal Analysis as a Tool for Optimizing Concentrated Solar Energy Elaboration of Wear Resistant Surface Layers

Concentrated Solar Energy (CSE) processing is considered a promising renewable energy source technique for elaborating thick, wear-resistant claddings onto metallic surfaces of large dimensions that are expected to operate in heavy duty applications, such as excavator shovels, mineral crushers, etc. However, the prediction of surface processing effects on the microstructure and the properties of the main construction base metal are of crucial importance, as they are commonly required in all surface modification techniques. Thus, the present study is focused on the inverse thermal analysis and parametric modeling of heat deposition associated with CSE surface processing of metals. In this preliminary attempt, experimental findings that concern the elaboration of TiC- and chromium carbide-reinforced clads onto common steel base metals were used to quantify the evaluation of the temperature histories within the volume of workpieces undergoing solar heating, where direct temperature measurements contain uncertainties and/or are not even possible. Results of prototype inverse thermal analyses of heat transfer in processed layer-substrate systems are presented, demonstrating the general aspects of a parametric model for thermal analysis and simulation.

Microstructure and wear behavior of (ZrTaNb)C/N quaternary ceramic coatings prepared by double-cathode glow plasma surface alloying on titanium alloy

Multi-principal component coating is a new type of surface protection material developed in recent years. To improve the surface hardness and wear resistance of aviation titanium alloy, (ZrTaNb)C, (ZrTaNb)N and ZrTaNb coatings were prepared by double cathode glow plasma surface alloying. The microstructure, mechanical properties and high temperature tribological behavior of quaternary ceramic coatings were studied. The results show that the quaternary ceramic coating has an FCC cubic structure, which is different from the BCC structure of the ZrTaNb coating. Meanwhile, the solid-soluble C and N elements improve the surface hardness and toughness of the multi-principal component coating, resulting in a significant reduction in wear rate, which is only 1/10 and 1/5 of that of the substrate and pure metal coating (25 °C). When the temperature increases to 500 °C, the compliant islets of oxidized and compacted debris are gradually activated as a wear-resistant oxidation glaze layer. The gradient structure of amorphous-nanocrystalline composite is formed in the subsurface layer, which can effectively improve the surface strength and wear resistance. This study provides an effective strategy for improving the wear resistance of titanium alloy surface in a wide temperature range.

Effect of Nano-La2O3 and Mo on Wear Resistance of Ni60a/SiC Coatings by Laser Cladding

To improve the wear resistance of the TMR blade and investigate the effect of nano-La2O3 and Mo on the wear resistance of laser cladding coating. 65Mn blade as the substrate, La2O3, Mo and Mo-La2O3 composite powders were added into Ni60a/SiC composite powder. Using scanning electron microscopy, X-ray diffraction, X-ray photoelectron spectroscopy and the CFT-I surface synthesizer, the phase composition, element distribution and friction and wear properties of the coating were analyzed to obtain the best composition of the composite coating. The results showed that the wear resistance of Mo-La2O3-Ni60a/SiC composite coating was the best. The coating was analyzed by X-ray diffraction and X-ray photoelectron spectroscopy. The coating contained hard phases such as CrB, CrC and Cr7C3, and the element distribution was uniform. It can be seen from the scanning electron microscope that the addition of nano-Mo and La2O3 improves the toughness and compactness of Ni60a/SiC composite coating, and the microstructure is refined. The friction coefficient of Mo-La2O3-Ni60a/SiC composite coating is 0.5, and the wear depth is 12.35 μm, 23% and 89% lower than that of 65Mn substrate, respectively. The surface roughness of the Mo-La2O3-Ni60a/SiC coating after wear is 2.06 μm, and the wear amount is 0.001 g. The wear mechanism of the coating is mainly adhesive wear, abrasive wear, and oxidation wear. The wear surface of the Mo-La2O3-Ni60a/SiC composite coating is mainly composed of micro furrows, accompanied by the generation of new wear-resistant layers.

A new type of gradient structure FeCoCrNiWMo high entropy alloy layer by plasma solid-state surface metallurgy

In this paper, the FeCoCrNiWMo HEA layer with metallurgical bonding and gradient structure was successfully prepared by plasma solid-state surface metallurgy for the first time. The microstructure, composition, growth and deposition kinetics of HEA layer was studied by XRD, SEM and EDS. The results show that the FeCoCrNiWMo HEA layer consists of HCP and FCC phase. In the equipotential mode, the high vacancy concentration gradient layer can't be formed continuously on the substrate surface. In addition, the serious lattice distortion and the increase of atomic packing density caused by different atomic sizes decrease the density of vacancy formation. So the composite strengthening layer structure of HEA layer (deposit layer + diffusion layer) is formed on the substrate surface instead of conventional alloying layer. According to Boltzmann's hypothesis, the entropy value of calculating the surface mixing entropy of HEA layer is >1.5 R, which accords with the definition of high-entropy alloy. Compared with the substrate, the wear resistance and high-temperature oxidation resistance of the HEA layers are improved to some extent and the wear mechanism of substrate and HEA layers is mainly abrasive wear, which is accompanied by adhesive wear and oxidation wear. The results show that it is reasonable and feasible to prepare a new type metallurgical bonding and gradient structure of wear resistant and high-temperature oxidation resistant HEA layer by plasma solid-state surface metallurgy.

Influence of the tribological properties of the Zr,Hf-(Zr,Hf)N-(Zr,Me,Hf,Al)N coatings (where Me is Mo, Ti, or Cr) with a nanostructured wear-resistant layer on their wear pattern during turning of steel

An increase in the speed of cutting and, accordingly, the temperature in the zone of cutting predetermines the need to develop wear-resistant coatings, functioning effectively under such operation conditions. One of the key functions of the coating is the creation of optimal tribological conditions under the influence of temperatures and force factors of the operation of the coating. The coatings of Zr,Hf-(Zr,Hf)N-(Zr,Me,Hf,Al)N (Me is Mo, Ti, or Cr) with nanostructured wear-resistant layer were studied. At temperatures up to 700 °C, the minimum adhesive component fadh of the friction coefficient was exhibited by a coating containing chromium (Cr), and at temperatures above 700 °C – by a coating containing molybdenum (Mo). At the turning of steel, the highest resistance to wear at the speed of cutting of vc = 250 m/min was exhibited by a tool with a Cr-containing coating, and at the speed of cutting of vc = 400 m/min – by a tool with a Mo-containing coating. Thus, the optimal composition of the coating depends on the speed of cutting. Information about the adhesive component fadh of the coefficient of friction makes it possible to fairly reliably predict the wear rate of the tool during cutting under the conditions of the temperatures corresponding to the temperatures at which the value of fadh was measured.It has been found that an oxide layer with a complex structure is formed in the areas of the coatings adjacent to a wear crater. Iron (Fe) and its oxide dominate in the outer regions of this oxide layer, a high content of aluminum (Al) oxide is detected in the intermediate region, and oxides of zirconium (Zr), titanium (Ti), chromium (Cr), and hafnium (Hf) dominate in the inner region.