Wear Resistance Properties Research Articles

Heat treatment effect on the carbides in T-15 and M-4 steels

ABSTRACT In the present work, the effect of heat treatment on the microstructure and mechanical properties of T-15 and M-4 high-speed steels was investigated. These steels were produced by powder metallurgy. Due to their frictional wear resistance properties, T-15 and M-4 high-speed steels are widely used in the cutting tool manufacture of the metalworking industry. A heat treatment was applied to both steels, heating them to 1250°C, then air quenching and, finally tempering at 550°C for 2 h, 3 times (triple tempering at 550°C). Steels were characterized by hardness test, metallographic analysis, tensile strength test, and fracture analysis after the heat treatment. Results were compared and related to the metallurgical microstructure, mainly to the distribution of carbides, and also to fracture type and characteristics. Test results and chemical analysis showed important differences between T-15 and M-4 steels.

Assessing the Tribological Impact of 3D Printed Carbon-Reinforced ABS Composite Cylindrical Gears

The tribological performance of carbon-reinforced acrylonitrile butadiene styrene (ABS) composites is very important in determining their suitability for advanced engineering applications. This study employs response surface methodology (RSM) to evaluate the effects of printing temperature and post-processing annealing on the wear resistance and frictional properties of these composites. A central composite design is used to systematically explore the interaction between these two factors, enabling the development of predictive models for key tribological parameters. The results reveal that both the coefficient of friction (COF) and wear are affected by printing and annealing temperatures, although in a non-linear manner. Moderate printing temperatures and lower annealing temperatures were found to reduce friction and wear, with annealing temperature having a more pronounced effect on wear. To further optimize these responses, the desirability approach was applied for predicting the optimal conditions. The optimal combination of input parameters for minimizing both COF and wear was found to be a printing temperature of 256 °C and an annealing temperature of 126 °C. This research provides valuable insights for optimizing additive manufacturing processes of carbon-reinforced ABS composites, contributing to enhanced material durability in practical applications.

Hot isostatic pressing of ball milled novel grade high entropy alloys at different sintering time and the investigation of their mechanical and corrosion resistance properties

Abstract With the discovery of high entropy alloys, new materials with superior properties have emerged. According to recent research, high-entropy alloys’ multi-component structure and mixing entropy have made them more prominent than other alloys. Because of their excellent chemical and mechanical properties—such as high hardness, high-temperature resistance, high wear resistance, chemical stability, and high corrosion resistance—high entropy alloys outperform other material types in various applications. A new grade of mechanically alloyed high entropy alloy (HEA) of composition 23Fe-21Cr-18Ni-20Ti-18Mn was consolidated by a hot isostatic pressing (HIP) at a temperature of 1000 °C, at different sintering time of 30, 60, and 90 min respectively. We have investigated the impact of sintering time on the microstructure, mechanical, corrosion, and wear-resistance properties. The x-ray diffraction (XRD) spectra of the 30 min HIPed HEA sample showed dominant s-FeCr phases and traces of γ-Fe, and the Ni-Ti phases. Whereas, the 90 min HIPed HEA samples showed more dominant Ni-Ti and traces of γ-Fe, and β-Mn phases. There is a phase transformation from BCC to HCP of consolidated HEA at increased holding time. The density of the samples increases from 5.882 to 6.327 g cm−3 and the porosity percentage decreases from 12.93 to 6.35% with the increase in the holding time. The Vickers microhardness value for 30, 60, and 90 min HIPed 23Fe-21Cr-18Ni-20Ti-18Mn HEA at 1000 °C was found to be 433, 513, and 793 HV respectively at an indentation load of 0.1 kgf. The consolidated HEA sample undergoes an abrasive and oxidative wear mechanism with ploughing and plastic deformation modes. The morphology of the wear debris was investigated using SEM. The 90 min sintered sample showed an excellent corrosion resistance due to the high rate of material densification and minimum surface flaws.

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

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

Effect of kaolin ratio on wear, water absorption, acidic resistance, and mechanical properties of thermoset composites

Natural fiber reinforced composites are easy to decompose in nature compared to synthetic fiber reinforced composites. However, due to environmental effects, natural fibers cannot maintain their properties for a long time. This situation has led researchers to search for natural but non-degradable materials. Kaolin is one of the most abundant minerals in nature and is an easy material to obtain. This study investigated the use of kaolin as a potential natural additive for polymer composites. In this direction, different proportions by weight of kaolin were added to two different polymer matrices (polyester and polyvinylester) materials. Mechanical tests were performed on the samples, and a series of tests were carried out to understand the acid resistance, wear resistance and water absorption properties of the samples. Also, SEM images of the fracture surface, wear surface, and surface exposed to the acidic solutions were taken and examined. According to test results, kaolin improved compression strength while reducing tensile and flexural strength. However, serious improvements have been achieved by nearly 45% and 115% in the tensile modulus and nearly 84% and 218% in the flexural modulus of polyester and polyvinylester composites, respectively. Also, kaolin improved acid resistance and wear properties and reduced the water absorption rate of the composites.

Dual-Mode cellulose acetate@Al2O3/MWCNTs Janus fabric with radiative cooling and solar heating for personal thermal management

Personal thermal management (PTM) textiles with heating and cooling functionalities are highly appealing due to their potential to offer personalized comfort while also contributing to decrease energy consumption. However, most PTM fabrics are static and unable to meet the human body’s thermal comfort needs during seasonal and ambient temperature fluctuations. Herein, this work presents a dual-mode Janus Metafabric to provide radiation cooling and solar heating. The cooling side of Metafabric (cellulose acetate@Al2O3 porous coating) offers high solar reflectance (92.12 %), infrared emissivity (83.22 %), and net cooling power of 55.85 W·m−2. The heating side (multi-walled carbon nanotubes) exhibits a high solar absorption rate (88.4 %). Compared with raw fabric, it can achieve an additional cooling of 4.58 °C and heating of 38.02 °C. In addition, Metafabric also have excellent ultraviolet resistance, wear resistance, and washing properties, making it suitable for practical wearing. By flipping the Janus fabric, it is easy to switch between the cooling and heating modes to adapt to dynamic ambient temperature changes, which have great potential for maintaining human thermal comfort and alleviating the energy crisis.

Effect of La on Microstructure, Mechanical Properties and Friction Behavior of In Situ Synthesized TiB2/6061 Composites

In situ synthesized 3 wt.%TiB2/6061 composites with different La contents were fabricated by an Al-K2TiF6-KBF4 system at 850 °C with ball milling and stirring casting. The effects of La content (0 wt.%, 0.1 wt.%, 0.3 wt.%, 0.5 wt.%) on the microstructures and mechanical properties of the composites at room temperature were investigated. The results showed that the addition of La could refine α-Al grains and modify the morphology of TiB2 particles significantly. In 0.3 wt.%La-3 wt.%TiB2/6061 composites, there are chamfering planes on the surface of TiB2 particles, which are caused by the adsorption of La on the {112¯0}, {12¯12} and {101¯1} crystal planes. The values of YS, UTS and EL of the composites with 0.3 wt.% La were 216.8 MPa, 273.0 MPa and 11.2%, which were 69.2%, 34.8% and 5.7% higher than those of the 3 wt.%TiB2/6061 composites. The improvement of mechanical properties was mainly attributed to the grain refinement, distributed particles and transformation of particle morphology. In friction behavior, 0.3 wt.%La-3 wt.%TiB2/6061 composites have the best wear resistance properties with the smallest and shallowest grooves on the surface after wearing. The main mechanisms of the composites are adhesive wear and abrasive wear. In summary, the best content of La addition in 3 wt.%TiB2/6061 composites is 0.3 wt.%.

Influence of Si Content on the Microstructure, Wear Resistance, and Corrosion Resistance of FeCoNiCrAl0.7Cu0.3Six High Entropy Alloy

This study explores microstructure, wear, and corrosion resistance properties of FeCoNiCrAl0.7Cu0.3Six (x = 0, 0.2, 0.3, 0.5) high-entropy alloys. The FeCoNiCrAl0.7Cu0.3Six alloy contains FCC and BCC structures; as the x increases, the FeCoNiCrAl0.7Cu0.3Si0.2, FeCoNiCrAl0.7Cu0.3Si0.4, and FeCoNiCrAl0.7Cu0.3Si0.5 high-entropy alloys transition to BCC structures. The morphological transition in FeCoNiCrAl0.7Cu0.3Six evolves from bamboo leaf-like intergranular features to a discontinuous intergranular structure as Si content increases. The hardness of these alloys gradually increases with higher Si content. The addition of Si promotes a uniform distribution of Cr within and between grains, reducing the intergranular segregation of Cu. Al and Ni show a consistent pattern of elemental distribution throughout the alloy. Wear measurements of FeCoNiCrAl0.7Cu0.3Six alloys demonstrate that adding Si enhances wear resistance, resulting in smoother wear surfaces with reduced deformation. The wear mechanism for all alloys is primarily abrasive, with no brittle fractures observed. Corrosion resistance is optimized when Si content is 0.2, with pitting corrosion being the primary corrosion form.

Effect of multidirectional forging on grain structure and mechanical properties of hypereutectic Al–20%Si alloys with added refiners and modifiers

ABSTRACT The present work is focused on the multidirectional forging (MDF) of Al–20 wt-% Si alloys with the addition of refiners and modifiers. The MDF process was performed at 200°C with a cumulative strain of 0.63. Microstructural characterization and mechanical performance were evaluated on the Al–20Si, Al–20Si–4.5Cu, Al–20Si–4.5Cu–1(Al–Ti–B), Al–20Si–4.5Cu–1(Al–Ti–B)–10(Al–Sr). The microstructure analysis revealed significant changes in the eutectic and primary phase refinement. The micro-Vickers hardness confirmed that the MDF process resulted in increased hardness (125 ± 1.9 VHN) compared to the homogenized samples (96 ± 2.7 VHN). Tensile test results showed that with the accumulation of strain, ultimate tensile strength increased to 435 MPa from 302 MPa with reduction in the percentage of elongation from 7.8 to 5.6. The grains were more uniformly distributed with addition of modifiers, and refiners further reduced the nucleation number of eutectic grains. The wear study demonstrated that the wear resistance is more in the Al–Si-Cu-Sr sample due to the increased level of hardness. The combination of multidirectional forging techniques with judicious incorporation of refiners and modifiers engenders a synergistic enhancement of microstructural integrity, hardness profiles, and wear-resistant properties in hypereutectic Al-20Si alloys.

Evaluation of Fracture Durability and Wear Resistance Properties for Orthopaedic Implant Application

Hydroxyapatite (HA) coated metallic substrates are commonly used for load-bearing orthopedic implants. In the present work Titanium grade 2 and Titanium grade 5 substrates were coated with hydroxyapatite and hydroxyapatite reinforced with 5% (by wt.) multiwalled carbon nanotubes (MCNT) separately using plasma spray coating. The wear behavior of these coated substrates was studied with the simulated body fluid (SBF) having a pH between 7.20 to 7.40. Fracture toughness and wear resistance of HA reinforced with 5 % (by wt.) MCNT composite coating was found to be higher as compared to pure HA coating. This improvement is by virtue of inherent mechanical properties and the crack bridging effect offered by MCNT. The addition of MCNT also helped in restricting crack propagation in the coatings. As evident from SEM images, abrasive and adhesive wear mechanism were observed which reduces greatly with reinforcement of MCNT.

Quarter Century Outcomes of Alumina Ceramic-on-Ceramic Total Hip Arthroplasty

BackgroundAlumina ceramic-on-ceramic (CoC) bearings were widely used in total hip arthroplasty (THA) due to their superior wear resistance and inert properties, making them ideal for young, active patients who require long-lasting implants. This study aimed to synthesize findings from previous reports, providing a comprehensive follow-up of at least 25 years on the clinical and radiologic outcomes, the prevalence of osteolysis, and implant survivorship in patients undergoing primary cementless CoC THA. MethodsWe have previously reported five-to-ten-year outcomes following the implementation of third-generation alumina-on-alumina bearings in a consecutive series of 100 primary cementless THAs. This report updates those results with a minimum follow-up of 25 years. Of the original cohort, 58 patients who had 67 hips were available for the latest follow-up. Clinical assessments were performed using the Harris Hip Score (HHS) and pain questionnaires. Radiographic evaluations were employed to assess implant fixation and osteolysis. ResultsAt the final follow-up, the implant survival rate was an impressive 96.3%, with revision of the implant as the endpoint. The mean HHS improved significantly from preoperative values to 90.1, indicating excellent functional outcomes. The incidence of ceramic-related noise increased over time, with three cases of ceramic head fractures requiring a change of bearings. Notably, the extent of stem notching observed in earlier reports did not show further progression. Radiologically, all implants demonstrated bony ingrowth with no signs of aseptic loosening or major osteolysis. ConclusionThe long-term (minimum 25-year) follow-up of alumina-on-alumina bearings in primary cementless THA demonstrates outstanding implant survivorship, excellent functional outcomes, and minimal adverse effects over twenty-five years. Despite some issues like ceramic-related noise and component fractures, the overall performance of CoC bearings remains highly encouraging, particularly suitable for young, active patients. Surgeons should provide appropriate education to both potential THA candidates and patients who already have THAs with CoC bearings.

Severe plastic deformation of Zn and Zn-based alloys

There has been much research on zinc and its alloys for being used in different industries and applications, mainly due to their low cost, availability, good wear resistance and mechanical properties. Moreover, zinc alloys have emerged as the latest advancement in the field of biodegradable metals, offering a more sustainable option with their moderate corrosion rate when compared to other biodegradable metals like magnesium and iron-based alloys. Nevertheless, mechanical properties of zinc alloys typically fall below the necessary levels for use in load-bearing implant applications. In this regard, severe plastic deformation serves as a distinctive technique to enhance the mechanical characteristics of zinc-based alloys, all while keeping the chemical composition intact. In addition to mechanical properties, and as is discussed in this article, SPD can affect other properties of Zn alloys, including biological and corrosion behavior. Over the past few years, extensive studies have been conducted to explore how various SPD processes impact the properties of zinc and its alloys. In this study, the main effects of SPD on the microstructure, mechanical properties, superplastic behavior, and corrosion of zinc and zinc allots together with the underlying mechanisms are reviewed.

Influence of laser scanning speed on the microstructure and wear resistance properties of Inconel 718 coating

Influence of laser scanning speed on the microstructure and wear resistance properties of Inconel 718 coating

An integrated approach for developing a durable and superhydrophobic anti-corrosion coating inspired by biomimetic starfish surface structures

Applying superhydrophobic coatings with excellent anti-corrosion, anti-fouling, self-cleaning, antibacterial, and wear-resistant properties is a promising approach to protect metal surfaces. This study presents a novel and cost-effective approach, inspired by the biomimetic structure of starfish, to develop a durable and superhydrophobic coating. Unlike traditional methods, we introduce a meticulously engineered tetrapodal ZnO@SiO2-fluorosilane composite that forms a unique hierarchical micro-nano core-shell structure, reducing surface energy and exceptional performance. The formulation combines perfluorooctyl triethoxysilane (FOTS)-modified SiO2, silicone polyester, and tetrapodal ZnO (T-ZnO) in thermoplastic polyurethane (TPU), resulting in a first-of-its-kind T-ZnO@SiO2-FOTS (ZSF) coating with superhydrophobic properties, demonstrated by a water contact angle of 160°, a sliding angle of 3°, and the lowest surface free energy of 14.50 mN/m, contributing to excellent anti-corrosion properties (corrosion rate of 1.44 × 10−6 mm/year) and a corrosion inhibition efficiency of 99.87 %. In addition, the coating exhibits remarkable mechanical durability, adhesion enhancement, and stability against harsh environmental agents, including salt spray, HCl, and NaOH. Our biomimetic approach leverages the starfish-inspired surface design and highly crosslinked interface to enhance resilience, making this coating more robust under real-world conditions. These results provide a promising pathway for the development of multifunctional coating materials suitable for various solid surfaces.

Microstructure and properties of Al/FeCoNiCrMo coatings prepared by different plasma spraying currents on carbon fiber reinforced plastic surfaces

Al/FeCoNiCrMo high-entropy alloy (HEA) coatings were prepared on the surface of carbon fiber reinforced plastic using plasma spraying technology. The microstructure of the HEA coatings was characterized under different spraying currents, and the hardness, interfacial bonding, corrosion resistance and friction and wear properties of the coatings were tested. The results showed that with the increase of the current, the unfused particles in the coatings decreased, and the coating porosity and thickness also decreased gradually; the hardness, corrosion resistance and friction and wear resistance properties increased with the increase of the current, in which the maximum hardness was 740.3 HV0.1, and the minimum self-corrosion current was 1.21 × 10−5 A·cm−2, and the minimum volumetric wear rate was 7.66 × 10−5 mm3·N−1·m−1.

The effect of the modification mechanism of SiO2 in resin‐based friction materials on the mechanical and tribological performance

AbstractThis study aimed to address the thermal degradation of resin‐based friction materials in the mid‐temperature stage (200–250°C), as well as the resulting instability of the friction coefficient and decrease in the mechanical properties. To investigate the impact on the toughening and wear resistance properties, this study employed nanosilica‐modified resin‐based friction materials. The mechanical, friction, and wear properties of the modified samples were tested using a Rockwell hardness tester, hydraulic universal testing machine, and constant speed friction tester. The phase composition and microstructure of the samples were analyzed by scanning electron microscope, energy‐dispersive x‐ray spectroscopy, x‐ray diffraction. When the mass fraction of nanosilica was 3%, modified sample S3 exhibited excellent mechanical properties, with shear strength and compressive strength reaching 40.3 and 171.7 MPa, respectively, which were increased by 30% and 9% compared to unmodified sample S1. Moreover, the density and hardness of sample S3 showed minimal variation compared to those of unmodified sample S1. In the temperature range of 100–250°C, the wear rate of modified sample S3 remained within the range of 0.22 × 10−7–0.38 × 10−7 N−1 m−1, with a friction coefficient of 0.38 at 200°C, demonstrating excellent wear resistance.

Ultrahigh hardness with exceptional wear resistance of novel cost-effective nanostructured Fe40Ni25Cr25Mo5Al5 high-entropy alloy through cyclic closed-die forging process

Industry applications of current high-entropy alloys (HEAs) are limited by their prohibitive costs. Here, we present a cost-effective and facile approach to producing nanostructured HEAs with lower cost and exceptional mechanical properties. In the present work, the key was to design a novel cost-effective Fe40Ni25Cr25Mo5Al5 high-entropy alloy with an ultrafine-grained (UFG) microstructure through cyclic closed-die forging (CCDF) at room temperature for up to six passes. The as-homogenized alloy exhibited a dual-phase structure, with minor [CrMoFe]-rich dendrites dispersed in a nearly homogenous face-centered cubic (FCC) matrix. Increasing CCDF passes resulted in achieving a more homogeneous nanograin, accumulation of dislocations, fragmentation of [CrMoFe]-rich dendrites, and efficient distribution within the matrix, which provided ideal conditions for the development of a nanostructured Fe40Ni25Cr25Mo5Al5 alloy with superior mechanical properties (hardness and wear resistance). The highest microhardness (∼ 843 HV) and the lowest wear rate (∼ (0.9 ± 0.1) × 10–5 mm3.N−1.m−1) were obtained in the Fe40Ni25Cr25Mo5Al5 alloy after six CCDF passes. It was suggested that the Rotated Cube {001}<110> texture component of the CCDF-processed alloy contributed positively to the improvement of wear resistance properties. These findings suggest that CCDF processing has the potential to achieve cost-effective nanostructured high-entropy alloys and implement them in engineering and structural applications.

Influence of carbon percentage on the wear and friction characteristics of ATOMET 4601 alloys in heavy-duty machinery

Heavy-duty machinery demands materials with strong wear resistance and good frictional properties, which conventional materials often lack. The knowledge of PM alloys’ friction and wear characteristics versus standard steel materials is limited. ATOMET 4601, a high-strength prealloyed powder with excellent compressibility, allows for parts with densities over 6.8 g/cm³. Carbon (0, 0.5, 1.0 wt.%) was added to enhance performance. These alloys, compacted to 75% of theoretical density and sintered at 1100 ± 10°C, were tested for wear and friction against EN31 steel. Results showed carbon improved tribological performance, with ATOMET 4601 + 1.0%C exhibiting the best wear resistance. Regression models and interaction plots indicated significant effects of load and speed on wear rate and coefficient of friction. Microstructural analysis revealed carbides and oxides in the ferrite matrix, with adhesive, abrasive, and oxidative wear as primary mechanisms.

Influence of deep-sea hydrostatic pressure on the tribocorrosion behavior and mechanism of La2O3–TiB2–Ni coating

To understand the tribocorrosion mechanism of TiB2–Ni coating doped with La2O3 in the deep ocean, the wear and corrosion test of La2O3–TiB2–Ni under various hydrostatic pressures was conducted and discussed in 3.5 wt % NaCl solution. The results indicate that the tribocorrosion mechanism of the La2O3–TiB2–Ni coating transitions from abrasive wear with corrosion under 0.1 MPa to abrasive wear with corrosion and adhesive wear under high hydrostatic pressure. The La2O3–TiB2–Ni coating shows significant enhancements in wear resistance and anti-friction properties compared to the TiB2–Ni coating. As the hydrostatic pressure increases from 0.1 MPa to 30 MPa, the self-corrosion current density experiences an approximate increase of 43.6 μA/cm2.

Wear Prediction of Functionally Graded Composites Using Machine Learning.

This study focuses on the production of functionally graded composites by utilizing magnesium matrix waste chips and cost-effective eggshell reinforcements through centrifugal casting. The wear behavior of the produced samples was thoroughly examined, considering a range of loads (5 N to 35 N), sliding speeds (0.5 m/s to 3.5 m/s), and sliding distances (500 m to 3500 m). The worn surfaces were carefully analyzed to gain insights into the underlying wear mechanisms. The results indicated successful eggshell particle integration in graded levels within the composite, enhancing hardness and wear resistance. In the outer zone, there was a 25.26% increase in hardness over the inner zone due to the particle gradient, with wear resistance improving by 19.8% compared to the inner zone. To predict the wear behavior, four distinct machine learning algorithms were employed, and their performance was compared using a limited dataset obtained from various test operations. The tree-based machine learning model surpassed the deep neural-based models in predicting the wear rate among the developed models. These models provide a fast and effective way to evaluate functionally graded magnesium composites reinforced with eggshell particles for specific applications, potentially decreasing the need for extensive additional tests. Notably, the LightGBM model exhibited the highest accuracy in predicting the testing set across the three zones. Finally, the study findings highlighted the viability of employing magnesium waste chips and eggshell particles in crafting functionally graded composites. This approach not only minimizes environmental impact through material repurposing but also offers a cost-effective means of utilizing these resources in creating functionally graded composites for automotive components that demand varying hardness and wear resistance properties across their surfaces, from outer to inner regions.