Wear Test Data Research Articles

Lubricated Wear Properties of Zn-30Al-3Cu-Si Alloys

To assess the effect of silicon content (SC) and test parameters on the lubricated wear of Zn-30 wt.% Al-3 wt.% Cu-(0.5–5) wt.% Si alloys, six quaternary alloys were produced by casting. Their wear properties were investigated at different ranges of contact pressure (CP) of 1–8 MPa and sliding velocity (SV) of 1–3 ms−1 for two different sliding distances (SD) of 20 km and 108 km. It was observed that Si addition (SA) improved the tribological properties of Zn-30Al-3Cu alloy, but an increase in the SC above a certain percentage (0.5%) adversely affected these properties. Therefore, Zn-30Al-3Cu-0.5Si alloy demonstrated the lowest friction coefficient (FC) and wear volume (WV) among the alloys tested. The correlations between the lubricated wear properties (FC and WV) of the alloys and test conditions (CP and SV) were made by non-linear regression analysis using the wear test data. Finally, the equations for the relationship between the wear properties of the alloys and the test parameters were determined.

Effect of line parameters on wheel wear of heavy–haul freight vehicle

Purpose The serious wear problem of heavy-haul freight vehicle wheels affects the safety and economy of vehicle operation. This paper aims to study wheel wear evolution law and the influence of line parameters on wheel wear of heavy-haul freight, and provide the basis for operation and line maintenance. Design/methodology/approach The wheel wear test data of heavy-haul freight vehicles were analyzed. Then a heavy-haul freight vehicle dynamic model was established. The line parameters influencing wheel wear in heavy-haul freight vehicles were also analyzed by the Jendel wear model, and the effects of rail cant, rail gauge, rail profile and line ramp on wheel wear were analyzed. Findings A rail cant of 1:40 results in less wheel wear; an increase in the rail gauge can reduce wheel wear; and when matched with the CHN60 rail, the wear depth is relatively small. A decrease of 9.21% in wheel wear depth when matched with the CHN60 rail profile. The ramp of the heavy-haul line is necessary to consider for calculating wheel wear. When the ramp is considered, the wear depth increases by 8.47%. The larger the ramp, the greater the braking force and therefore, the greater of the wheel wear. Originality/value This paper first summarizes the wear characteristics of wheels in heavy-haul freight vehicles and then systematically analyzes the effect of line parameters on wheel wear. In particular, this study researched the effects of rail cant, rail gauge, rail profile and line ramp on wheel wear. Peer review The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-02-2024-0038/

Effect of inert environment on the sliding wear behaviour of the HVOF sprayed WC-12Co coating

The reciprocating sliding wear behaviour of high velocity oxy-fuel sprayed WC-12Co coatings in the inert environment at room temperature, and 300 °C temperature with varying load conditions was investigated. The worn-out coatings and the debris were analyzed by scanning electron microscopy and Raman spectroscopy. From the wear test data, the coefficient of friction was measured as lower in the air environment at both room temperature and 300 °C, compared with the argon environment due to the development of self-lubricating tribo-oxide layers. The development of CoWO4 phases at the surface decreases friction and wear and allows the coating to uphold the tribological properties at higher temperatures. Higher loads mechanically damage the coatings and quickly remove the protective oxide layer compared with the lower loads. In the protective environment, abrasive wear and adhesive wear mechanisms were observed to be played predominant role, whereas, in the air environment, the oxidative wear mechanism was found to be significant.

Long-sliding distance experiment and heuristic model prediction of the electrical sliding abrasion of an overhead wire/current collector

Several long-sliding distance tests on the electrical sliding abrasion of an overhead wire/current collector were performed on a test rig. The test parameters cover electric currents of DC 0, 100, 200, 300, 400 A, normal force of 15, 25, 35, 45 N, sliding speeds of 60, 80, 100 km/h, and sliding distance of 6000 km. Test results illuminate that the electric current significantly impacts the electric sliding abrasion performance of the Cu-Ag alloy overhead wire and current collector. Its main wear mechanisms involve adhesive, plowing, electrical, and arc wears. Bucca and Collina’s wear prediction models of overhead wires and current collectors were established using the obtained wear test data. More parameter sensitivity analyses were carried out using the wear prediction models.

Mesoscopic scale simulation and wear investigation of self-lubricating fabric liner based on representative volume element

As the self-lubricating layer of self-lubricating spherical plain bearings, fabric liner shows obvious heterogeneous anisotropic characteristics, so it is a technical difficulty to predict its wear properties. In this paper, the continuous wear of self-lubricating fabric liner was simulated based on the mesoscopic scale wear model. The macroscopic wear properties of the fabric liner were characterized by establishing a representative volume element, and subsequently imposing periodic boundary restrictions on periodic surfaces. In order to avoid excessive mesh distortion, voxel grids meshing method was used, and then continuous wear of the heterogeneous material was realized by adjusting node coordinates and combining nodes. Detailed comparison between simulation prediction results and wear test data of fabric liner was made. The good correlation of the results confirmed that the mesoscopic scale wear model could be used in accurately predict the tribological performance of fabric composite.

Wear of Spiral Seal Cone Bit in Complex Formations

Summary Sealing is a technical bottleneck that affects drilling efficiency and cost in deep, difficult-to-drill formations. The spiral combination seal with active sand removal performance is a new type of seal, and the wear mechanism is not clear, resulting in no effective design. In this study, the wear properties of materials were measured by a friction-and-wear testing machine, and the measurement methods and criteria of wear loss and friction coefficient were established. The fitting function of working condition and friction coefficient was studied by fitting regression method. The law of influence of working conditions on friction coefficient and wear amount was determined. The actual wear model and evaluation criteria of wear condition were established by using wear test data and geometric relationship. The relationship among working conditions, contact stress, and wear depth is determined by numerical simulation method, and the wear mechanism of the new seal is revealed, which provides a theoretical basis for its application.

Analisa Laju Permukaan Keausan Pada Model Uji Mekanis Bushing Kuningan

Bushing is a bearing between movable and immovable components. These spare parts function are to hold the rotating shaft and through the gear box into the shaft which is held by the brass material bushing, where those processes are able to reduce the vibrations and the shock of shock loads. The purpose of this research is to know the level of roughness and wear rate of brass bushing, this research is conducted to find out how efficient it is, the use of a bushing with a field that is very likely to have a large shock load and to know the wear test data, and roughness of the brass bushing. The type of this research used an experimental method. From the results of the study it was concluded that to get the roughness and wear value using a conventional lathe, the spindle rotation was 970 rpm. Based on the experiments with predetermined parameters, the lowest roughness value was Ra 1.13 and the highest roughness was Ra 2.41. In the experiments for the wear test of each specimen, the wear rate obtained after the initial weight was subtracted from the third one hour weight, from the lightest of 0.07 grams and the heviest of 1.62 grams.

Study on the wear-resistant mechanism of concrete based on wear theory

In order to prepare wear-resistant concrete to solve the common problem of concrete wear, the wear model with elastic modulus, splitting tensile strength and porosity as variables were established based on the wear theory and test data. Results showed the proportional coefficients of elastic modulus, porosity and splitting tensile strength are 8.56, 3.97 and −9.72, respectively for abrasive wear model, 6.97, 1.10, 4.27 and 2.32, 0.37, 1.42 for fatigue wear and adhesive wear. The results of preparing wear-resistant concrete showed that 5% polyacrylic ester + 5% silicon powder maximized the wear resistance. To prepare wear-resistant concrete, the hardness would be considered first, then improve the density and interfacial bond strength corresponding to abrasive wear and fatigue wear/adhesion wear, respectively.

Tensile and erosion behaviour of medium calcined alumina microparticles on GFRP composites fabricated with vacuum bagging process

Fiber-reinforced polymer matrix composites have high specific stiffness and high strength to weight ratio draw the attention of researchers to enhance the properties of the composite with a reduced cost. The performance of the composites is being affected by fiber volume fraction and microparticulate reinforcement. Fiber volume fraction can be controlled with vacuum pressure. A medium calcined alumina micro particulates (Al2O3) was considered as a 3% weight percentage of the matrix at random. The particles were distributed using mechanical stirrer and spraying machines. The parametric effect was studied using tensile test data and erosion wear test data. From the results, it was observed that the particulate addition may increase the erosion resistance of the composite.

Quantitative ultrahigh-molecular-weight polyethylene wear in total elbow retrievals

The purpose of this study was to evaluate ultrahigh-molecular-weight polyethylene (UHMWPE) wear and damage from retrieved total elbow arthroplasty components and compare invivo wear with wear produced invitro. Explanted total elbow components were collected at revision surgery. UHMWPE damage was characterized visually, whereas penetration and wear were quantified using micro-computed tomography and gas pycnometry. Volumetric wear rates were compared with historical hip data, and wear data were compared with reported invitro wear test data. Humeral bushing damage primarily occurred in the form of burnishing, scratching, and pitting at the articular face in the region of contact with the ulnar component. Wear of the ulnar bushings was concentrated on the edge of the component at the point of contact with the axis pin. Pitting and embedded debris were dominant damage modes, in addition to burnishing and delamination. Backside wear was negligible. The median linear penetration rates of the lateral, medial, and ulnar bushings were 0.14 mm/yr (range, 0.01-0.78 mm/yr), 0.12mm/yr (range, 0.03-0.55 mm/yr), and 0.11 mm/yr (range, 0.01-0.69 mm/yr), respectively. The volumetric wear rates of the lateral, medial, and ulnar bushings were 5.5 mm3/yr (range, 0.7-37.2 mm3/yr), 5.9 mm3/yr (range, 0.6-25.5 mm3/yr), and 5.5 mm3/yr (range, 1.2-51.2 mm3/yr), respectively. The observed wear rates were similar to those reported in well-functioning total hip replacement patients with conventional UHMWPE bearings. We found limitations in reported invitro testing resulting in wear that was not consistent with our retrieval data. We recommend further investigation to clinically validate invitro simulation to provide appropriate loading protocols for elbow wear simulation.

ANTICORROSION PROPERTIES OF Zn–Al–Mg–ZnO COMPOSITE COATING PREPARED BY COLD SPRAYING

Two kinds of composite coatings, Zn[Formula: see text]Al[Formula: see text]Mg5ZnO[Formula: see text] and Zn[Formula: see text]Al[Formula: see text]Mg5ZnO[Formula: see text], were prepared on steel matrix (Q235) by cold spraying. The Zn, Al, Mg, and ZnO in raw materials were calculated by percentage of mass. The morphology of the original coating was observed by scanning electron microscopy (SEM) and characterized by energy dispersive spectroscopy (EDS). It was found that the microstructures of Zn[Formula: see text]Al[Formula: see text]Mg5ZnO[Formula: see text] and Zn[Formula: see text]Al[Formula: see text]Mg5ZnO[Formula: see text] composite coatings prepared by cold spraying were compact without oxidation products, and the plastic deformation of powder particles was significant. The friction and wear test data of the two coatings showed that the Zn[Formula: see text]Al[Formula: see text]Mg5ZnO[Formula: see text] coating had longer-lasting protective properties and wear resistance under the same conditions. Neutral salt spray test (NSS) and electrochemical accelerated corrosion test were carried out on samples at different time periods. The results of samples’ corrosion microstructure and electrochemical curves showed that Zn[Formula: see text]Al[Formula: see text]Mg5ZnO[Formula: see text] and Zn[Formula: see text]Al[Formula: see text]Mg5ZnO[Formula: see text] have good electrochemical protection performance, and Zn[Formula: see text]Al[Formula: see text]Mg5ZnO[Formula: see text] coating has better protection effect.

Analysing wear behaviour of Al–CaCO3 composites using ANN and Sugeno-type fuzzy inference systems

Design of experiment for the development of stir cast calcium carbonate-reinforced aluminium composite is a search for optimum combination of material and process control parameters for best physical and mechanical properties. A soft-computing model can accurately learn the complex interactions between process parameters to provide great insights in the development of this composite. This paper demonstrates and analyses the potential of artificial neural network (ANN) and Sugeno-type fuzzy inference systems (FIS) for wear behaviour prediction of calcium carbonate-reinforced aluminium composites. The models were trained with data collected from the experiment. The data consist of filler particle size of 150 μm with weights fractions varied from 0 to 25 wt%, in step of 5. Wear test data at different time of contacts (30, 60, 90, 120 and 150 s) and variable loads of 2.27 N, 4.54 N and 6.80 N were collected, resulting to 120 length vectors. Comparing the experimental results of wear test with those predicted using the ANN and Sugeno-type FIS, the integration of calcium carbonate particulate enhanced the wear characteristics of Al matrix up to 200%. On the use of back-propagation neural network with 4–3–1 architecture for wear prediction, the Levenberg–Marquardt training algorithm performs better. For Sugeno-type FIS, the Gaussian membership function resulted to the best prediction of wear rate. When ANN and Sugeno-type FIS performance on the test set were analysed based on some statistical parameters, the later returned an R2 value of 0.9775 as against ANN’s value of 0.3684. The predicted wear rate using ANFIS with Gaussian membership functions was in good agreement with the experimental values.

Tribological Performance of Molybdenum Stellite Alloys under Dry-Sliding Wear

Elements tungsten and molybdenum are the key constituents of Stellite alloys as solutes to strengthen the solid solution matrix. Meanwhile, they also promote formation of W-rich and Mo-rich carbides when present in large quantities in high-carbon Stellite alloys. Extensive studies on tungsten Stellite alloys, in particular, Stellite® 6, have been reported in the literature; however, molybdenum Stellite alloys, especially, the influence of Mo content on the performance of the alloys, have been rarely investigated. In this research, the tribological performance of three molybdenum Stellite alloys with varying C and Mo contents is studied using pin-on-disk dry-sliding wear test at ambient temperature, focusing on the effect of test duration and interrupted test on the wear behavior of the alloys. The worn surfaces are examined using SEM/EDS, and the analyses of the surface morphologies help explore the wear mechanisms of these alloys in dry-sliding condition. A wear model is developed for molybdenum Stellite alloys, based on the Archard equation in check with the wear test data, using hardness as a controlling factor.

A microstructure-based wear model for grid-to-rod fretting of clad nuclear fuel rods

Coolant flow-induced, grid-to-rod-fretting (GTRF) can occur in pressurized water nuclear reactor cores leading to cladding wear-through, fuel material leakage, and plant shutdowns. The goal of this effort was to derive a microstructure-based interpretation of the fretting wear factor (Wf) for use in an existing, multi-stage GTRF wear model. Physically, the magnitude of Wf (expressed in units of mm3/N-m) reflects the effectiveness of converting frictional work into material removal during fretting between Zircaloy-4 clad nuclear fuel rods and their supporting grids of a similar or dissimilar material. A tribosystem analysis of this complex situation not only involves mechanical influences on cladding wear, but also the effects of temperature and tribo-corrosion. A previously published GTRF wear model underlies this work. It assumes that the cladding wear rate can change over time and takes place in stages depending on the evolving nature of the materials in the interface. A materials science-based derivation of wear factor introduces four concepts: a wear process volume (WPV) from which debris particles originate, a population of wear debris embryos (DEms) of a critical size within the WPV, primary debris origins from the subsurface of the cladding alloy, and secondary debris detachment from third-body layers. The probability of nucleating loose particles from DEms and the coalescence of cracks in highly-worked Zircaloy-4 to form primary debris is estimated from wear test data obtained with a high-temperature, pressurized-water GTRF wear simulator at Oak Ridge National Laboratory (USA). The limitations and challenges for quantifying certain microstructure-based parameters that comprise the wear factor derivation are discussed.

Effect of equal channel angular pressing on the mechanical and tribological behavior of Al-Zn-Mg-Cu alloy

Microstructure, mechanical properties and wear behavior of severely deformed Al-7075 alloy by equal channel angular pressing (ECAP) were studied. Microhardness, tensile and shear strength tests were performed to evaluate the mechanical properties of the material. The relationship between tensile and shear strength was also extracted. In addition, with the aim of study the wear behavior, the wear tests were performed by using a pin-on-disk machine under different normal loads. The microscopic observations i.e. transmission electron microscopy (TEM) and scanning electron microscope (SEM), were used to analyze the microstructure of specimens as well as the surface, subsurface and debris of worn specimens. Mechanical properties results showed that the hardness and strength (tensile and shear) of the ECAP-processed alloy were higher than that of the annealed alloy and increased with the increment of pass number. The wear test data revealed that the wear rate and friction coefficient decreased with increasing ECAP passes. The SEM analysis of worn specimens demonstrated that the dominant wear mechanisms of the annealed alloy were adhesion wear and delamination and the dominant wear mechanisms of ECAP processed alloy were abrasive wear and plowing bands. Oxidative wear was also observed at both annealed and ECAPed alloy. Totally, these results demonstrated that ultrafine-grained structure fabricated by ECAP, improves the wear resistance of the Al-7075 alloy.

Role of Metallic Nanofillers on Mechanical and Tribological Behaviour of Carbon Fabric Reinforced Epoxy Composites

In this study, hybrid composites based on carbon fabric and epoxy (C/Ep) were fabricated by hand lay-up method followed by compression moulding. The C/Ep with optimum carbon fiber (60 wt%) was chosen as a reference material, and to it, the metallic nanoparticles like aluminum (Al) and zinc (Zn) of different wt% (0.5 and 1.0) were included as secondary fillers. To understand the synergism effect of these hybrid reinforcements, mechanical properties and tribological behavior of composites were studied. From the test results, it was proved that hybridization improved the mechanical and tribological properties. The C/Ep consisting of 0.5 wt% Zn and Al showed higher tensile properties in comparison with all other fabricated composites. Increase in flexural strength and flexural modulus also observed as the filler content increased in C/Ep composite. Higher impact strength is noted at 1 wt% Zn filled C/Ep composite. Wear test data revealed that 0.5 wt% Zn in C/Ep has got superior wear resistance. Wear mechanisms were discussed using scanning electron micrographs of selected worn surfaces of the composites.

UJI PREDIKSI UMUR KEANDALAN OPERASI RADIAL BALL BEARING PADA MOTOR DIESEL SINGLE CYLINDER DENGAN PENDEKATAN AMBANG BATAS KEAUSAN

Factually where the bearingss are not functioning properly makes the performance of the entire system will decrease or can not work properly. In this study, the wear test data that will be used is the data for the operating hours of 100 hours, 200 hours, 300 hours, 400 hours and 500 hours and the first converted into a linear function to obtain a threshold of wear of each specimen. In accordance with the objectives to be achieved in this study was to determine the relationship between the limits hours of operation and wear limit set maximum ball bearings manufacturer. The data used in this study is through the mechanism of experimental tests on Diesel engines Yanmar 15 HP, 1700 RPM using 3 specimens to be validated. Furthermore, these data will be generated from a particular distribution which will provide an overview wear limit as a function of operating hours.

Predicting the Wear of High Friction Surfacing Aggregate

High friction surfacing (HFS) is a specialist type of road coating with very high skid resistance. It is used in the UK at locations where there is significant risk of serious or fatal accidents. This paper considers the aggregate used in HFS. Calcined bauxite is the only aggregate that provides the highest levels of skid resistance over the longest period. No naturally occurring aggregate has been found to give a comparable level of in-service performance. This paper reviews the historical development of HFS in the UK relating to aggregate. In-service performance is predicted in the laboratory using the Wear test which subjects test specimens to an estimated 5–8 years simulated trafficking. Examples are given of Wear test data. They illustrate why calcined bauxite performs better than natural aggregate. They show how the amount of calcined bauxite can be reduced by blending with high skid resistant natural aggregates. Data from the Wear test can be related to every HFS laboratory experiment and road trial carried out in the UK for over the last 50 years. Anyone considering the prediction of HFS performance needs to carefully consider the data given in this paper with any other test method currently being considered or used to investigate HFS.

Abrasive wear response of TIG-melted TiC composite coating: Taguchi approach

In this study, Taguchi design of experiment approach has been applied to assess wear behaviour of TiC composite coatings deposited on AISI 4340 steel substrates by novel powder preplacement and TIG torch melting processes. To study the abrasive wear behaviour of these coatings against alumina ball at 600° C, a Taguchi’s orthogonal array is used to acquire the wear test data for determining optimal parameters that lead to the minimization of wear rate. Composite coatings are developed based on Taguchi’s L-16 orthogonal array experiment with three process parameters (welding current, welding speed, welding voltage and shielding gas flow rate) at four levels. In this technique, mean response and signal-to-noise ratio are used to evaluate the influence of the TIG process parameters on the wear rate performance of the composite coated surfaces. The results reveal that welding voltage is the most significant control parameter for minimizing wear rate while the current presents the least contribution to the wear rate reduction. The study also shows the best optimal condition has been arrived at A3 (90 A), B4 (2.5 mm/s), C3 (30 V) and D3 (20 L/min), which gives minimum wear rate in TiC embedded coatings. Finally, a confirmatory experiment has been conducted to verify the optimized result and shows that the error between the predicted values and the experimental observation at the optimal condition lies within the limit of 4.7 %. Thus, the validity of the optimum condition for the coatings is established.

Dry Sliding Wear Performance of Al/7075/Al2O3p/Grp Hybrid Metal Matrix Composites

In this paper, the dry sliding wear performance of Alumina-Al2O3 and graphite-Gr particles reinforced with Al7075 (aluminum alloy 7075) hybrid metal matrix composites is studied by means of a pin-on-disc tribometer. Ceramic particles Al2O3 along with solid lubricant Gr are incorporated into Al7075 matrix to accomplish improvement in the wear properties such as wear and coefficient of friction. These Al7075/Al2O3p/Grp hybrid composites with varying percentages of Al2O3 and Gr are produced by stir casting method in a controlled atmosphere. Uniform distribution of reinforcing particles is confirmed by SEM views. The influence of various parameters such as Al2O3 (0 and 3 wt.%), Gr (2, 4 and 6 wt.%), applied load (10, 20 and 30N) and sliding distance (1000, 1500 and 2000m) is evaluated on dry sliding wear performance of these hybrid composites namely, wear and coefficient of friction. The wear tests are designed according to Taguchi’s L18 orthogonal array (21 x 33) to observe the wear performance of these composites during dry sliding wear tests. Analysis of variance and main effects plots are used to analyze the wear test data. It is observed that the wear is mainly influenced by the Al2O3% reinforcement and applied load. Wear decreases with the increase of Al2O3% reinforcement and increases with increase of applied load. Whereas, coefficient of friction is mainly influenced by Gr% reinforcement and the applied load. Applied load affects significantly both wear and coefficient of friction, whereas sliding distance has insignificant effect on both.