Showing 29 results for Wear
F. Mahzoon, S. A. Behgozin, N. Afsar Kazerooni, M. E. Bahrololoom,
Volume 10, Issue 3 (9-2013)
Abstract
The wear mechanism of plasma electrolytic nitrocarburised (PEN/C) 316L stainless steel samples was studied after a pin on disc wear test. The surface morphology of samples after application of PEN/C process was studied using scanning electron microscope technique. The sliding tracks resulting from the wear tests on the treated specimens indicated no signs of plastic deformation and adhesive wear, but the slider wear particles were trapped in the micro-craters of the counterface. The results showed that this mechanism may further improve the tribological performance of the system by increasing the wear resistance and lowering friction. PEN/C treated surfaces are therefore believed to have the potential to limit metal-to-metal wear mechanisms on a microscale, if contact pressures are sufficiently low
A. Azizi, S. Z. Shafaei, M. Noaparast, M. Karamoozian,
Volume 10, Issue 4 (12-2013)
Abstract
This paper was aimed to address the modeling and optimization of factors affecting the corrosive wear of low alloy and high carbon chromium steel balls. Response surface methodology, central composite design (CCD) was employed to assess the main and interactive effects of the parameters and also to model and minimize the corrosive wear of the steels. The second-order polynomial regression model was proposed for relationship between the corrosion rates and relevant investigated parameters. Model fitted to results indicated that the linear effects of all of factors, interactive effect of pH and grinding time and the quadratic effects of pH and balls charge weight, were statistically significant in corrosive wear of low alloy steel balls. The significant parameters in the corrosive wear of high carbon chromium steel balls were the linear effects of all factors, the interactions effect of solid concentration, mill speed, mill throughout, grinding time, and the quadratic effects of pH and solid content. Also, the results showed that within the range of parameters studied, the corrosion rate of 78.38 and 40.76 could be obtained for low alloy and high carbon chromium steel balls, respectively.
M. Akbarzadeh, A. Shafyei, H. R. Salimijazi,
Volume 12, Issue 1 (3-2015)
Abstract
In the present study, CrN, TiN and (Ti, Cr)N coatings were deposited on D6 tool steel substrates. Physical and mechanical properties of coatings such as microstructure, thickness, phase composition, and hardness were evaluated. Phase compositions were studies by X-ray diffraction method. Mechanical properties were determined by nano-indentation technique. The friction and wear behaviour of the coatings were investigated using ball-on-disc tests under normal loads of 5, 7 and 9 N at sliding distance of 500 m, at room temperature. Scanning electron microscope equipped with energy dispersive spectroscopy, optical microscope, and 2D/3D profilometry were utilized to investigate the microstructures and wear mechanisms. Wear test results clarified that the wear resistance of (Ti, Cr)N and TiN coatings was better than that of CrN coating. The wear resistance of the (Ti, Cr)N coatings was related to the Ti content in the coatings and reduced by decreasing the Ti content. The dominant wear mechanisms were characterized to be abrasive and tribochemical wear
A. Azizi, S.z. Shafaei, R. Rooki,
Volume 13, Issue 2 (6-2016)
Abstract
Nowadays steel balls wear is a major problem in mineral processing industries and forms a significant part of the grinding cost. Different factors are effective on balls wear. It is needed to find models which are capable to estimate wear rate from these factors. In this paper a back propagation neural network (BPNN) and multiple linear regression (MLR) method have been used to predict wear rate of steel balls using some significant parameters including, pH, solid content, throughout of grinding circuit, speed of mill, charge weight of balls and grinding time. The comparison between the predicted wear rates and the measured data resulted in the correlation coefficients (R), 0.977 and 0.955 for training and test data using BPNN model. However, the R values were 0.936 and 0.969 for training and test data by MLR method. In addition, the average absolute percent relative error (AAPE) obtained 2.79 and 4.18 for train and test data in BPNN model, respectively. Finally, Analysis of the predictions shows that the BPNN and MLR methods could be used with good engineering accuracy to directly predict the wear rate of steel balls.
M. Paidpilli, K. Verma, R. Pandey, A. Upadhyaya,
Volume 14, Issue 1 (3-2017)
Abstract
In the present work, one batch of prealloyed 6061Al powder was processed by mixing and another one was ball milled with varying amount of lead content (0-15 vol. %). These powders were compacted at 300MPa and sintered at 590˚C under N2. The instrumented hardness and the young’s modulus of as-sintered 6061Al-Pb alloys were examined as a function of lead content and processing route. The wear test under dry sliding condition has been performed at varying loads (10-40 N) using pin-on-disc tribometer. The microstructure and worn surfaces have been investigated using SEM to evaluate the change in topographical features due to mechanical alloying and lead content. The mechanically alloyed materials showed improved wear characteristics as compared to as-mixed counterpart alloys. Delamination of 6061Al-Pb alloys decreases up to an optimum lead composition in both as-mixed and ball-milled 6061Al-Pb alloys. The results indicated minimum wear rate for as-mixed and ball-milled 6061Al alloy at 5 and 10 vol. % Pb, respectively.
B.m. Viswanatha, M. Prasanna Kumar, S. Basavarajappa, T.s. Kiran,
Volume 14, Issue 2 (6-2017)
Abstract
The effects of applied load, sliding speed and sliding distance on the dry sliding wear behavior of aged Al-SiCp-Gr composites were investigated. The specimen were fabricated by stir-casting technique. The pin-on-disc wear testing machine was used to investigate the wear rate by design of experiments based on L27 using Taguchi technique. Sliding distance was the most important variable that influenced the wear rate followed by sliding speed and applied load. The worn out surfaces were analyzed by SEM and EDS to study the subsurface mechanism of wear. The addition of reinforcements showed improved tribological behavior of the composite than base alloy.
F. Farzan, H. R. Shahverdi, F. Malek Ghaeni,
Volume 15, Issue 2 (6-2018)
Abstract
Recently, wear resistant properties of metallic glasses has attracted a lot of interest. Because the surface of metallic glasses are prone to phase transformation, finding the effects of test condition on structure and wear behavior of metallic glasses is important. In this research, by using an automated electrospark deposition (ESD), a layer of Fe
51Cr
18Mo
7B
16C
4Nb
4 was deposited on AISI 316l stainless steel. Metallographic,
scanning electron microscope (SEM) and Energy-dispersive X-ray spectroscopy (EDS) analyses of the coating were conducted for measuring the thickness and analyzing composition of the coating. X-ray diffraction (XRD), Transmission electron microscopy (TEM) and selected area electron diffraction (SAED) investigations showed that the structure of the coating was amorphous. Ball on disc wear tests were conducted in dry and wet conditions and Ringer’s solution was chosen as the wetting agent. The wear test results showed that the coefficient of friction in dry condition was lower than the wet condition and wear modes were fatigue and corrosive wear in dry and wet conditions respectively. SEM and EDS analyses showed different features and elemental inhomogeneity on the surface of the dry wear track, which were not detectable in wet wear track. In addition, activation of diffusion process and formation of carbides and borides were observed on the wear track in dry condition.
M.r. Tavakoli Shoushtari, M. Goodarzi, H. Sabet,
Volume 15, Issue 4 (12-2018)
Abstract
In this study, the microstructure, hardness, and dry sliding wear behavior of the hardfaced layers made by a cored wire Fe-B-C-Ti alloy were investigated. St37 steel was used as the substrate and the deposition of the hardfaced layers was conducted by the flux cored arc welding (FCAW) process under single-, two-, and three-pass conditions. Dry sliding wear tests were performed by a pin-on-disk apparatus, based on ASTM-G99, at room temperature (250C) at the normal applied loads of 50, 100, and 150 N with a constant speed of 0.08 m/s for a sliding distance of 1000 m. The microstructural and phase analyses were carried out by field emission scanning electron microscopy (FE-SEM) and X-ray diffraction (XRD), respectively. The results showed that the hardfaced layer produced by the single-pass process contains TiC rectangular phase distributed within a matrix containing ferrite and the eutectic of (α-Fe2B). But, the hardfaced layers produced by the two- and three-pass process contain TiB2 hexagonal phase in addition to TiC, which prevents the formation of detrimental FeB phase around Fe2B and reduces the number of micro-cracks. Moreover, the sample hardfaced by the three-pass process had the best wear resistance due to the greater hardness resulted from the higher amounts of TiC and TiB2 phases. In addition, increasing the number of passes has led to the reduction of wear rate at all the three applied loads. At the applied load of 100 N, the wear mechanism for the all three hardfaced samples was an oxidation wear. However, at the applied load of 150 N, the wear mechanism was a combination of oxidation and delamination.
M. Senthil Kumar , R. V. Managalaraja, K. Senthil Kumar, L. Natrayan,
Volume 16, Issue 2 (6-2019)
Abstract
The present requirement of automobile industry is seeking lightweight material that satisfices the technical and technological requirements with better mechanical and tribological characteristics. Aluminium matrix composite ( AMC ) materials meet the requirements of the modern demands. AMCs are used in automotive applications as engine cylinders, pistons, disc and drum brakes. This paper investigates the effect of particle size and wt% of Al2O3/SiC reinforcement on mechanical and tribological properties of hybrid metal matrix composites (HMMCs). AA2024 aluminium alloy is reinforced with Al2O3/SiC different particle sizes (10, 20 and 40 µm) and weight fractions (upto 10 wt %) were fabricated by using squeeze casting technique. HMMCs were characterized for its properties such asX-ray diffraction (XRD), density, scanning electron microscope ( SEM ), hardness, tensile strength, wear and coefficient of friction. AA2024/5wt%Al2O3/5wt%SiC with 10 μm reinforced particle size showed maximum hardness and tensile strength 156.4 HV and 531.43 MPa and decrease in wear rate was observed from from 0.00307 to 0.00221 for 10N. Hybrid composites showed improved mechanical and wear resistance suitable for engine cylinder liner applications.
R. Kumar, Y. Chandra Sharma, V. Vidya Sagar, D. Bhardwaj,
Volume 17, Issue 2 (6-2020)
Abstract
In this study an effort has been made for the plasma ion nitriding (PIN) of Inconel 600 and 601 alloys at low temperatures. After plasma ion nitriding, microstructure study, growth kinetics of nitrided layer formation and wear properties were investigated by various characterization techniques such as; scanning electron microscope (SEM), X-ray diffraction (XRD) analysis, micro-hardness measurement and wear test by pin on disk technique. It was found that, surface micro-hardness increases after PIN process. A mix peak of epsilon (ε) phase with fcc (γ) phase was detected for all temperature range (350 0C to 450 0C), while the chromium nitride (CrN) phase was detected at elevated temperature range ~450 0C in inconel 601 alloy. The calculated values of diffusion coefficient and activation energy for diffusion of nitrogen are in accordance with the literature. Volume loss and wear rate of the plasma nitrided samples decreases, but it increases as PIN process temperature increases.
R. Niazi, E. Tohidlou, H. Khosravi,
Volume 17, Issue 3 (9-2020)
Abstract
The effects of erbium (Er) addition at various weight percentages (0-0.6 wt.% at an interval of 0.2) on the microstructural characteristics, tensile response and
wear properties of as-cast Al-7.5Si-0.5Mg alloy were evaluated. The microstructure of samples was examined by X-ray diffraction, optical microscopy and scanning electron microscopy. The obtained results demonstrated that the incorporation of erbium obviously decreased the α-Al grain size and eutectic Si, and altered the Si morphology from plate to semi-globular. Further addition of erbium (> 0.2 wt.%) did not alter the eutectic morphology and size. Moreover, the Al
3Er phase was also observed in the eutectic region after modification. Out of the erbium contents used, 0.2 wt.% erbium showed the best influence on the tensile and wear properties. Compared with those of unmodified specimen, the values of ultimate tensile strength and elongation were enhanced by 31% and 39%, respectively with the introduction of 0.2 wt.% erbium. Additionally, a remarkable enhancement in the wear properties was observed with the addition of 0.2 wt.% erbium.
M. Hamdi, H. Saghafian Larijani, S. G. Shabestari, N. Rahbari,
Volume 17, Issue 3 (9-2020)
Abstract
Aluminum matrix composites are candidate materials for aerospace and automotive industries owing to their specific properties such as high elastic modulus (E), improved strength and low wear rate. The effect of thixoforming process on the wear behavior of an Al-Mg2Si composite was studied in this paper. During applying thixoforming process, casting defects such as macrosegration, shrinkage and porosity are being effectively reduced. These advantages are sufficient to attract more exploration works of thixoforming operation. Thermal analysis of the composite, as-cast microstructure, wear surface and subsurface area of the thixoformed alloy were investigated. Wear behavior of the specimens were examined using a pin-on-disk machine based on ASTM-G99, at the applied loads of 25, 50 and 75 N and the constant sliding velocity of 0.25m/s. The worn surfaces and subsurfaces were examined by scanning electron microscopy (SEM). The experimental results indicated that the thixoformed specimens exhibited superior wear resistance than the as-cast alloy. Moreover, the dominant wear mechanism is an adhesive wear followed by the formation of a mechanical mixed layer (MML). However, a severer wear regime occurs in the as cast specimens compared with the thixoformed ones
M. T. Basha G, V. Bolleddu,
Volume 17, Issue 3 (9-2020)
Abstract
The microstructural characteristics, mechanical properties, and wear characterization of air plasma sprayed coatings obtained from Carbon nanotubes (CNTs) reinforced Al2O3-3wt%TiO2 powders were examined at different loading conditions and different percentage proportion of CNTs. The CNTs in the proportion of 2, 4, and 6wt% were used as nanofillers to modify the properties of coatings. The uniform dispersion of CNTs throughout the powder particles can be observed from the SEM micrographs. The porosity of the microstructure of the coatings was measured by image analysis. Also, the mechanical properties such as microhardness and surface roughness were measured by microhardness tester and profilometer, respectively. The wear tribometer was used to analyze the tribology of the coatings by varying different parameters. The different loading conditions used were low load (0.5 kgf), moderate load (1.0 kgf), and elevated load (1.5kgf), respectively. The microhardness showed a slight increase with an increase in the percentage of CNTs proportion. Similarly, the surface roughness value showed a decreasing trend, since the CNTs were filled in the pores. From wear tests, it was observed that the coefficient of friction and wear rate were very less at 6wt% CNTs and 1.5kgf load. This was mainly due to the bridging of CNTs in between the splats. This implies that CNTs were one of the most suitable additives for improving the microstructural and tribological characterization of the ceramic coatings.
Dillibabu Surrya Prakash, Narayana Dilip Raja,
Volume 18, Issue 4 (12-2021)
Abstract
Hybrid composites consisting of AA6061 matrix reinforced with TiB2 (2, 4, 6, and 8 wt. %), Al2O3 (2 wt. %) particles were produced by the sintering process. In comparison to the base material AA6061, the composite produced had improved mechanical properties. The sintered composites' mechanical properties, such as tensile strength and hardness, are measured and compared to the wear-tested specimen. Optical micrographs reveal that composites were riddled with defects like blowholes, pinholes, and improper bonding between the particulates before sintering. However, the post-sintered optical micrograph showed that the defects were greatly suppressed. Micrographic images revealed the changes in surface characteristics before and after wear. Until a sliding distance of 260 m, the wear rate of the hybrid composites was kept lower than that of the base material. The coefficient of all the composite materials produced for this study was noted to be less than that of the base material. The results reveal that the hardness of hybrid composites having 4 wt. % and 6 wt. % of TiB2 particulates increased by 5.98 % and 1.35 %. Because of the frictional heating during the wear test, the tensile properties lowered by up to 49.6%. It is concluded that the hybrid composites having 4 wt. % and 6 wt. % of TiB2 particulates exhibited less wear rate for extended sliding distance, good hardness, moderate tensile strength, and decent elongation percentage compared to its counterparts.
Muhammad Muzibur Rahman, Shaikh Reaz Ahmed,
Volume 18, Issue 4 (12-2021)
Abstract
This paper reports the wear behavior of Cu, high Cu-Sn alloy, high Cu-Pb alloy and high Cu-Sn-Pb alloy under dry sliding at ambient conditions. These four materials were chosen for the wear resistance characterization of SnPb-solder affected old/scraped copper (high Cu-Sn-Pb alloy) to explore its reusing potentials. Wear tests were conducted using a pin-on-disk tribometer with the applied load of 20N for the sliding distance up to 2772 m at the sliding speed of 0.513 ms-1. The applied load was also changed to observe its effect. The investigation reveals that the presence of a little amount of Sn increased the hardness and improved the wear resistance of Cu, while a similar amount of Pb in Cu reduced the hardness but improved the wear resistance. The general perception of ‘the harder the wear resistant’ was found to match partially with the results of Cu, Cu-Sn alloy and Cu-Sn-Pb alloy. Coefficient of friction (COF) values revealed non-linearly gradual increasing trends at the initial stage and after a certain sliding distance COF values of all four sample materials became almost steady. SnPb-solder affected Cu demonstrated its COF to be in between that of Cu-Pb alloy and Cu-Sn alloy with the maximum COF value of 0.533.
Abdur Rahman, Serajul Haque,
Volume 19, Issue 3 (9-2022)
Abstract
The effect of the milling time & ageing on the hardness, density, and wear characteristics of Al 7150 alloy specimens made via powder metallurgy has been studied. The different constituents of Al 7150 alloy were processed in a planetary ball milling set up with a BPR of 10:1 for 5 hours, 10 hours, and 20 hours. At 400 °C, the milled powders were subsequently hot compacted in a punch die setup. The hot-pressed specimens were solutionized initially, then aged artificially at 115 °C for 3, 6, 12, 24, 30, 45, 60, and 96 hours. The relative density was inversely proportional to the milling time. Microhardness tests showed a maximum VHN of 255 was measured for the 24 h aged T6 specimens produced from 20 h milled powders whereas the non-aged specimens, made from unmilled 7150 alloy powders showed a VHN of 40. However the samples showed a decline in microhardness beyond 24 h of ageing. Under various conditions of sliding distance and loading conditions, the samples subjected to T6 aging showed a reduced volumetric wear rate indicating the beneficial effect of artificial aging up to 24 hours. The volumetric wear rate gradually declined for the samples aged beyond 24 hours of aging. The HRTEM studies revealed a high density of uniformly scattered (MgZn2) precipitates in the base matrix, as well as (MgZn2) phases precipitating along grain boundaries. The presence of such second phase precipitates in the matrix improved the wear characteristics of the alloy matrix. The results showed that optimization of process parameters such as milling time, ageing as well as reducing the particle size of the base powders, the hardness and wear behavior of Al 7150 alloy may be improved.
Mohammad Roostaei, Hossein Aghajani, Majid Abbasi, Behzad Abasht,
Volume 19, Issue 3 (9-2022)
Abstract
This study investigates the synthesis of Al/MoS2 nanocomposite coating by the electro spark deposition (ESD) method for its lubricating properties. ESD method was selected because it is a very easy, rapid, and cost-saving method and the resulting coating has a strong bonding with the substrate. As a substrate, a Ti-6Al-4V alloy sheet containing 6.12 % Al, 4.06 % V, 0.19% Fe, and 0.05 % Ni was used. For coating, an aluminum-molybdenum disulfide composite electrode in the form of a cylindrical rod was employed. Three frequencies of 5, 8, and 11 kHz, three current limits of 15, 25, and 35 amps, and three duty cycles of 50, 60, and 70% were used in the coating operation. AFM analysis was used to study the topography, morphology, and calculate roughness. The samples were then subjected to hardness tests. To determine the wear resistance of the samples, pin on disk tests were performed. XRD analysis was performed to identify the phases on the surface of the coated samples. SEM was used to examine the microstructure of the coating before and after wear testing, in order to determine the wear mechanism. The results indicated that the Al/MoS2 nanocomposite coating was synthesized on the substrate surface. The hardness of the reference sample is 353 Vickers, and that of the coated samples is about 200 Vickers. For the reference sample, the roughness was measured at 15.7 nm, and for the coated sample at 268.1 nm. As spark energy increased, the coefficient of friction increased by approximately 0.09. As spark energy increased, the wear rate increased by 27%. A significant increase in the Lancaster coefficient occurred around 5 joules of energy. According to the wear rate results, the sample with the lowest thickness wears 4% less than the sample with the highest thickness. The wear rate of sample 351170 is 78% lower than that of sample 150550.
Erfan Lotfi-Khojasteh, Hassan Elmkhah, Meisam Nouri, Omid Imantalab, Arash Fattah-Alhosseini,
Volume 19, Issue 4 (12-2022)
Abstract
This paper aims to study the tribological and electrochemical properties of the CrN/AlCrN nano-layer deposited on H13 tool steel. Arc physical technique was employed to deposit multilayer coating. X-ray diffraction technique, thermionic and field emission scanning electron microscopy and energy dispersive spectroscopy have been used to determine the characteristics of the samples. To study the samples' wear behavior, coating adhesion, and surface hardness, reciprocating wear test, Rockwell-C test, and microhardness Vickers tester were employed, respectively. The measured values of the coefficient of friction and the calculated wear rates showed that the CrN/AlCrN multilayer coating has a much higher wear resistance than the uncoated sample. The coefficient of the friction of the coated sample was 0.53 and that of the uncoated sample was 0.78. Moreover, the wear rate of the coated H13 steel was about 127 times lower than the bare H13 steel sample. The results obtained from electrochemical impedance spectroscopy and polarization tests demonstrated that the corrosion current density of the H13 steel sample was 8 μA/cm2 and that of the CrN/AlCrN multilayer-coated sample was 3 μA/cm2. In addition, the polarization resistance of the treated and the substrate specimens was estimated at 4.2 and 2.7 kΩ.cm2, respectively.
Veeresh Kumar G B, Gantasala Sreenivasulu, Mohan C B, Ananthaprasad M G,
Volume 19, Issue 4 (12-2022)
Abstract
In the present research work physical, mechanical and tribological behavior of Aluminum (Al) alloy LM13 reinforced with Nano-sized Titanium Dioxide (TiO2) particulates were fabricated, mechanical and tribological properties were investigated. The amount of nano TiO2 particulates in the composite was added from 0.5% to 2% in 0.5 weight percent (wt %) increments. The Al-LM13-TiO2 Metal Matrix Composites (MMCs) were prepared through the liquid metallurgical method by following the stir casting process. The different types of Al LM13-TiO2 specimens were prepared for conduction of Physical, Mechanical, and Tribological characteristics by ASTM standards. Microstructural images, hardness, tensile, and wear test results were used to evaluate the effect of TiO2 addition to Al LM13. Scanning Electron Microscope (SEM), Energy Dispersive Spectroscopy (EDS), and X-Ray Diffractometer (XRD) were used to examine the microstructure and distribution of particulates in the matrix alloy. In the Al LM13 matrix, microstructure analysis indicates a consistent distribution of reinforced nanoparticles. The attributes of the MMCs, including density, hardness, tensile strength, and wear resistance, were improved by adding up to 1 wt% TiO2. Fractured surfaces of tensile test specimens were studied using SEM pictures. The standard pin-on-disc tribometer device was used to conduct the wear experiments; the tribological characteristics of unreinforced matrix and TiO2 reinforced composites were investigated. The composites’ wear resistance was increased by adding up to 1 wt% of TiO2. The wear height loss of Al LM13-TiO2 composite increased when the sliding distance and applied load were increased. Overall, the Al LM13 with one wt% of TiO2 MMCs showed excellent Physical, Mechanical and Tribological characteristics among all the percentages considered in the present study.
Alireza Zibanejad-Rad, Ali Alizadeh, Seyyed Mehdi Abbasi,
Volume 21, Issue 2 (6-2024)
Abstract
Pressureless sintering was employed at 1400 °C to synthesize Ti matrix composites (TMCs) reinforced with in-situ TiB and TiC reinforcements using TiB2 and B4C initial reinforcements. The microstructure and wear behavior of the synthesized composites were evaluated and compared and the results showed that B4C caused the formation of TiB-TiC in-situ hybrid reinforcements in the Ti matrix. Also, TiB was in the form of blades/needles and whiskers, and TiC was almost equiaxed. Moreover, the volume fraction of the in-situ formed reinforcement using B4C was much higher than that formed using TiB2. In addition, although the hardness of the B4C-synthesized composites was higher, the composite synthesized using 3 wt.% TiB2 exhibited the highest hardness (425 HV). The wear test results showed that the sample synthesized using 3 wt.% TiB2 showed the lowest wear rate at 50 N, mainly because of its higher hardness. The dominant wear mechanism in the samples synthesized using 3 wt.% B4C was abrasive and delamination at 50 N and 100 N, respectively while in the samples synthesized 3 wt.% TiB2, a combination of delamination and adhesive wear and adhesive wear was ruling, respectively.
