Pub Date : 2025-12-10DOI: 10.1016/j.wear.2025.206464
Aosong Li , Wendong Fang , Tongyue Liang , Sima A. Alidokht , Phuong Vo , Bertrand Jodoin , Richard R. Chromik
To investigate the effect of ceramic particle addition on the properties of cold sprayed MoS2-based metal matrix composite coatings, Cu-MoS2 and Cu-MoS2-TiC coatings were deposited using feedstocks containing 0 (CM), 15 (CM-15T), 30 (CM-30T) and 50 (CM-50T) wt% TiC, respectively, while maintaining a constant MoS2 ratio of 5.5 wt% relative to the combined Cu and MoS2 powders. The influence of TiC content on the coatings microstructure and mechanical properties was systematically evaluated. TiC addition led to a tamping effect that densified the coatings and enhanced plastic deformation of the Cu matrix, thereby improving cohesion strength as well as nano- and micro-hardness. However, MoS2 retention decreased in CM-30T and CM-50T. Polished coating surfaces were tested for reciprocating sliding wear using a ball-on-plate tribometer in dry air and nitrogen, with Al2O3 spheres as counterbodies. CM showed low coefficients of friction but the highest wear rate in both environments because of its inferior mechanical properties. In dry air, CM-15T demonstrated the lowest friction and superior wear resistance, attributed to its high MoS2 retention and improved mechanical properties. Mild abrasive wear in CM-15T suggested a significant reduction in adhesive wear which was dominant for the other coatings. In nitrogen, adhesive wear was minimal for all coatings. The high MoS2 content in CM-15T contributed to low coefficients of friction. CM-50T exhibited the lowest wear rate, benefiting from its high hardness, enhanced cohesion strength, and more retained TiC particles that facilitated the fast formation of hard tribo-layers. These findings highlight the interplay between tribological behavior, mechanical properties, tribo-oxidation, and third-body effects in metal matrix composite coatings incorporating solid lubricants and hard phases.
{"title":"Microstructure and third-body behavior of Cu-MoS2-TiC composite coatings deposited by cold spray","authors":"Aosong Li , Wendong Fang , Tongyue Liang , Sima A. Alidokht , Phuong Vo , Bertrand Jodoin , Richard R. Chromik","doi":"10.1016/j.wear.2025.206464","DOIUrl":"10.1016/j.wear.2025.206464","url":null,"abstract":"<div><div>To investigate the effect of ceramic particle addition on the properties of cold sprayed MoS<sub>2</sub>-based metal matrix composite coatings, Cu-MoS<sub>2</sub> and Cu-MoS<sub>2</sub>-TiC coatings were deposited using feedstocks containing 0 (CM), 15 (CM-15T), 30 (CM-30T) and 50 (CM-50T) wt% TiC, respectively, while maintaining a constant MoS<sub>2</sub> ratio of 5.5 wt% relative to the combined Cu and MoS<sub>2</sub> powders. The influence of TiC content on the coatings microstructure and mechanical properties was systematically evaluated. TiC addition led to a tamping effect that densified the coatings and enhanced plastic deformation of the Cu matrix, thereby improving cohesion strength as well as nano- and micro-hardness. However, MoS<sub>2</sub> retention decreased in CM-30T and CM-50T. Polished coating surfaces were tested for reciprocating sliding wear using a ball-on-plate tribometer in dry air and nitrogen, with Al<sub>2</sub>O<sub>3</sub> spheres as counterbodies. CM showed low coefficients of friction but the highest wear rate in both environments because of its inferior mechanical properties. In dry air, CM-15T demonstrated the lowest friction and superior wear resistance, attributed to its high MoS<sub>2</sub> retention and improved mechanical properties. Mild abrasive wear in CM-15T suggested a significant reduction in adhesive wear which was dominant for the other coatings. In nitrogen, adhesive wear was minimal for all coatings. The high MoS<sub>2</sub> content in CM-15T contributed to low coefficients of friction. CM-50T exhibited the lowest wear rate, benefiting from its high hardness, enhanced cohesion strength, and more retained TiC particles that facilitated the fast formation of hard tribo-layers. These findings highlight the interplay between tribological behavior, mechanical properties, tribo-oxidation, and third-body effects in metal matrix composite coatings incorporating solid lubricants and hard phases.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"586 ","pages":"Article 206464"},"PeriodicalIF":6.1,"publicationDate":"2025-12-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145748878","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-09DOI: 10.1016/j.wear.2025.206459
Ruijuan Liu , Yali Zhang , Xinle Li , Xiaogang Zhang , Jian Pu , Qin Xiong , Wen Shi , Zhongmin Jin
In traditional metal-on-polyethylene (MoP) implants, especially cobalt chrome molybdenum-ultra high molecular polyethylene (CoCrMo-UHMWPE) pairing, wear primarily occurs in the PE component. The wear particles from PE are considered a major cause of implant loosening and artificial joint failure. The development of oxidized zirconium-2.5 % niobium (Zr-2.5Nb) and zirconia-toughened alumina (ZTA) has shown promise in reducing wear and osteolysis risks. However, comparative studies on the wear mechanisms and wear particle characteristics of Zr-2.5Nb-UHMWPE, ZTA-UHMWPE, and CoCrMo-UHMWPE remain limited. In this study, Zr-2.5Nb, ZTA, and CoCrMo were selected and paired with UHMWPE as pairing materials. The wear mechanism was studied from the aspects of wear behavior and wear particle characterization at different contact pressures from 2 MPa to 4 MPa under multidirectional motion. The UHMWPE wear loss from Zr-2.5Nb-UHMWPE was 48 %, 27 %, and 18 % lower than that of CoCrMo-UHMWPE bearings at 2, 3, and 4 MPa. The results showed that there was no significant difference in the wear loss of UHMWPE from Zr-2.5Nb-UHMWPE and ZTA-UHMWPE at 2 MPa, but 34.5 % higher than that of ZTA-UHMWPE at 4 MPa. Zr-2.5Nb-UHMWPE exhibited a similar wear performance to ZTA-UHMWPE with no visible scratches on the surface of Zr-2.5Nb and ZTA, while multidirectional scratches appeared on the surface of CoCrMo. Moreover, the UHMWPE wear particles were consistent in size range and morphology, but different in quantity and size distribution at all loading conditions. The number of UHMWPE wear particles produced by the Zr-2.5Nb-UHMWPE pairing was 44 %–60 % lower than that of the CoCrMo-UHMWPE at 2, 3, and 4 MPa. However, the UHMWPE wear particles produced by Zr-2.5Nb-UHMWPE and ZTA-UHMWPE were very similar, which were 153 and 157 at 4 MPa, respectively. With increasing load, size distribution results revealed that the proportion of large-sized wear particles gradually increased for the three pairings. Notably, the UHMWPE wear particle from the Zr-2.5Nb-UHMWPE pairing exhibited the largest average particle size. Shape distribution analysis further indicated that the UHMWPE wear particle generated by the Zr-2.5Nb-UHMWPE pairing was predominantly fibrous in morphology, whereas that from the CoCrMo-UHMWPE pairing displayed the highest proportion of round and oval shapes. Based on the analysis of wear morphology and wear particle characteristics, the results showed that the wear mainly occurred in UHMWPE. Plastic deformation was the main cause of wear particle formation, and the wear mechanisms were adhesive wear and abrasive wear. This study compared the tribological behaviors of three typical pairings, providing a valuable understanding of artificial hip joint materials, which will contribute to optimizing orthopedic implant materials.
{"title":"Wear mechanism and wear particles characterization of Zr-2.5Nb, ZTA, and CoCrMo articulating with UHMWPE in multidirectional motion","authors":"Ruijuan Liu , Yali Zhang , Xinle Li , Xiaogang Zhang , Jian Pu , Qin Xiong , Wen Shi , Zhongmin Jin","doi":"10.1016/j.wear.2025.206459","DOIUrl":"10.1016/j.wear.2025.206459","url":null,"abstract":"<div><div>In traditional metal-on-polyethylene (MoP) implants, especially cobalt chrome molybdenum-ultra high molecular polyethylene (CoCrMo-UHMWPE) pairing, wear primarily occurs in the PE component. The wear particles from PE are considered a major cause of implant loosening and artificial joint failure. The development of oxidized zirconium-2.5 % niobium (Zr-2.5Nb) and zirconia-toughened alumina (ZTA) has shown promise in reducing wear and osteolysis risks. However, comparative studies on the wear mechanisms and wear particle characteristics of Zr-2.5Nb-UHMWPE, ZTA-UHMWPE, and CoCrMo-UHMWPE remain limited. In this study, Zr-2.5Nb, ZTA, and CoCrMo were selected and paired with UHMWPE as pairing materials. The wear mechanism was studied from the aspects of wear behavior and wear particle characterization at different contact pressures from 2 MPa to 4 MPa under multidirectional motion. The UHMWPE wear loss from Zr-2.5Nb-UHMWPE was 48 %, 27 %, and 18 % lower than that of CoCrMo-UHMWPE bearings at 2, 3, and 4 MPa. The results showed that there was no significant difference in the wear loss of UHMWPE from Zr-2.5Nb-UHMWPE and ZTA-UHMWPE at 2 MPa, but 34.5 % higher than that of ZTA-UHMWPE at 4 MPa. Zr-2.5Nb-UHMWPE exhibited a similar wear performance to ZTA-UHMWPE with no visible scratches on the surface of Zr-2.5Nb and ZTA, while multidirectional scratches appeared on the surface of CoCrMo. Moreover, the UHMWPE wear particles were consistent in size range and morphology, but different in quantity and size distribution at all loading conditions. The number of UHMWPE wear particles produced by the Zr-2.5Nb-UHMWPE pairing was 44 %–60 % lower than that of the CoCrMo-UHMWPE at 2, 3, and 4 MPa. However, the UHMWPE wear particles produced by Zr-2.5Nb-UHMWPE and ZTA-UHMWPE were very similar, which were 153 and 157 at 4 MPa, respectively. With increasing load, size distribution results revealed that the proportion of large-sized wear particles gradually increased for the three pairings. Notably, the UHMWPE wear particle from the Zr-2.5Nb-UHMWPE pairing exhibited the largest average particle size. Shape distribution analysis further indicated that the UHMWPE wear particle generated by the Zr-2.5Nb-UHMWPE pairing was predominantly fibrous in morphology, whereas that from the CoCrMo-UHMWPE pairing displayed the highest proportion of round and oval shapes. Based on the analysis of wear morphology and wear particle characteristics, the results showed that the wear mainly occurred in UHMWPE. Plastic deformation was the main cause of wear particle formation, and the wear mechanisms were adhesive wear and abrasive wear. This study compared the tribological behaviors of three typical pairings, providing a valuable understanding of artificial hip joint materials, which will contribute to optimizing orthopedic implant materials.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"586 ","pages":"Article 206459"},"PeriodicalIF":6.1,"publicationDate":"2025-12-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145798143","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-08DOI: 10.1016/j.wear.2025.206460
Guangzhao Wang , Hui Chen , Xiaoyu Sun , Wenqi Song , Zhenyu Wang , Guorui Zhu
In Generation IV lead-cooled fast reactors, austenitic 316L stainless steel steam generator tubes are susceptible to both dissolution corrosion and fretting fatigue wear in liquid lead–bismuth eutectic (LBE) environment. To address this challenge, a Cr2AlC nanocoating was deposited on 316L tubes and evaluated through multi-stage fretting wear tests in LBE at 450 °C, using a self-developed high temperature tribo-tester with a tube–plate contact configuration. The results demonstrate that the coating maintains a stable friction coefficient (0.6 ± 0.05) throughout 5 × 103 to 2 × 106 cycles, representing an approximately 40 % reduction compared to bare 316L stainless steel. The maximum wear depth stabilizes at 14.2 ± 0.1 μm, approximately 70 % lower than that of uncoated 316L. Multiscale characterization by SEM/EDS, XRD, and nanoindentation revealed a three-stage friction response on the coating: an initial stage where the coating surface remains intact, and wear occurs mainly on the plate; a transitional stage characterized by the formation of a discontinuous third-body layer (TBL) comprising oxides and wear debris, exhibiting relatively low mechanical properties; and a stable stage dominated by a compact TBL primarily consisting of Cr3+-doped α-Al2O3, the wear surface H2/E3 ratio increases, which enhances resistance to both wear and Pb-Bi corrosion. The proposed Cr2AlC self-adaptive protection mechanism offers a scientific basis for designing wear-resistant coatings for steam generator tubing in Generation IV nuclear reactors.
{"title":"Tribo-mechanisms of Cr2AlC nanocoating in lead-bismuth eutectic under multi-stage fretting cycles: Oxide-driven self-adaptive fretting wear protection","authors":"Guangzhao Wang , Hui Chen , Xiaoyu Sun , Wenqi Song , Zhenyu Wang , Guorui Zhu","doi":"10.1016/j.wear.2025.206460","DOIUrl":"10.1016/j.wear.2025.206460","url":null,"abstract":"<div><div>In Generation IV lead-cooled fast reactors, austenitic 316L stainless steel steam generator tubes are susceptible to both dissolution corrosion and fretting fatigue wear in liquid lead–bismuth eutectic (LBE) environment. To address this challenge, a Cr<sub>2</sub>AlC nanocoating was deposited on 316L tubes and evaluated through multi-stage fretting wear tests in LBE at 450 °C, using a self-developed high temperature tribo-tester with a tube–plate contact configuration. The results demonstrate that the coating maintains a stable friction coefficient (0.6 ± 0.05) throughout 5 × 10<sup>3</sup> to 2 × 10<sup>6</sup> cycles, representing an approximately 40 % reduction compared to bare 316L stainless steel. The maximum wear depth stabilizes at 14.2 ± 0.1 μm, approximately 70 % lower than that of uncoated 316L. Multiscale characterization by SEM/EDS, XRD, and nanoindentation revealed a three-stage friction response on the coating: an initial stage where the coating surface remains intact, and wear occurs mainly on the plate; a transitional stage characterized by the formation of a discontinuous third-body layer (TBL) comprising oxides and wear debris, exhibiting relatively low mechanical properties; and a stable stage dominated by a compact TBL primarily consisting of Cr<sup>3+</sup>-doped α-Al<sub>2</sub>O<sub>3</sub>, the wear surface H<sup>2</sup>/E<sup>3</sup> ratio increases, which enhances resistance to both wear and Pb-Bi corrosion. The proposed Cr<sub>2</sub>AlC self-adaptive protection mechanism offers a scientific basis for designing wear-resistant coatings for steam generator tubing in Generation IV nuclear reactors.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"586 ","pages":"Article 206460"},"PeriodicalIF":6.1,"publicationDate":"2025-12-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145748881","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-08DOI: 10.1016/j.wear.2025.206463
Guijiang Diao , Zhen Xu , Anqiang He , Doug Fraser , Reinaldo Chung , Jing Li , D.Y. Li
High-entropy alloys (HEAs), particularly those with an A2+B2 dual-phase structure, offer balanced strength and toughness, leading to superior and well-adjustable wear resistance. The effect of titanium, known to promote the formation of hard intermetallic phases and enhance mechanical properties, on A2+B2 dual-phase HEAs remains less understood. In this work, selecting a representative AlCr3Fe3Ni alloy with A2+B2 phases as the base alloy, we systematically investigated the phase evolution induced by various amounts of Ti addition and their differential effects on the sliding wear and solid-particle erosion of AlCr3Fe3NiTix HEAs (x = 0–1.5, molar ratio). Microstructural analysis reveals that Ti addition promotes the formation of AlNi2Ti-type L21 and (Fe,Cr)2Ti-type C14 Laves phases, both of which strengthen the alloys at the expense of plasticity. However, a low Ti content (i.e., x = 0.2) helps improve both yield strength and plasticity, due to the solid-solution strengthening effect and refinement of grain size. Micro-indentation and scratching tests demonstrate that the C14 Laves phase exhibits the highest hardness but the lowest toughness, whereas the A2+B2 dual-phase structure possesses the highest toughness but the lowest hardness. The L21 phase displays intermediate properties between the two. Sliding wear and dry-sand erosion tests reveal that moderate Ti additions enhance wear resistance through solid-solution strengthening, hard-phase reinforcement, and oxidation-induced surface protection. However, erosion resistance deteriorates with increasing Ti content, primarily due to lowered toughness under impact conditions. This study elucidates the dual roles of Ti-induced hard yet brittle phases, i.e., beneficial for sliding wear resistance but detrimental to erosion performance in impact-involving environments requiring higher toughness. The findings provide valuable insights into structure-property relationships for the design of advanced structural and tribo-materials.
{"title":"Differential effects of Ti addition on microstructure and corresponding mechanical and tribological properties of AlCr3Fe3NiTix high-entropy alloys","authors":"Guijiang Diao , Zhen Xu , Anqiang He , Doug Fraser , Reinaldo Chung , Jing Li , D.Y. Li","doi":"10.1016/j.wear.2025.206463","DOIUrl":"10.1016/j.wear.2025.206463","url":null,"abstract":"<div><div>High-entropy alloys (HEAs), particularly those with an A2+B2 dual-phase structure, offer balanced strength and toughness, leading to superior and well-adjustable wear resistance. The effect of titanium, known to promote the formation of hard intermetallic phases and enhance mechanical properties, on A2+B2 dual-phase HEAs remains less understood. In this work, selecting a representative AlCr<sub>3</sub>Fe<sub>3</sub>Ni alloy with A2+B2 phases as the base alloy, we systematically investigated the phase evolution induced by various amounts of Ti addition and their differential effects on the sliding wear and solid-particle erosion of AlCr<sub>3</sub>Fe<sub>3</sub>NiTi<sub>x</sub> HEAs (x = 0–1.5, molar ratio). Microstructural analysis reveals that Ti addition promotes the formation of AlNi<sub>2</sub>Ti-type L2<sub>1</sub> and (Fe,Cr)<sub>2</sub>Ti-type C14 Laves phases, both of which strengthen the alloys at the expense of plasticity. However, a low Ti content (i.e., x = 0.2) helps improve both yield strength and plasticity, due to the solid-solution strengthening effect and refinement of grain size. Micro-indentation and scratching tests demonstrate that the C14 Laves phase exhibits the highest hardness but the lowest toughness, whereas the A2+B2 dual-phase structure possesses the highest toughness but the lowest hardness. The L2<sub>1</sub> phase displays intermediate properties between the two. Sliding wear and dry-sand erosion tests reveal that moderate Ti additions enhance wear resistance through solid-solution strengthening, hard-phase reinforcement, and oxidation-induced surface protection. However, erosion resistance deteriorates with increasing Ti content, primarily due to lowered toughness under impact conditions. This study elucidates the dual roles of Ti-induced hard yet brittle phases, i.e., beneficial for sliding wear resistance but detrimental to erosion performance in impact-involving environments requiring higher toughness. The findings provide valuable insights into structure-property relationships for the design of advanced structural and tribo-materials.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"586 ","pages":"Article 206463"},"PeriodicalIF":6.1,"publicationDate":"2025-12-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145749898","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-05DOI: 10.1016/j.wear.2025.206458
T. Bergs , M. Meurer , M. Abouridouane , K. Bobzin , C. Kalscheuer , M. Tayyab
PVD coatings are widely used to improve tool life and machining efficiency, yet accurate tool-life prediction remains challenging because thin layers require very fine meshes, coating wear mechanisms are complex, and the coating-substrate interface introduces difficult thermal and mechanical boundary conditions. Traditional white-box models frequently neglect coating effects due to simplified assumptions, whereas black-box models capture complexity but lack physical interpretability. Grey-box approaches offer a promising compromise but require detailed coating- and load-dependent datasets. This study develops a finite-element (FE) model to predict in-process thermo-mechanical loading on PVD-coated carbide tools. The white-box model supports the extensive experimental testing typically required to generate thermo-mechanical load tables for grey-box tool-life prediction. Monolayer TiAlCrSiN and bilayer TiAlCrSiN/TiAlCrSiON coatings-commercially established and representative of industrial thermal-barrier behaviour were tested in orthogonal cutting of C45 + N steel. Cutting forces and tool temperatures were measured using a dynamometer and an embedded two-colour pyrometer for model validation. The model reproduces forces and temperatures with deviations below 10 % and shows that tool wear strongly affects local thermo-mechanical load distributions, while global loads remain similar between the coatings. Friction characterization reveals a tribological advantage of the bilayer coating, with reduced interface friction and smoother surfaces. High-resolution stress and temperature fields are correlated with coating properties to improve wear modelling and provide structured inputs for future grey-box model development.
{"title":"Development of a white-box model for predicting in-process thermo-mechanical loading on PVD-coated carbide tools","authors":"T. Bergs , M. Meurer , M. Abouridouane , K. Bobzin , C. Kalscheuer , M. Tayyab","doi":"10.1016/j.wear.2025.206458","DOIUrl":"10.1016/j.wear.2025.206458","url":null,"abstract":"<div><div>PVD coatings are widely used to improve tool life and machining efficiency, yet accurate tool-life prediction remains challenging because thin layers require very fine meshes, coating wear mechanisms are complex, and the coating-substrate interface introduces difficult thermal and mechanical boundary conditions. Traditional white-box models frequently neglect coating effects due to simplified assumptions, whereas black-box models capture complexity but lack physical interpretability. Grey-box approaches offer a promising compromise but require detailed coating- and load-dependent datasets. This study develops a finite-element (FE) model to predict in-process thermo-mechanical loading on PVD-coated carbide tools. The white-box model supports the extensive experimental testing typically required to generate thermo-mechanical load tables for grey-box tool-life prediction. Monolayer TiAlCrSiN and bilayer TiAlCrSiN/TiAlCrSiON coatings-commercially established and representative of industrial thermal-barrier behaviour were tested in orthogonal cutting of C45 + N steel. Cutting forces and tool temperatures were measured using a dynamometer and an embedded two-colour pyrometer for model validation. The model reproduces forces and temperatures with deviations below 10 % and shows that tool wear strongly affects local thermo-mechanical load distributions, while global loads remain similar between the coatings. Friction characterization reveals a tribological advantage of the bilayer coating, with reduced interface friction and smoother surfaces. High-resolution stress and temperature fields are correlated with coating properties to improve wear modelling and provide structured inputs for future grey-box model development.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"586 ","pages":"Article 206458"},"PeriodicalIF":6.1,"publicationDate":"2025-12-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145748879","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-04DOI: 10.1016/j.wear.2025.206449
Dongsheng Yang , Zhilong Zhao , Yushan Geng , Qichun Sun , Wenyuan Chen , Juanjuan Chen , Shengyu Zhu , Jun Cheng , Peiqing La
This study successfully developed a (NiCrFe)83(TiAl)17-Al2O3-Ag/(BaF2/CaF2) composite self-lubricating coating and systematically investigated its tribological performance in helium environments from room temperature to 600 °C. The results revealed that the coating possessed a stable high-entropy phase structure consisting of a (Ni, Ti)-enriched BCC matrix and (Cr, Fe)-enriched FCC precipitates. The Al2O3 reinforcement phase increased the surface hardness to 692.17 HV through particle strengthening, representing a 21.3 % improvement over the (NiCrFe)83(TiAl)17 base material. The synergistic effect between the lubricating phases and Al2O3 reduced the friction coefficient to 0.25–0.31 and significantly decreased the wear rate to (0.8–3.5) × 10−5 mm3/N·m within the RT-400 °C range. As temperature increased, the friction interface underwent systematic evolution: a partial lubricating film formed at RT with dominant abrasive wear; the composite lubricating film expanded between 200–400 °C, effectively suppressing three-body wear; at 600 °C, BCC phase depletion caused the wear mechanism to transition to a mixed abrasive-adhesive mode. The synergistic strengthening between Al2O3 and the lubricating phases was identified as the key factor enabling the coating's excellent performance across the wide temperature range.
{"title":"Investigation on the tribological performance of (NiCrFe)83(TiAl)17 high-entropy alloy-matrix self-lubricating coatings in helium environment","authors":"Dongsheng Yang , Zhilong Zhao , Yushan Geng , Qichun Sun , Wenyuan Chen , Juanjuan Chen , Shengyu Zhu , Jun Cheng , Peiqing La","doi":"10.1016/j.wear.2025.206449","DOIUrl":"10.1016/j.wear.2025.206449","url":null,"abstract":"<div><div>This study successfully developed a (NiCrFe)<sub>83</sub>(TiAl)<sub>17</sub>-Al<sub>2</sub>O<sub>3</sub>-Ag/(BaF<sub>2</sub>/CaF<sub>2</sub>) composite self-lubricating coating and systematically investigated its tribological performance in helium environments from room temperature to 600 °C. The results revealed that the coating possessed a stable high-entropy phase structure consisting of a (Ni, Ti)-enriched BCC matrix and (Cr, Fe)-enriched FCC precipitates. The Al<sub>2</sub>O<sub>3</sub> reinforcement phase increased the surface hardness to 692.17 HV through particle strengthening, representing a 21.3 % improvement over the (NiCrFe)<sub>83</sub>(TiAl)<sub>17</sub> base material. The synergistic effect between the lubricating phases and Al<sub>2</sub>O<sub>3</sub> reduced the friction coefficient to 0.25–0.31 and significantly decreased the wear rate to (0.8–3.5) × 10<sup>−5</sup> mm<sup>3</sup>/N·m within the RT-400 °C range. As temperature increased, the friction interface underwent systematic evolution: a partial lubricating film formed at RT with dominant abrasive wear; the composite lubricating film expanded between 200–400 °C, effectively suppressing three-body wear; at 600 °C, BCC phase depletion caused the wear mechanism to transition to a mixed abrasive-adhesive mode. The synergistic strengthening between Al<sub>2</sub>O<sub>3</sub> and the lubricating phases was identified as the key factor enabling the coating's excellent performance across the wide temperature range.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"586 ","pages":"Article 206449"},"PeriodicalIF":6.1,"publicationDate":"2025-12-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145749899","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
As a transformative engineering discipline, additive manufacturing has greatly improved rapid prototyping by dramatically reducing lead times, enabling mass production of complex material types and shapes, and offering unparalleled functionalities in intended applications. In this study, the material and tribological properties of 316L austenitic stainless steel produced through the laser-directed energy deposition (LDED) method are examined at multiple length scales. These analyses include material and tribological characterization, particularly on LDED-induced defects such as cavities containing unfused powders, porosities at micro-to-macro scales, and oxide-rich inclusions. Extensive wear tests using a linear reciprocating wear machine were carried out to evaluate how these defects influence the wear behavior of LDED-printed 316L against hardened 52100 steel balls under dry sliding conditions, specifically targeting the defective regions. The results revealed that oxide-rich inclusions, with a high average Vickers hardness of 855 HV, substantially impair the wear performance of steel balls used, increasing the volumetric wear loss of balls by approximately 130 %. This emphasizes the need to minimize such defects during LDED for superior tribological performance.
{"title":"Effect of chemical and structural defects on the tribological performance of additively manufactured 316L stainless steel: Micro-to-macroscale characterization","authors":"Erfan Salehi , Cagatay Yelkarasi , Puskar Pathak , Venkat Selvamanickam , Amrutha Dinesh , Mathew Kuttolamadom , Ali Erdemir","doi":"10.1016/j.wear.2025.206450","DOIUrl":"10.1016/j.wear.2025.206450","url":null,"abstract":"<div><div>As a transformative engineering discipline, additive manufacturing has greatly improved rapid prototyping by dramatically reducing lead times, enabling mass production of complex material types and shapes, and offering unparalleled functionalities in intended applications. In this study, the material and tribological properties of 316L austenitic stainless steel produced through the laser-directed energy deposition (LDED) method are examined at multiple length scales. These analyses include material and tribological characterization, particularly on LDED-induced defects such as cavities containing unfused powders, porosities at micro-to-macro scales, and oxide-rich inclusions. Extensive wear tests using a linear reciprocating wear machine were carried out to evaluate how these defects influence the wear behavior of LDED-printed 316L against hardened 52100 steel balls under dry sliding conditions, specifically targeting the defective regions. The results revealed that oxide-rich inclusions, with a high average Vickers hardness of 855 HV, substantially impair the wear performance of steel balls used, increasing the volumetric wear loss of balls by approximately 130 %. This emphasizes the need to minimize such defects during LDED for superior tribological performance.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"586 ","pages":"Article 206450"},"PeriodicalIF":6.1,"publicationDate":"2025-12-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145693390","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-04DOI: 10.1016/j.wear.2025.206448
Jianpeng Wu , Ao Ding , Wenya Shu , Heyan Li , Liyong Wang , Chengbing Yang
As a key element in the power transmission of heavy machinery, the wet friction component is essential for maintaining the safe and stable operation of mechanical systems. Its frictional behaviour directly influences transmission efficiency, which makes the study of its wear-related failure particularly important. In particular, the steel disc is composed of 65Mn steel, whereas the friction disc is fabricated from a copper-based powder metallurgy material. This study develops an elastohydrodynamic lubrication (EDL) model based on the microscopic contact characteristics under mixed lubrication, aiming to explore the interface topography and coefficient of friction (COF) of a circularly micro-textured friction component. Furthermore, a statistical model of microscopic wear failure probability (MWFP) is established using a limit state function and Monte Carlo simulation to analyse the microscopic wear failure of the friction component. Test data are used to validate the accuracy of both models. The results show that the EDL model accurately predicts the interface morphology and overall COF of the friction component, while the MWFP effectively estimates the probability of wear failure. Finally, this study examines the surface wear mechanisms exhibited by the micro-textured friction components during testing, particularly copper transfer and self-healing behaviour within the friction material.
{"title":"Microscopic wear failure probability analysis of multiform micro-textured friction component under mixed lubrication","authors":"Jianpeng Wu , Ao Ding , Wenya Shu , Heyan Li , Liyong Wang , Chengbing Yang","doi":"10.1016/j.wear.2025.206448","DOIUrl":"10.1016/j.wear.2025.206448","url":null,"abstract":"<div><div>As a key element in the power transmission of heavy machinery, the wet friction component is essential for maintaining the safe and stable operation of mechanical systems. Its frictional behaviour directly influences transmission efficiency, which makes the study of its wear-related failure particularly important. In particular, the steel disc is composed of 65Mn steel, whereas the friction disc is fabricated from a copper-based powder metallurgy material. This study develops an elastohydrodynamic lubrication (EDL) model based on the microscopic contact characteristics under mixed lubrication, aiming to explore the interface topography and coefficient of friction (COF) of a circularly micro-textured friction component. Furthermore, a statistical model of microscopic wear failure probability (MWFP) is established using a limit state function and Monte Carlo simulation to analyse the microscopic wear failure of the friction component. Test data are used to validate the accuracy of both models. The results show that the EDL model accurately predicts the interface morphology and overall COF of the friction component, while the MWFP effectively estimates the probability of wear failure. Finally, this study examines the surface wear mechanisms exhibited by the micro-textured friction components during testing, particularly copper transfer and self-healing behaviour within the friction material.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"586 ","pages":"Article 206448"},"PeriodicalIF":6.1,"publicationDate":"2025-12-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145798150","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-03DOI: 10.1016/j.wear.2025.206437
Qi Sun , Qian Yang , Haowen Tang , Yuanyu Zhu , Pengfei Yang , Minhao Zhu
In this paper, the impacts of tangential and impact-sliding fretting on the damage behavior of 316L steel in lead-bismuth eutectic at 420 °C were comparatively analyzed, with particular emphasis on the microstructural evolution. The results revealed that abrasive and delamination wear represent the primary damage mechanisms in both fretting modes. However, delamination wear contributes more significantly under tangential fretting, leading to a higher average damage volume. This phenomenon is attributed to fretting-induced dynamic recrystallization beneath the contact interface during tangential fretting. In this mode, significant heat accumulation at the contact interface exceeds the threshold temperature for dynamic recrystallization. Based on these findings, a potential damage evolution model for these two fretting modes is proposed.
{"title":"Comparative study on microstructural evolution and damage behavior of 316L steel under tangential and impact-sliding fretting in liquid lead-bismuth eutectic","authors":"Qi Sun , Qian Yang , Haowen Tang , Yuanyu Zhu , Pengfei Yang , Minhao Zhu","doi":"10.1016/j.wear.2025.206437","DOIUrl":"10.1016/j.wear.2025.206437","url":null,"abstract":"<div><div>In this paper, the impacts of tangential and impact-sliding fretting on the damage behavior of 316L steel in lead-bismuth eutectic at 420 °C were comparatively analyzed, with particular emphasis on the microstructural evolution. The results revealed that abrasive and delamination wear represent the primary damage mechanisms in both fretting modes. However, delamination wear contributes more significantly under tangential fretting, leading to a higher average damage volume. This phenomenon is attributed to fretting-induced dynamic recrystallization beneath the contact interface during tangential fretting. In this mode, significant heat accumulation at the contact interface exceeds the threshold temperature for dynamic recrystallization. Based on these findings, a potential damage evolution model for these two fretting modes is proposed.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"586 ","pages":"Article 206437"},"PeriodicalIF":6.1,"publicationDate":"2025-12-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145693394","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-03DOI: 10.1016/j.wear.2025.206447
Lingling Liu , Xianhui Wang , Hangyu Li , Yuan Fei , Hang Zhang , Zhiren Xue
To unveil the effect of intrinsic material properties, eroded morphology evolution, and electric load characteristics on the bouncing arc behavior of Ag-based contact materials, electrical contact tests were performed on Ag-8wt.%Ni, Ag-8wt.%SnO2, and Ag-4wt.%SnO2-4wt.%Ni contact materials under resistive and inductive loads of 18, 24, and 30 V. The arc duration, eroded morphology, and bounce characteristics were analyzed, and the correlation between contact bounce and arc behavior for the Ag-based contact materials was established. It is found that different arc states are present during each bouncing process and thus exert a profound impact on the make-arc duration. A larger bounce height is observed for the Ag-8wt.%Ni contact material because of its high elastic limit. However, for the Ag-8wt.%SnO2 contact material, greater bouncing energy loss arises from the stress concentration on SnO2 particles. Moreover, good bonding between the Ag matrix and the eroded layer is beneficial to bounce, whereas separation of the eroded layer gives rise to bouncing energy loss, thereby decreasing the bounce. Additionally, because temperature rise and stress release occur at the contact spots due to the rapid response to current, a small bounce height is observed under the resistive load and at higher voltage. In contrast, a large bounce height occurs under the inductive load without the presence of a sharply increased current.
为了揭示材料特性、侵蚀形态演变和电负载特性对ag基触点材料弹跳电弧行为的影响，在Ag-8wt上进行了电触点试验。%倪,Ag-8wt。%SnO2, ag -4wt, %SnO2-4wt。%Ni触点材料在18、24和30 V的电阻性和感性负载下。分析了银基触点材料的电弧持续时间、侵蚀形貌和回弹特性，建立了触点回弹与电弧行为的相关性。研究发现，在每次弹跳过程中，电弧状态都不同，从而对造弧时间产生深远的影响。Ag-8wt的弹跳高度更大。Ni接触材料因其高弹性极限。然而，对于Ag-8wt。在SnO2接触材料中，由于应力集中在SnO2颗粒上，弹跳能损失较大。此外，银基体与侵蚀层之间良好的结合有利于弹跳，而侵蚀层的分离会导致弹跳能量的损失，从而降低弹跳。此外，由于对电流的快速响应导致接触点温度升高和应力释放，因此在电阻负载和较高电压下观察到较小的弹跳高度。相反，在没有急剧增加电流的情况下，在感应负载下会出现较大的反弹高度。
{"title":"Correlation of contact bounce and arc behavior for Ag-based contact materials under resistive and inductive load","authors":"Lingling Liu , Xianhui Wang , Hangyu Li , Yuan Fei , Hang Zhang , Zhiren Xue","doi":"10.1016/j.wear.2025.206447","DOIUrl":"10.1016/j.wear.2025.206447","url":null,"abstract":"<div><div>To unveil the effect of intrinsic material properties, eroded morphology evolution, and electric load characteristics on the bouncing arc behavior of Ag-based contact materials, electrical contact tests were performed on Ag-8wt.%Ni, Ag-8wt.%SnO<sub>2</sub>, and Ag-4wt.%SnO<sub>2</sub>-4wt.%Ni contact materials under resistive and inductive loads of 18, 24, and 30 V. The arc duration, eroded morphology, and bounce characteristics were analyzed, and the correlation between contact bounce and arc behavior for the Ag-based contact materials was established. It is found that different arc states are present during each bouncing process and thus exert a profound impact on the make-arc duration. A larger bounce height is observed for the Ag-8wt.%Ni contact material because of its high elastic limit. However, for the Ag-8wt.%SnO<sub>2</sub> contact material, greater bouncing energy loss arises from the stress concentration on SnO<sub>2</sub> particles. Moreover, good bonding between the Ag matrix and the eroded layer is beneficial to bounce, whereas separation of the eroded layer gives rise to bouncing energy loss, thereby decreasing the bounce. Additionally, because temperature rise and stress release occur at the contact spots due to the rapid response to current, a small bounce height is observed under the resistive load and at higher voltage. In contrast, a large bounce height occurs under the inductive load without the presence of a sharply increased current.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"586 ","pages":"Article 206447"},"PeriodicalIF":6.1,"publicationDate":"2025-12-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145658705","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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