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Transient wear prediction and optimization for water-lubricated stave bearings 水润滑壁轴承瞬态磨损预测与优化
IF 6.1 1区 工程技术 Q1 ENGINEERING, MECHANICAL Pub Date : 2026-01-09 DOI: 10.1016/j.wear.2025.206483
Juan Guo , Ke Xiao , Dongxing Tang
To fill the research gap on the wear behavior of water-lubricated stave bearings (WLSBs) under mixed lubrication conditions, a transient friction–wear model was developed by coupling a transient mixed lubrication model with a transient wear model, incorporating cavitation effects and evolving surface roughness. Two wear models—a modified Archard wear model and a frictional fatigue wear model—were evaluated, showing higher predictive accuracy of the fatigue-based wear model compared with experimental results. Based on this framework, two single-parameter optimization strategies targeting curvature radius and inclination angle of staves were proposed, and their sensitivity to key parameters (number of staves and stave width ratio) was analyzed. Subsequently, a dual-parameter optimization was conducted, and its effectiveness in performance improvements was quantitatively assessed. The results indicate that a negative stave curvature radius coefficient (concave staves) combined with a small number of staves (≤8) and a large stave width ratio (≥0.8), or a moderate inclination angle (0.01°–0.04°) with commonly used stave numbers (6-10) across a wide range of width ratios, can enhance the mixedlubrication and anti-wear performance of WLSBs compared with untreated ones. Moreover, the findings reveal that dual-parameter optimization outperforms single-parameter strategies, particularly in wear reduction, achieving an additional 19–42 % decrease in wear volume under the current operating conditions. This work provides meaningful insights into the design of high-performance water-lubricated bearing systems in engineering applications.
为了填补混合润滑条件下水润滑壁板轴承磨损行为研究的空白,将瞬态混合润滑模型与瞬态磨损模型耦合,建立了考虑空化效应和表面粗糙度变化的瞬态摩擦磨损模型。对两种磨损模型——改进的Archard磨损模型和摩擦疲劳磨损模型进行了评估,结果表明疲劳磨损模型的预测精度高于实验结果。在此框架下,提出了两种以壁板曲率半径和倾角为目标的单参数优化策略,并分析了其对关键参数(壁板数和壁板宽比)的敏感性。随后,进行了双参数优化,并定量评估了其在性能改进方面的有效性。结果表明:与未处理的壁板相比,采用负的壁板曲率半径系数(凹壁)、小的壁板数(≤8)和大的壁板宽比(≥0.8)相结合,或在宽比范围内采用常用的壁板数(6 ~ 10)、适度的倾角(0.01°~ 0.04°)相结合,可以提高壁板的混合润滑和抗磨性能。此外,研究结果表明,双参数优化策略优于单参数优化策略,特别是在减少磨损方面,在当前运行条件下,可将磨损量减少19 - 42%。这项工作为工程应用中高性能水润滑轴承系统的设计提供了有意义的见解。
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引用次数: 0
Novel approach for a compressor blade using ultrasound-assisted chemical mechanical polishing performed by a developed polisher 压缩机叶片采用超声辅助化学机械抛光的新方法
IF 6.1 1区 工程技术 Q1 ENGINEERING, MECHANICAL Pub Date : 2026-01-09 DOI: 10.1016/j.wear.2026.206522
Yaowen Wu , Zhenyu Zhang , Xiaofei Yang , Xibing Zhang , Zhiqiang Li , Yubao Liu , Xiaopei Li , Xiaoping Wu , Hongye Chen
A compressor blade of martensitic stainless steel with complex surface and structure is difficult to machine, due to its wear and corrosion resistance. Mechanical polishing is widely employed to polish the blade, causing the surface roughness Ra >0.3 μm and profile tolerance >0.04 mm. To solve this challenge, a novel approach of immersed ultrasonic-assisted green chemical mechanical polishing (CMP) was developed, which was performed by a new custom-made polisher, regardless of complex surfaces and structures. Novel CMP slurry is proposed, containing silicon carbide, malic acid, serine and hydrogen peroxide. After CMP, surface roughness Ra of a compressor blade reduced from 0.668 to 0.085 μm, decreasing 87.2 %, and material removal rate is 87.6 mm3/h. Prior to and after CMP, profile tolerance is 0.028 mm. Transmission electron microscopy demonstrates that the thickness of damaged layer decreased from 280.16 to 15.24 nm, lowering 94.5 %. A mechanical model of a compressor blade is suggested to investigate the stress exerted by slurry, according to the calculations of computational fluid dynamics. X-ray photoelectron spectroscopy and Fourier transform infrared confirm that hydrogen peroxide oxidized the surface of compressor blade, forming oxides. The oxides were dissolved by the ionized H+ ions from malic acid and serine. Dissolved Fe2+, Fe3+ and Cr3+ ions were chelated by -COOH, -OH and -NH2 affiliated from malic acid and serine. Subsequently, soft oxide layer was removed by slurry. Our proposed novel ultrasonic-assisted green CMP offers new findings to achieve smooth surface with high profile tolerance on the surface of compressor blade, despite of its complex surface and structure.
马氏体不锈钢压气机叶片具有复杂的表面和结构,由于其耐磨损和耐腐蚀,因此难以加工。叶片广泛采用机械抛光,表面粗糙度Ra >;0.3 μm,轮廓公差>;0.04 mm。为了解决这一挑战,研究人员开发了一种浸入式超声辅助绿色化学机械抛光(CMP)的新方法,该方法由一种新型定制抛光机进行,无论复杂的表面和结构如何。提出了含碳化硅、苹果酸、丝氨酸和过氧化氢的新型CMP浆料。经过CMP处理后,压气机叶片表面粗糙度Ra从0.668 μm降低到0.085 μm,降低了87.2%,材料去除率为87.6 mm3/h。CMP前后,型材公差为0.028 mm。透射电镜显示,损伤层厚度由280.16 nm减小到15.24 nm,减小了94.5%。根据计算流体力学的计算,建立了压气机叶片的力学模型来研究浆液对叶片施加的应力。x射线光电子能谱和傅里叶红外变换证实,过氧化氢氧化压气机叶片表面,形成氧化物。氧化物被苹果酸和丝氨酸电离的H+离子溶解。溶解的Fe2+、Fe3+和Cr3+离子被苹果酸和丝氨酸附着的-COOH、-OH和-NH2螯合。随后,用浆料除去软氧化层。我们提出的新型超声辅助绿色CMP为压气机叶片表面的光滑和高轮廓公差提供了新的发现,尽管其表面和结构复杂。
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引用次数: 0
Chemical wear of cemented carbide tools in contact with Cu-Zn alloy – investigated using thermodynamic calculations 用热力学计算方法研究了与Cu-Zn合金接触的硬质合金刀具的化学磨损
IF 6.1 1区 工程技术 Q1 ENGINEERING, MECHANICAL Pub Date : 2026-01-09 DOI: 10.1016/j.wear.2026.206530
F. Ekholm, J. Heinrichs Lindgren, S. Jacobson
Cemented carbide (WC-Co) tools are worn at a very slow rate when shearing Cu-Zn alloy wire into zipper elements. Despite this, the wear is the limiting factor in the operation. Analysis of worn WC-Co from both the zipper production and tribological tests, mimicking the wear caused by the shearing action, indicate that WC grains and Co binder are worn through oxidative mechanisms. The Zn in the alloy is believed to preferentially react with oxygen in the contact. The wear mechanisms are still not fully understood since the wear occurs at a very fine scale, and consequently leaves diminutive damage. In the present study, CALPHAD based thermodynamic calculations, proven successful for studying chemical wear of tool materials in other machining operations, are performed to further investigate the chemical wear of WC-Co against Cu-Zn alloy. Equilibrium conditions are set to represent the tribological contact. This enables the stable phases and their compositions, as well as their driving forces in the contact, to be calculated and coupled, to study possible chemical wear mechanisms.
The calculations indicate that wear of WC-Co is governed by oxidative mechanisms. Zn in the alloy can preferentially react with oxygen and this reduces its availability, so that both WC and Co become thermodynamically stable and thus not oxidise. This calculated effect of Zn becomes stronger with increasing Zn content and is therefore in line with the results from experimental work. This shows that CALPHAD is a suitable approach for investigating fine scale chemical wear of cemented carbides.
在将铜锌合金丝剪切成拉链元件时,硬质合金(WC-Co)工具的磨损速度非常慢。尽管如此,磨损仍然是作业中的限制因素。对拉链生产和摩擦试验中WC-Co磨损的分析,模拟了剪切作用引起的磨损,表明WC颗粒和Co粘结剂通过氧化机制磨损。合金中的Zn在接触中优先与氧反应。由于磨损发生在非常小的尺度上,因此留下的损伤很小,因此磨损机制仍未完全了解。在本研究中,基于CALPHAD的热力学计算被证明是成功的,用于研究其他加工操作中刀具材料的化学磨损,从而进一步研究WC-Co对Cu-Zn合金的化学磨损。设定平衡条件来表示摩擦学接触。这使得稳定相及其组成,以及它们在接触中的驱动力,可以被计算和耦合,以研究可能的化学磨损机制。计算结果表明,WC-Co的磨损受氧化机制控制。合金中的Zn可以优先与氧反应,这降低了它的可用性,因此WC和Co都变得热力学稳定,因此不会氧化。随着锌含量的增加,计算得到的锌的作用越来越强,与实验结果一致。这表明CALPHAD是研究硬质合金细尺度化学磨损的合适方法。
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引用次数: 0
Effect of groove texturing on fretting wear behavior of TC4 under plane/plane contact with dry and grease lubrication 槽织构对干润滑和脂润滑平面/平面接触TC4微动磨损行为的影响
IF 6.1 1区 工程技术 Q1 ENGINEERING, MECHANICAL Pub Date : 2026-01-09 DOI: 10.1016/j.wear.2026.206527
Shenglin Liang , Zeeshan Anjum , Dingjun She , Xuanqi Sun , Qingwen Dai , Wei Huang , Xiaolei Wang
To explore the influence of surface textures, laser-processed grooved textures with varying area ratios were applied to TC4 (Ti-6Al-4V) alloy. Fretting wear tests were conducted using a plane-on-plane contact configuration under dry and grease-lubricated conditions. The results demonstrated that the grooved textures help store wear debris and reduce the energy friction coefficient. However, higher texture area ratios lead to increased contact stress and higher wear rates. Groove orientation also presents significant influence: the grooves in parallel to the direction of motion promoted debris removal, while the perpendicular grooves entrapped more debris. Under grease lubrication, the perpendicular grooves helped to squeeze the stored lubricant into the contact area and reduced the running-in period.
为了探讨表面织构对TC4 (Ti-6Al-4V)合金的影响,采用不同面积比的激光加工槽织构。在干润滑和润滑脂润滑条件下,采用平面对平面接触方式进行微动磨损试验。结果表明,沟槽织构有利于磨损碎片的储存,降低了能量摩擦系数。然而,较高的织构面积比导致接触应力增加和更高的磨损率。沟槽方向也有显著的影响,与运动方向平行的沟槽促进了岩屑的清除,而垂直的沟槽则捕获了更多的岩屑。在润滑脂润滑下,垂直凹槽有助于将储存的润滑剂挤压到接触区域,缩短了磨合期。
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引用次数: 0
Investigation of three-body abrasive wear behavior in TiC particle-reinforced Martensitic/Austenitic multiphase steel TiC颗粒增强马氏体/奥氏体多相钢三体磨粒磨损行为研究
IF 6.1 1区 工程技术 Q1 ENGINEERING, MECHANICAL Pub Date : 2026-01-07 DOI: 10.1016/j.wear.2026.206515
Xin Wang , Aiguo Yao , Zihan Zhang , Shuai Tong , Xinjun Sun
This study systematically investigates the influence of austenite content and its synergistic interaction with TiC particles on wear behavior. A novel “pre-partitioning-quenching” heat treatment process was employed as a key strategy to successfully fabricate TiC particle-reinforced martensite/austenite (M/A) multiphase steels containing 38–57 % metastable reverse austenite (RA). The wear performance of the developed steels was evaluated under wet sand/rubber wheel three-body abrasive wear conditions (ASTM G105-20) and systematically compared with that of commercial NM450 steel at applied loads of 100 N, 170 N, and 225 N. The results demonstrate that, under the tested conditions, the wear resistance of the TiC-free M/A multiphase steel is 1.05–1.29 times higher than that of NM450. Upon addition of 0.31–0.38 wt% Ti, wear resistance is further enhanced and increases with both applied load and RA content. Notably, the 7.5MnTi steel, which exhibits a higher RA fraction, achieves a wear resistance 1.97 times greater than that of NM450, despite having a relatively low hardness of approximately HBW 402. Comprehensive analysis confirms a significant synergistic effect between austenite and TiC. The improvement in wear resistance exceeds the sum of their individual contributions, indicating that these two components collectively enhance the wear resistance through a cooperative mechanism in this wet sand three-body wear environment.
本研究系统地研究了奥氏体含量及其与TiC颗粒的协同作用对磨损行为的影响。采用一种新型的“预分割淬火”热处理工艺,成功制备了含38 ~ 57%亚稳反奥氏体(RA)的TiC颗粒增强马氏体/奥氏体(M/A)多相钢。在湿砂/橡胶轮三体磨料磨损条件下(ASTM G105-20)评价了所开发钢的磨损性能,并与NM450钢在100 N、170 N和225 N载荷下的磨损性能进行了系统比较。结果表明,在试验条件下,无tic的M/A多相钢的耐磨性比NM450高1.05-1.29倍。当添加0.31-0.38 wt% Ti时,耐磨性进一步增强,并且随施加载荷和RA含量的增加而增加。值得注意的是,具有较高RA分数的7.5MnTi钢的耐磨性是NM450的1.97倍,尽管硬度相对较低,约为HBW 402。综合分析证实奥氏体与TiC之间存在显著的协同效应。耐磨性的提高超过了它们各自贡献的总和,说明在这种湿砂三体磨损环境下,这两种成分通过协同机制共同提高了耐磨性。
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引用次数: 0
Stage-dependent protective behavior of Ni-Sn bilayer coating for armature surface damage 镍锡双镀层对电枢表面损伤的阶段性保护行为
IF 6.1 1区 工程技术 Q1 ENGINEERING, MECHANICAL Pub Date : 2026-01-06 DOI: 10.1016/j.wear.2026.206518
Xing Wang , Yongqiang Lin , Haibin Zhou , Ziyi Liu , Deshan Chen , Yuxuan Xu , Donglin Liu , Weihan Liang , Pingping Yao
In electromagnetic rail launch (ERL), the surface damage of the armature is a result of the coupling of multiple damage mechanisms, which evolve progressively during the launch process. In this study, a Ni-Sn bilayer coating was fabricated by electrodeposition to mitigate surface damage of the armature. During ERL testing, the armature and rail surfaces undergo a sequential evolution in damage mechanisms, evolving from mechanical wear to melting-induced damage and ultimately to arc ablation. The use of a Ni-Sn bilayer coating significantly reduced armature surface damage and mass loss as well as improved the contact condition. Mechanism analysis revealed that the lubrication performance of soft-metal Sn, combined with the thermal barrier effect of Ni and its ability to absorb crack energy, jointly contributed to the suppression of mechanical and electrical damage, and the protective function changes with the variation of the contact state. This work provides a promising design strategy for enhancing the durability and reliability of materials used in ERL systems.
在电磁轨道发射中,电枢表面损伤是多种损伤机制耦合的结果,这些损伤机制在发射过程中逐步演化。在本研究中,采用电沉积法制备了一层镍锡双层涂层,以减轻电枢表面的损伤。在ERL测试过程中,电枢和钢轨表面的损伤机制经历了一系列的演变,从机械磨损到熔化损伤,最后到电弧烧蚀。镍锡双层涂层的使用显著减少了电枢表面损伤和质量损失,并改善了接触条件。机理分析表明,软金属Sn的润滑性能与Ni的热障效应及其吸收裂纹能的能力共同起到抑制机械和电气损伤的作用,且保护作用随接触状态的变化而变化。这项工作为提高ERL系统中使用的材料的耐久性和可靠性提供了一种有前途的设计策略。
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引用次数: 0
Toward greener alternative: Comparative tribological study of Sb2O3 and Bi2O3 additives in bonded MoS2-based solid lubricants for aerospace applications 走向更环保的替代品:航空航天应用中结合mos2基固体润滑剂中Sb2O3和Bi2O3添加剂的比较摩擦学研究
IF 6.1 1区 工程技术 Q1 ENGINEERING, MECHANICAL Pub Date : 2026-01-06 DOI: 10.1016/j.wear.2026.206526
Parastoo Fallah , Cara Hensley , Charles J. Beall , Pantcho Stoyanov , Rolf Wuthrich
To mitigate the environmental and health hazards associated with antimony trioxide (Sb2O3) widely used in aerospace solid lubricants, this study investigates bismuth oxide (Bi2O3) as a sustainable alternative additive for bonded molybdenum disulfide (MoS2)-based coatings. MoS2-Bi2O3 coating was fabricated using a spray bonding process and tribologically evaluated against a commercial MoS2-Sb2O3 benchmark (Everlube 620C) under reciprocating sliding conditions. Interfacial phenomena and wear mechanisms were characterized utilizing SEM, FIB, Raman spectroscopy, and XRD. Results indicated that while Bi2O3 possesses a favorable low interaction parameter—chemically suitable for lubricity—the MoS2-Bi2O3 coating exhibited higher friction and wear compared to the Sb2O3-containing baseline. This performance gap is likely attributed to the higher intrinsic hardness and shear strength of Bi2O3, which compromised tribofilm stability, induced micro-cracking, and promoted loose debris formation, thereby intensifying abrasive wear. Conversely, Sb2O3 demonstrated a predominantly shear-driven wear mechanism, likely due to its superior mechanical compatibility with the matrix, facilitating more desirable tribo/transfer film formation and basal plane alignment parallel to the sliding direction. Thus, while the tribological behavior of the MoS2-Sb2O3 coating was governed by the development of a stable tribo/transfer film, the MoS2-Bi2O3 formulation was dominated by fracture-driven wear mechanism. Despite the observed reduction in tribological performance relative to the benchmark, the MoS2-Bi2O3 system yielded performance comparable to—or better than—other eco-friendly alternatives reported in the literature, establishing it as a viable candidate for non-toxic solid lubrication subject to further compositional optimization.
为了减轻三氧化二锑(Sb2O3)在航空航天固体润滑剂中的广泛应用对环境和健康的危害,本研究研究了氧化铋(Bi2O3)作为键合二硫化钼(MoS2)基涂料的可持续替代添加剂。采用喷射结合工艺制备MoS2-Bi2O3涂层,并在往复滑动条件下对商用MoS2-Sb2O3基准(Everlube 620C)进行摩擦学评估。利用扫描电镜(SEM)、FIB、拉曼光谱(Raman spectroscopy)和x射线衍射(XRD)等手段对界面现象和磨损机理进行了表征。结果表明,虽然Bi2O3具有良好的低相互作用参数(化学上适合于润滑),但与含sb2o3的涂层相比,MoS2-Bi2O3涂层具有更高的摩擦磨损性能。这种性能差距可能归因于Bi2O3较高的固有硬度和剪切强度,这损害了摩擦膜的稳定性,诱发微裂纹,促进了松散碎屑的形成,从而加剧了磨粒磨损。相反,Sb2O3表现出主要的剪切驱动磨损机制,可能是由于其与基体的优越机械相容性,促进了更理想的摩擦/转移膜的形成和平行于滑动方向的基面对齐。因此,虽然MoS2-Sb2O3涂层的摩擦学行为是由稳定的摩擦/转移膜的发展决定的,但MoS2-Bi2O3配方是由断裂驱动的磨损机制主导的。尽管与基准相比,MoS2-Bi2O3体系的摩擦学性能有所下降,但其性能与文献中报道的其他环保替代品相当,甚至更好,这使其成为无毒固体润滑的可行候选材料,但需要进一步优化成分。
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引用次数: 0
Sustainable tribological solutions: laser-textured Cr3C2/Cr2O3-coated shaft sleeves 可持续摩擦学解决方案:激光织构Cr3C2/ cr2o3涂层轴套
IF 6.1 1区 工程技术 Q1 ENGINEERING, MECHANICAL Pub Date : 2026-01-06 DOI: 10.1016/j.wear.2026.206525
Masih Paknejad , Robert Bösinger , Bahman Azarhoushang , Andreas Kailer , Georg Konrath , Andreas Killinger , Matthias Blum , Tom Pfindel , Esmaeil Ghadiri Zahrani
Sliding bearings in pumps operating under corrosive and insufficiently lubricated conditions are subjected to high levels of wear and degradation, frequently resulting in accelerated component failure. These bearings typically utilize tungsten carbide with a cobalt binder (WC-Co) due to its superior resistance to wear and corrosion. However, growing concerns regarding the sustainability and limited availability of tungsten and cobalt have intensified the efforts to develop alternative, resource-efficient solutions. To address this challenge, a novel ceramic coating composed of chromium carbide-chromium oxide (Cr3C2/Cr2O3), deposited using high-velocity suspension flame spraying (HVSFS), was evaluated as an environmentally sustainable replacement for WC-Co coatings in sliding bearing applications. Shaft sleeves were coated and subsequently cylindrical grinding was applied to achieve tight dimensional tolerances and optimal surface finish. Ultrashort-pulsed laser surface texturing was then employed to create engineered dimples designed to improve friction behavior under challenging lubrication conditions. A fine cylindrical grinding was subsequently applied to remove residual pile-up and flatten inter-dimple areas. Grinding performance evaluation demonstrated 20 % reduction in tangential grinding force and 37 % improvement in surface roughness (Rz) compared to WC-Co, confirming the coating's suitability for precision finishing. Tribological tests under water-lubricated sliding conditions revealed that laser-textured Cr3C2/Cr2O3 coatings exhibited up to 50 % lower wear mass than non-textured coatings and achieved friction coefficients between 0.02 and 0.04, matching WC-Co performance while showing greater stability and lower variability. In speed-ramped Stribeck testing, laser-textured surfaces maintained reduced friction variability and closely followed the frictional trend of WC-Co, particularly in the boundary-to-mixed lubrication regime. These findings highlight the combined advantages of the proposed coating system in terms of machinability, wear resistance, friction control, and operational consistency, offering a viable and sustainable alternative for high-performance sliding bearing applications in water-lubricated environments.
在腐蚀和润滑不足的条件下运行的泵的滑动轴承受到高度磨损和退化,经常导致部件加速失效。这些轴承通常使用碳化钨与钴粘合剂(WC-Co),因为它具有优异的耐磨损和耐腐蚀性能。然而,对钨和钴的可持续性和有限供应的日益关注,加强了开发替代资源节约型解决方案的努力。为了解决这一挑战,一种由碳化铬-氧化铬(Cr3C2/Cr2O3)组成的新型陶瓷涂层,通过高速悬浮火焰喷涂(HVSFS)沉积,被评估为滑动轴承中WC-Co涂层的环保可持续替代品。对轴套进行涂层处理,然后进行外圆磨削,以获得严格的尺寸公差和最佳的表面光洁度。然后利用超短脉冲激光表面织构技术制造出工程韧窝,以改善在具有挑战性的润滑条件下的摩擦性能。随后采用精细外圆磨削去除残余堆积,并使凹陷间区域平整。磨削性能评估表明,与WC-Co相比,切向磨削力降低了20%,表面粗糙度(Rz)提高了37%,证实了该涂层适合精密加工。水润滑滑动条件下的摩擦学测试表明,激光织构Cr3C2/Cr2O3涂层的磨损质量比非织构涂层低50%,摩擦系数在0.02 ~ 0.04之间,与WC-Co性能相当,同时具有更高的稳定性和更低的变异性。在Stribeck速度斜坡测试中,激光纹理表面保持了较小的摩擦变异性,并密切跟随WC-Co的摩擦趋势,特别是在边界-混合润滑状态下。这些发现突出了涂层系统在可切削性、耐磨性、摩擦控制和操作一致性方面的综合优势,为水润滑环境下的高性能滑动轴承应用提供了可行和可持续的替代方案。
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引用次数: 0
Experimental insights into temperature-dependent fretting fatigue and wear of aluminum conductor 温度依赖性微动疲劳与铝导体磨损的实验研究
IF 6.1 1区 工程技术 Q1 ENGINEERING, MECHANICAL Pub Date : 2026-01-05 DOI: 10.1016/j.wear.2026.206519
Miguel A. Garcia, Ricardo Lenon Da Silva Rodrigues, José Alexander Araújo, Jorge L.A. Ferreira, Cosme Roberto Moreira da Silva
Understanding the combined effects of temperature and cyclic loading on the fretting fatigue behavior of aluminum conductors is essential for reliable power transmission performance. This study investigates the impact of operating and emergency temperatures on the fretting fatigue life of 6201-T81 aluminum alloy wires extracted from 900 MCM All Aluminum Alloy Conductors (AAAC). Fretting fatigue tests were performed at 75 °C, representing standard operating conditions, and 100 °C, corresponding to the maximum emergency temperature permitted for this conductor type. A three-actuator fretting fatigue testing rig, equipped with a heating system capable of maintaining temperature within ±2 °C, was employed. A methodology was developed to achieve precise temperature control in the contact region, and the wire-against-wire fretting fatigue test configuration is detailed. Tests were displacement-controlled, with shear loads applied independently of the cyclic fatigue load. The apparatus successfully reproduced fretting fatigue conditions between aluminum wires, generating elliptical wear marks and maintaining a partial slip regime in accordance with Amontons' law, with clearly defined stick and slip zones. S-N (stress-life) curves were obtained for both temperature conditions. Results revealed a 34.7 % reduction in fatigue life at 75 °C and up to 42.9 % at 100 °C, reflecting temperature- and time-dependent changes in mechanical behavior. SEM analysis confirmed fretting fatigue failure, with larger stick zones observed at elevated temperatures due to thermal softening. Life reductions were attributed to microstructural changes: recovery at 75 °C, increasing ductility and reducing strength, and recrystallization at 100 °C, exceeding the typical recrystallization threshold of 90 °C for the 6201 alloy.
了解温度和循环载荷对铝导体微动疲劳行为的综合影响对可靠的电力传输性能至关重要。研究了工作温度和应急温度对从900 MCM全铝合金导体(AAAC)中提取的6201-T81铝合金丝微动疲劳寿命的影响。微动疲劳试验在75°C(代表标准操作条件)和100°C(对应于该导体类型允许的最高紧急温度)下进行。采用三致动器微动疲劳试验台,配备温度维持在±2°C的加热系统。提出了一种在接触区域实现精确温度控制的方法,并详细介绍了线对线微动疲劳试验配置。试验是位移控制的,剪切载荷独立于循环疲劳载荷。该装置成功地再现了铝线之间的微动疲劳状态,产生椭圆磨损痕迹,并根据Amontons定律保持部分滑移状态,具有明确定义的粘滑区。得到了两种温度下的S-N(应力-寿命)曲线。结果显示,在75°C时疲劳寿命降低34.7%,在100°C时疲劳寿命降低42.9%,这反映了机械行为随温度和时间的变化。扫描电镜分析证实了微动疲劳失效,由于热软化,在高温下观察到更大的粘滞区。显微组织的变化导致了寿命的缩短:75°C时的恢复、延展性的提高和强度的降低,以及100°C时的再结晶,超过了6201合金的典型再结晶阈值90°C。
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引用次数: 0
Friction interface evolution and braking performance of high-speed trains on long downhill slopes under extreme cold environment 极寒环境下高速列车长下坡摩擦界面演化与制动性能
IF 6.1 1区 工程技术 Q1 ENGINEERING, MECHANICAL Pub Date : 2026-01-05 DOI: 10.1016/j.wear.2026.206521
Hang Liu , Zhicheng He , Qixiang Zhang , Caiqi Liao , Kun Xiong , Xiaocui Wang , Chunguang Zhao , Jiliang Mo
As high-speed railways extend into complex terrains, prolonged drag braking on long downhill slopes is required to maintain constant speed. Throughout this process, the friction pair is subjected to the combined effects of frictional heating and ambient temperature, which may cause performance deterioration and compromise braking safety. In this study, full-process “drag-parking” braking tests were conducted at −40 °C and 25 °C using a temperature-controlled braking simulation rig. Multi-scale characterizations, including friction coefficient, temperature rise, surface morphology, wear debris characteristics, and residual stress, were employed to elucidate the thermo–mechanical–wear evolution of the friction interface and its influence on parking braking performance. The results indicate that, under extreme cold conditions, the rapid dissipation of frictional heat promoted crack propagation and the accumulation of hard debris at the interface, while also inducing significant residual stress in the brake disc after braking. The resulting local interlocking effect shortened the braking distance, causing severe fluctuations in the friction coefficient, resulting in poor interface stability and braking controllability. In contrast, at room temperature, substantial heat accumulation enhanced material flow and induced matrix softening of the friction block, intensifying high-temperature adhesive wear and thermal ablation. The resulting exfoliated debris was compacted into a sliding layer, which lowered interfacial shear resistance and led to progressive thermal fade of friction performance, ultimately resulting in a considerable increase in braking distance. This study clarifies the coupled effects of frictional heat generation and ambient thermal exchange on friction interface evolution and parking braking performance, providing theoretical insights and experimental support for the safety assessment and structural optimization of high-speed train braking systems under extreme conditions.
随着高速铁路延伸到复杂的地形,在漫长的下坡上需要长时间的阻力制动来保持恒定的速度。在整个过程中,摩擦副受到摩擦加热和环境温度的综合影响,可能导致性能下降并危及制动安全。在本研究中,使用温控制动模拟装置在- 40°C和25°C下进行了全程“拖停”制动试验。采用摩擦系数、温升、表面形貌、磨损碎片特征和残余应力等多尺度表征,分析了摩擦界面的热-机械-磨损演化过程及其对驻车制动性能的影响。结果表明,在极冷工况下,摩擦热的快速耗散促进了裂纹扩展和界面处硬屑的积累,同时也在制动后的制动盘中产生了显著的残余应力。由此产生的局部联锁效应缩短了制动距离,导致摩擦系数波动剧烈,导致界面稳定性和制动可控性差。相反,在室温下,大量的热积累增强了材料流动,诱导摩擦块的基体软化,加剧了高温粘着磨损和热烧蚀。由此产生的脱落碎屑被压实成滑动层,降低了界面剪切阻力,导致摩擦性能逐渐热衰减,最终导致制动距离大幅增加。本研究阐明了摩擦产热与环境热交换对摩擦界面演化和驻车制动性能的耦合影响,为极端工况下高速列车制动系统的安全性评估和结构优化提供了理论见解和实验支持。
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