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Evolution of tool wear and machining quality during dry milling of AlCoCrFeNi2.1 eutectic high entropy alloy 干铣 AlCoCrFeNi2.1 共晶高熵合金时刀具磨损和加工质量的变化
IF 5.3 1区 工程技术 Q1 ENGINEERING, MECHANICAL Pub Date : 2024-10-29 DOI: 10.1016/j.wear.2024.205616
Yong Zhao , Jinlong Zhang , Linguang Li , Saurav Goel , Chao Zhang , Xingsheng Wu , Chengwei Kang , Jiang Guo
AlCoCrFeNi2.1, a new class of eutectic high entropy alloy (EHEA) has drawn significant interest owing to the lamellar structure of alternating face-centered cubic (FCC) and B2 phases. Properties such as high strength and high plasticity render the machining of this alloy challenging. Addressing this issue, the milling experiments were conducted under dry conditions to investigate the machining quality of AlCoCrFeNi2.1 EHEA as well as the tool wear. The cutting temperature and cutting force were measured to explain the changes in tool wear and machining quality. The tool wear mechanisms and evolution modes were clarified. Finally, the change of surface roughness and surface morphology under different parameters were analyzed and the characterization method of plastic flow marked by B2 phase was proposed. Results showed that both the cutting temperature and cutting force increase as the milling parameters become larger. The width of flank wear increases with the increase of the cutting speed and the feed rate when the volume of material removal volume is constant. The tool wear modes evolved differently with different cutting parameters, for instance, abrasive wear dominated while the cutting speed was less than 80 m/min, but for higher speeds up to 110 m/min, adhesive wear and coating peeling occurred. As the cutting speed increases further, crater wear on the rake face starts to arise in addition to the flank wear. Abrasive wear and adhesive wear with increasing feed rate were dominant until a certain threshold (0.10 mm/tooth) beyond which the coating peels off the tool. Furthermore, chipping occurred for a higher feed rate of 0.14 mm/tooth. In particular, the formation of tool adhesive wear is mainly caused by the FCC phase adheres. In terms of machining quality, larger cutting parameters will worsen the surface roughness and morphology as well as lead to deeper subsurface plastic flow. The research will be conducive to promoting the applications of AlCoCrFeNi2.1 HEA.
AlCoCrFeNi2.1 是一种新型共晶高熵合金 (EHEA),由于具有面心立方(FCC)和 B2 相交替的层状结构,因此引起了人们的极大兴趣。高强度和高塑性等特性使这种合金的加工具有挑战性。针对这一问题,我们在干燥条件下进行了铣削实验,以研究 AlCoCrFeNi2.1 EHEA 的加工质量以及刀具磨损情况。通过测量切削温度和切削力来解释刀具磨损和加工质量的变化。明确了刀具磨损机理和演变模式。最后,分析了不同参数下表面粗糙度和表面形貌的变化,并提出了以 B2 相为标志的塑性流动表征方法。结果表明,随着铣削参数的增大,切削温度和切削力都会增加。在材料去除量不变的情况下,刀面磨损宽度随切削速度和进给量的增加而增加。刀具磨损模式随切削参数的不同而变化,例如,当切削速度小于 80 m/min 时,磨料磨损占主导地位,但当切削速度达到 110 m/min 时,则出现粘着磨损和涂层剥落。随着切割速度的进一步提高,除了侧面磨损外,耙面上也开始出现凹坑磨损。磨料磨损和粘着磨损随着进给速度的增加而加剧,直到达到一定的临界值(0.10 毫米/齿),涂层才会从刀具上剥落。此外,当进给量达到 0.14 毫米/齿时,会出现崩刃现象。特别是,刀具附着磨损的形成主要是由 FCC 相附着造成的。在加工质量方面,较大的切削参数会使表面粗糙度和形貌恶化,并导致更深的表面下塑性流动。该研究将有利于促进 AlCoCrFeNi2.1 HEA 的应用。
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引用次数: 0
Modeling the competitive relationship between wear and rolling contact fatigue of railway wheel steel 铁路车轮钢磨损与滚动接触疲劳竞争关系建模
IF 5.3 1区 工程技术 Q1 ENGINEERING, MECHANICAL Pub Date : 2024-10-29 DOI: 10.1016/j.wear.2024.205615
Kelian Luo , Xiaolong Liu , Yan Yang , Tao Cong , Fenbo Zhang , Wenjing Wang
Wear and spalling caused by rolling contact fatigue (RCF) are common failure modes on the tread of railway wheels. The competitive relationship between wear and RCF in heavy-haul railway freight wheel steel was investigated. Wear and RCF tests under dry friction and oil lubrication conditions were conducted on the wheel steel with three different hardness of A# (329 HB), B# (341 HB), and C# (355 HB). The outer surface and cross-section of the specimens were observed using a scanning electron microscope and an optical microscope. The results indicate that the failure type of wear dominates the competitive relationship between wear and RCF in the wear tests, and the failure type of RCF dominates the competitive relationship between wear and RCF in the RCF tests. A significant plastic deformation layer was observed on the cross-section of specimens in the wear tests, while noticeable spalling cracks were found on the cross-section of specimens in the RCF tests. The higher the hardness, the deeper the crack propagation. Based on the Archard wear model and a RCF model, a model and a competition coefficient TC were proposed to describe the competition between wear and RCF. when TC1, wear dominates corresponding to the wear tests. when TC1, RCF dominates corresponding to the RCF tests. Wear and RCF are in a relative balanced state when TC1.
由滚动接触疲劳(RCF)引起的磨损和剥落是铁路车轮胎面常见的失效模式。本文研究了重载铁路货运车轮钢磨损和 RCF 之间的竞争关系。对 A# (329 HB)、B# (341 HB) 和 C# (355 HB) 三种不同硬度的车轮钢进行了干摩擦和油润滑条件下的磨损和 RCF 试验。使用扫描电子显微镜和光学显微镜观察了试样的外表面和横截面。结果表明,在磨损试验中,磨损的失效类型主导磨损与 RCF 之间的竞争关系;在 RCF 试验中,RCF 的失效类型主导磨损与 RCF 之间的竞争关系。在磨损试验中,试样横截面上出现了明显的塑性变形层,而在 RCF 试验中,试样横截面上出现了明显的剥落裂纹。硬度越高,裂纹扩展越深。根据 Archard 磨损模型和 RCF 模型,提出了描述磨损和 RCF 之间竞争的模型和竞争系数 TC。当 TC≈1 时,磨损和 RCF 处于相对平衡的状态。
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引用次数: 0
Environmental impact evaluation of wear protection materials 磨损防护材料的环境影响评估
IF 5.3 1区 工程技术 Q1 ENGINEERING, MECHANICAL Pub Date : 2024-10-28 DOI: 10.1016/j.wear.2024.205612
H. Rojacz , D. Maierhofer , G. Piringer
Wear protection materials, especially those for high-temperature service, often contain substantial amounts of chromium, cobalt and/or nickel and/or with embedded hard phases or forming harder intermetallic phases. Due to the comparatively high environmental impact of those elements, more sustainable alternatives must be found. This study presents a life cycle assessment quantifying the environmental impacts of three groups of cast alloys for wear protection: iron-, nickel-, and cobalt-based alloys. The assessment includes the production stage from raw materials extraction to casting (upstream impacts from cradle-to-gate), with the functional unit defined as 1 dm³ wear protection material. Global average process data were used to estimate the environmental impact of the respective alloy. Results indicate that iron-based alloys as studied here cause lower greenhouse gas (GHG) emissions during production (57–103 kg CO2eq/dm³ or 8.4–13.8 t CO2eq/t) compared to nickel-based (185–205 CO2eq/dm³ or 20–22 t CO2eq/t) and cobalt-based alloys (318–347 CO2eq/dm³ or 31.2–39.5 t CO2eq/t). The lowest emissions during production are caused by iron aluminide-based alloys at around 57 kg CO2eq/dm³ or approx. 8.4 t CO2eq/t, which is up to 90 % less than cobalt-based alloys, of up to 60 % less than nickel-based alloys, and around 50 % relative to Cr-rich iron-based alloys. Further, lifetime considerations based on actual wear data of the respective alloys at ambient and elevated temperatures were accounted for, and three different case studies were evaluated, namely abrasive wear at feeder plates, erosive wear on sieves (both at ambient and high temperatures) as well as wear on grate bars of a sintering plant for pig iron. Here, it was shown that the wear materials’ lifetime of wearing materials has a crucial effect on the environmental impact, since a prolonged lifetime reduces the need for spare parts and of replacement of the goods with their embedded carbon footprint. For example, an average hot sieve can achieve GHG emission savings of approx. 50 t CO2eq/a when using an iron-aluminium alloy instead of a cobalt-based wear protection. The exchange of 10 m³ worn grate bars for a sintering plant made of an iron aluminide instead of a white cast iron saves over 500 t CO2eq/a. Further, over 50 % emission savings in other environmental impact categories can be achieved by this measure.
磨损保护材料,尤其是用于高温条件下的磨损保护材料,通常含有大量的铬、钴和/或镍和/或嵌入硬质相或形成较硬的金属间相。由于这些元素对环境的影响相对较大,因此必须找到更具可持续性的替代品。本研究提出了一项生命周期评估,量化了三组用于磨损保护的铸造合金对环境的影响:铁基合金、镍基合金和钴基合金。评估包括从原材料提取到铸造的生产阶段(从摇篮到大门的上游影响),功能单位定义为 1 dm³ 耐磨保护材料。全球平均工艺数据用于估算相应合金对环境的影响。结果表明,与镍基合金(185-205 CO2eq/dm³ 或 20-22 t CO2eq/t)和钴基合金(318-347 CO2eq/dm³ 或 31.2-39.5 t CO2eq/t)相比,本文研究的铁基合金在生产过程中产生的温室气体(GHG)排放量较低(57-103 kg CO2eq/dm³ 或 8.4-13.8 t CO2eq/t)。生产过程中排放量最低的是铝基铁合金,约为 57 kg CO2eq/dm³ 或约 8.4 t CO2eq/t,比钴基合金少达 90%,比镍基合金少达 60%,比富含铬的铁基合金少约 50%。此外,还根据各合金在环境温度和高温条件下的实际磨损数据考虑了使用寿命,并对三个不同的案例进行了评估,即给料板的磨料磨损、筛网的侵蚀磨损(环境温度和高温条件下)以及生铁烧结厂篦条的磨损。研究表明,耐磨材料的使用寿命对环境影响至关重要,因为使用寿命的延长可以减少对备件的需求,并减少因更换而产生的碳足迹。例如,当使用铁铝合金而不是钴基耐磨保护材料时,普通热筛的温室气体排放量可减少约 50 吨 CO2eq/a。将 10 立方米的磨损篦条换成由铝铁合金代替白口铸铁制成的烧结设备,可节省超过 500 吨 CO2eq/a。此外,这项措施还可在其他环境影响类别中实现 50% 以上的减排。
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引用次数: 0
Simulation and experimental verification of the orthogonal friction continuous wear of PTFE-Kevlar fabric liner 聚四氟乙烯-凯夫拉纤维衬里正交摩擦连续磨损的模拟和实验验证
IF 5.3 1区 工程技术 Q1 ENGINEERING, MECHANICAL Pub Date : 2024-10-28 DOI: 10.1016/j.wear.2024.205613
Fangfang Zhang , Yufan An , Yongchuan Duan , Quan Zhang , Zhixuan Wang , Song Zhu , Honglin Wu
Woven fabric liners, which are customizable and maintenance-free, have extensive applications in self-lubricating spherical bearings. However, owing to the orthogonal anisotropy and non-homogeneous characteristics, their frictional and wear behaviors are complex. Currently, average performance testing is primarily based on long-term macroscopic wear experiments. However, unobservable parameters such as mesoscopic stress and pressure distribution in liners are bottlenecks in the experimental exploration of wear sources and mechanisms. Therefore, an innovative strategy for modeling orthogonal friction and continuous wear in non-homogeneous liners is presented. This approach has the potential to overcome experimental limitations and significantly expedite liner design and cost-effective validation. The initial step involves establishing a mesoscopic voxel-based planar model of the liner that maintains the topological relationship during wear processes. This is achieved by introducing a circular voxel mesh and spatial transformation methods. Based on orthogonal friction and wear assumptions, separate constitutive models for orthogonal friction and wear are developed. Using the CETR UMT-3 friction and wear testing machine, GCr15 is selected as the counterface material, the pin disc wear method is adopted to conduct sliding test on PTFE and Kevlar fibers, and the required wear constitutive parameters are fitted. Furthermore, incremental equations for the total wear are derived. An element wear fusion strategy is introduced. This approach leads to the development of a continuous wear algorithm for liners and subsequently to the establishment of a voxel-based finite element model with continuous wear capability in the form of a circular voxel grid. This method transcends experimental methods and allows for the determination of the mesoscopic contact pressure, stress distribution, and variations in the contact material composition patterns of liner. The accuracy of the average macroscopic wear prediction is validated experimentally. This method has the potential for practical applications in bearing design.
可定制且免维护的编织物衬里在自润滑球面轴承中有着广泛的应用。然而,由于其正交各向异性和非均质特性,其摩擦和磨损行为非常复杂。目前,平均性能测试主要基于长期的宏观磨损实验。然而,内衬中的介观应力和压力分布等不可观测参数是实验探索磨损源和磨损机理的瓶颈。因此,本文提出了一种创新策略,用于模拟非均质衬里中的正交摩擦和连续磨损。这种方法有可能克服实验限制,大大加快衬垫设计和成本效益验证。第一步是建立一个基于网格体素的衬垫平面模型,在磨损过程中保持拓扑关系。这是通过引入圆形体素网格和空间变换方法实现的。根据正交摩擦和磨损假设,分别建立了正交摩擦和磨损的构成模型。利用 CETR UMT-3 摩擦磨损试验机,选择 GCr15 作为反面材料,采用针盘磨损法对 PTFE 和 Kevlar 纤维进行滑动测试,并拟合出所需的磨损构成参数。此外,还推导出了总磨损的增量方程。引入了元素磨损融合策略。通过这种方法,开发出了内衬连续磨损算法,并随后建立了基于体素的有限元模型,该模型具有圆形体素网格的连续磨损能力。这种方法超越了实验方法,可以确定衬垫的中观接触压力、应力分布以及接触材料成分模式的变化。实验验证了平均宏观磨损预测的准确性。该方法有望在轴承设计中得到实际应用。
{"title":"Simulation and experimental verification of the orthogonal friction continuous wear of PTFE-Kevlar fabric liner","authors":"Fangfang Zhang ,&nbsp;Yufan An ,&nbsp;Yongchuan Duan ,&nbsp;Quan Zhang ,&nbsp;Zhixuan Wang ,&nbsp;Song Zhu ,&nbsp;Honglin Wu","doi":"10.1016/j.wear.2024.205613","DOIUrl":"10.1016/j.wear.2024.205613","url":null,"abstract":"<div><div>Woven fabric liners, which are customizable and maintenance-free, have extensive applications in self-lubricating spherical bearings. However, owing to the orthogonal anisotropy and non-homogeneous characteristics, their frictional and wear behaviors are complex. Currently, average performance testing is primarily based on long-term macroscopic wear experiments. However, unobservable parameters such as mesoscopic stress and pressure distribution in liners are bottlenecks in the experimental exploration of wear sources and mechanisms. Therefore, an innovative strategy for modeling orthogonal friction and continuous wear in non-homogeneous liners is presented. This approach has the potential to overcome experimental limitations and significantly expedite liner design and cost-effective validation. The initial step involves establishing a mesoscopic voxel-based planar model of the liner that maintains the topological relationship during wear processes. This is achieved by introducing a circular voxel mesh and spatial transformation methods. Based on orthogonal friction and wear assumptions, separate constitutive models for orthogonal friction and wear are developed. Using the CETR UMT-3 friction and wear testing machine, GCr15 is selected as the counterface material, the pin disc wear method is adopted to conduct sliding test on PTFE and Kevlar fibers, and the required wear constitutive parameters are fitted. Furthermore, incremental equations for the total wear are derived. An element wear fusion strategy is introduced. This approach leads to the development of a continuous wear algorithm for liners and subsequently to the establishment of a voxel-based finite element model with continuous wear capability in the form of a circular voxel grid. This method transcends experimental methods and allows for the determination of the mesoscopic contact pressure, stress distribution, and variations in the contact material composition patterns of liner. The accuracy of the average macroscopic wear prediction is validated experimentally. This method has the potential for practical applications in bearing design.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"560 ","pages":"Article 205613"},"PeriodicalIF":5.3,"publicationDate":"2024-10-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142651170","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}
引用次数: 0
Laser cladding Ni60-SiC/Ti3SiC2 self-lubricating composite coatings on IN718 alloy: Wear mechanisms and oxidation behaviors 在 IN718 合金上激光熔覆 Ni60-SiC/Ti3SiC2 自润滑复合涂层:磨损机理和氧化行为
IF 5.3 1区 工程技术 Q1 ENGINEERING, MECHANICAL Pub Date : 2024-10-23 DOI: 10.1016/j.wear.2024.205611
Xiao-Ming Xie , Xiu-Bo Liu , Bo-Ming He , Fei-Zhi Zhang , Ji-Xiang Liang , Xiang-Yu Liu , Jun Zheng
To enhance the service performance of IN718 alloy under severe working conditions, the self-lubricating composite coating of Ni60-SiC/Ti3SiC2 was fabricated on its surface using laser cladding. By systematically analyzing the microstructure and properties of composite coatings, the wear mechanism at different temperatures and the oxidation behavior at 800 °C of coatings were discussed in depth. The results demonstrate that an increase in coatings’ microhardness by a factor of 1.9–3.1 over IN718 was achieved, benefiting from the fine-grained and solid-solution strengthening actions, and the hard phases such as C23C6, Ni3Si, TiC distributed diffusely inside the coatings. The tribological performance of coatings was also significantly improved, in which the coating with 10 wt% Ti3SiC2 added had the lowest wear rates of 2.13 and 3.57 × 10−5 mm3/N·m at RT and 600 °C, respectively, which were reduced by 82.74 % and 87.43 % compared to the substrate. When the test temperature changes from RT to 600 °C, the main wear form of coatings changes from adhesive and abrasive wear to oxidative wear. With the Ti3SiC2 content increasing, the oxide film is gradually dense and uniform, and the oxidation resistance is significantly improved.
为了提高 IN718 合金在恶劣工作条件下的使用性能,采用激光熔覆技术在其表面制造了 Ni60-SiC/Ti3SiC2 自润滑复合涂层。通过系统分析复合涂层的微观结构和性能,深入探讨了涂层在不同温度下的磨损机理和 800 °C 时的氧化行为。结果表明,与 IN718 相比,涂层的显微硬度提高了 1.9-3.1 倍,这得益于细粒度和固溶强化作用,以及涂层内部弥散分布的 C23C6、Ni3Si、TiC 等硬质相。涂层的摩擦学性能也得到了显著改善,其中添加了 10 wt% Ti3SiC2 的涂层在 RT 和 600 °C 下的磨损率最低,分别为 2.13 和 3.57 × 10-5 mm3/N-m,与基体相比分别降低了 82.74 % 和 87.43 %。当测试温度从 RT 变为 600 °C 时,涂层的主要磨损形式从粘着磨损和磨料磨损变为氧化磨损。随着 Ti3SiC2 含量的增加,氧化膜逐渐致密均匀,抗氧化性显著提高。
{"title":"Laser cladding Ni60-SiC/Ti3SiC2 self-lubricating composite coatings on IN718 alloy: Wear mechanisms and oxidation behaviors","authors":"Xiao-Ming Xie ,&nbsp;Xiu-Bo Liu ,&nbsp;Bo-Ming He ,&nbsp;Fei-Zhi Zhang ,&nbsp;Ji-Xiang Liang ,&nbsp;Xiang-Yu Liu ,&nbsp;Jun Zheng","doi":"10.1016/j.wear.2024.205611","DOIUrl":"10.1016/j.wear.2024.205611","url":null,"abstract":"<div><div>To enhance the service performance of IN718 alloy under severe working conditions, the self-lubricating composite coating of Ni60-SiC/Ti<sub>3</sub>SiC<sub>2</sub> was fabricated on its surface using laser cladding. By systematically analyzing the microstructure and properties of composite coatings, the wear mechanism at different temperatures and the oxidation behavior at 800 °C of coatings were discussed in depth. The results demonstrate that an increase in coatings’ microhardness by a factor of 1.9–3.1 over IN718 was achieved, benefiting from the fine-grained and solid-solution strengthening actions, and the hard phases such as C<sub>23</sub>C<sub>6</sub>, Ni<sub>3</sub>Si, TiC distributed diffusely inside the coatings. The tribological performance of coatings was also significantly improved, in which the coating with 10 wt% Ti<sub>3</sub>SiC<sub>2</sub> added had the lowest wear rates of 2.13 and 3.57 × 10<sup>−5</sup> mm<sup>3</sup>/N·m at RT and 600 °C, respectively, which were reduced by 82.74 % and 87.43 % compared to the substrate. When the test temperature changes from RT to 600 °C, the main wear form of coatings changes from adhesive and abrasive wear to oxidative wear. With the Ti<sub>3</sub>SiC<sub>2</sub> content increasing, the oxide film is gradually dense and uniform, and the oxidation resistance is significantly improved.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"560 ","pages":"Article 205611"},"PeriodicalIF":5.3,"publicationDate":"2024-10-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142554483","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}
引用次数: 0
Effect of electrical current on sliding friction and wear mechanisms in a-C and ta-C amorphous Carbon coatings 电流对 a-C 和 ta-C 非晶碳涂层滑动摩擦和磨损机制的影响
IF 5.3 1区 工程技术 Q1 ENGINEERING, MECHANICAL Pub Date : 2024-10-23 DOI: 10.1016/j.wear.2024.205608
Amir M.K. Behtash, A.T. Alpas
This study investigated the sliding wear behaviour of amorphous carbon (a-C) and tetrahedral amorphous carbon (ta-C) coatings, two forms of diamond-like carbon (DLC) coatings, against SAE 52100 steel using a modified ball-on-disk tribometer with applied electrical currents ranging from 100 mA to 1800 mA. It focused on the variations in sliding friction and wear characteristics of these coatings as electrical currents increased under constant load and speed conditions. The a-C coatings exhibited lower coefficient of friction (COF) values and reduced volumetric wear losses up to 1500 mA, while ta-C coatings studied displayed higher wear, similar to uncoated M2 steel, at 300 mA with degradation occurring at low currents, resulting in failure due to severe oxidational wear. The a-C coatings showed no significant electrical damage at these currents. Raman spectroscopy revealed structural changes on the wear tracks of sp2-rich a-C coatings, specifically the formation of graphene layers. In comparison, the wear tracks of sp3-rich ta-C coatings did not display such transformation under the conditions studied. The graphene coverage on the surfaces of the a-C coatings increased with the increase in the current as revealed by the Raman intensity maps of 2D peaks and this increase was accompanied by a higher defect density in the graphene. The low COF of graphene-covered a-C surfaces was consistent with the proposed mechanisms of moisture adsorption. However, at currents exceeding 900 mA, surface temperatures of a-C coatings exceeded 100 °C, impairing graphene's ability to maintain low friction, resulting in an increased COF.
本研究使用改良的球盘摩擦磨损试验仪,在 100 mA 至 1800 mA 的电流范围内,研究了无定形碳(a-C)和四面体无定形碳(ta-C)涂层(两种形式的类金刚石碳(DLC)涂层)与 SAE 52100 钢的滑动磨损行为。重点研究了在恒定负载和速度条件下,随着电流的增加,这些涂层的滑动摩擦和磨损特性的变化。a-C 涂层显示出较低的摩擦系数 (COF) 值,并减少了高达 1500 mA 的体积磨损损耗,而所研究的 ta-C 涂层在 300 mA 时显示出较高的磨损,与未涂层的 M2 钢类似,并在低电流时发生退化,导致因严重氧化磨损而失效。在这些电流下,a-C 涂层没有出现明显的电损伤。拉曼光谱显示,富含 sp2 的 a-C 涂层的磨损轨迹发生了结构变化,特别是形成了石墨烯层。相比之下,在所研究的条件下,富含 sp3 的 ta-C 涂层的磨损轨迹没有出现这种变化。二维峰的拉曼强度图显示,a-C 涂层表面的石墨烯覆盖率随着电流的增加而增加,同时石墨烯的缺陷密度也在增加。石墨烯覆盖的 a-C 表面的 COF 较低,这与所提出的湿气吸附机制是一致的。然而,当电流超过 900 mA 时,a-C 涂层的表面温度超过 100 °C,影响了石墨烯保持低摩擦的能力,导致 COF 增加。
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引用次数: 0
Wear mechanisms and failure analysis of a tool used in refill friction stir spot welding of AA6061-T6 用于 AA6061-T6 填充摩擦搅拌点焊的工具的磨损机理和失效分析
IF 5.3 1区 工程技术 Q1 ENGINEERING, MECHANICAL Pub Date : 2024-10-22 DOI: 10.1016/j.wear.2024.205610
S. Fritsche, F. Schindler, W.S. de Carvalho, S.T. Amancio-Filho
Investigating tool wear in refill friction stir spot welding (RFSSW) is essential for understanding its limitations and improving its efficiency. Increasing the tool's service life is important to push the technology's readiness level and transfer the technology from the laboratory to industrial applications. In this study, the quasi-static lap shear performance of AA6061-T6 similar welded spots was investigated and tool wear was continuously monitored until tool failure at 3450 welding cycles. Furthermore, the fundamentals of the wear mechanisms in RFSSW were further elucidated. The investigation shows that it is possible to achieve steady quasi-static lap shear performance of the spot welds over advancing tool wear by adjusting the heat input to compensate for losses in frictional heat generation efficiency (related to tool profile changes by abrasion). A subsequent tool failure case analysis showed the main causes for the continuous wear degradation of the shoulder. Tool wear was driven by plastic deformation of the hot-work tool steel and subsequent break-out of tool steel ridges, introducing big hard particles into the contact region between the moving and rotating tools. In addition, the formation and detachment of Fe-Al intermetallic compounds counteract with the rotating tools and increase tool wear.
研究填充式搅拌摩擦点焊(RFSSW)中的工具磨损对于了解其局限性和提高效率至关重要。延长工具的使用寿命对于提高技术的准备水平以及将技术从实验室转移到工业应用非常重要。本研究调查了 AA6061-T6 类似焊点的准静态搭接剪切性能,并连续监测了 3450 次焊接循环中的工具磨损,直至工具失效。此外,还进一步阐明了 RFSSW 磨损机制的基本原理。研究表明,通过调整热输入以补偿摩擦生热效率的损失(与磨损导致的工具轮廓变化有关),可以在工具磨损不断加剧的情况下实现稳定的点焊准静态搭接剪切性能。随后的工具失效案例分析表明了肩部持续磨损退化的主要原因。刀具磨损是由热加工刀具钢的塑性变形和随后刀具钢脊的断裂造成的,在移动和旋转刀具之间的接触区域引入了大的硬质颗粒。此外,Fe-Al 金属间化合物的形成和脱落与旋转刀具产生反作用,加剧了刀具磨损。
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引用次数: 0
Synergetic effect of in-situ TiB2 reinforcement and nano precipitation on wear behavior of ZE41 magnesium matrix composite 原位 TiB2 增强和纳米沉淀对 ZE41 镁基复合材料磨损行为的协同效应
IF 5.3 1区 工程技术 Q1 ENGINEERING, MECHANICAL Pub Date : 2024-10-20 DOI: 10.1016/j.wear.2024.205609
S.K. Sahoo, S.K. Panigrahi
The rise in carbon dioxide pollution and energy consumption has increased the demand for lightweight materials such as magnesium in automotive and aerospace industries. However, magnesium alloys face challenges like poor wear resistance and mechanical strength. To overcome these limitations, a promising approach involves developing heterogeneous hybrid microstructures through reinforcement addition and microstructural engineering. This study focuses on the tribological performance of a newly developed in-situ sub-micron sized TiB2/ZE41 composite under various microstructural conditions, comparing it to the unreinforced ZE41 Mg alloy. Wear experiments were conducted using a pin-on-disc tribometer under normal loads of 10, 20, 40, and 60 N at a sliding velocity of 1 m/s. Scanning electron microscopy (SEM) coupled with energy dispersive spectroscopy (EDS) was used to analyze the worn surfaces in order to identify damage types and surface distortions. By correlating worn surface microstructures with test parameters, predominant wear mechanisms for each material condition under specific loads were determined. Results consistently showed that the presence of in-situ TiB2 reinforcements, β-phase, and rare-earth precipitates enhanced wear resistance regardless of the load conditions. Additionally, the study established a scientific understanding of the wear behavior of ZE41 Mg alloy, with and without in-situ TiB2 particles and precipitates, through analysis of dominant wear mechanisms, wear-induced subsurface deformation mechanisms, kernel average misorientation, grain orientation spread, and microhardness evaluation.
二氧化碳污染和能源消耗的增加,增加了汽车和航空航天工业对镁等轻质材料的需求。然而,镁合金面临着耐磨性和机械强度差等挑战。为了克服这些限制,一种很有前景的方法是通过添加强化剂和微结构工程来开发异质混合微结构。本研究的重点是新开发的原位亚微米级 TiB2/ZE41 复合材料在各种微结构条件下的摩擦学性能,并将其与未增强的 ZE41 镁合金进行比较。在 10、20、40 和 60 N 的正常载荷和 1 m/s 的滑动速度下,使用针盘摩擦磨损试验机进行了磨损试验。使用扫描电子显微镜(SEM)和能量色散光谱(EDS)分析磨损表面,以确定损坏类型和表面变形。通过将磨损表面的微观结构与测试参数相关联,确定了每种材料在特定负载条件下的主要磨损机制。结果一致表明,无论负载条件如何,原位 TiB2 增强层、β 相和稀土析出物的存在都能增强耐磨性。此外,该研究还通过分析主要磨损机理、磨损引起的表面下变形机理、晶粒平均错位、晶粒取向扩散和显微硬度评估,建立了对有无原位 TiB2 颗粒和析出物的 ZE41 Mg 合金磨损行为的科学认识。
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引用次数: 0
A comprehensive investigation of the tribological behaviour of α, α+β, and β titanium alloys against a steel counterpart α、α+β 和 β 钛合金与钢的摩擦学行为综合研究
IF 5.3 1区 工程技术 Q1 ENGINEERING, MECHANICAL Pub Date : 2024-10-18 DOI: 10.1016/j.wear.2024.205595
Tania Sola , Pierre Maurel , Laurent Weiss , Eric Fleury , Thierry Grosdidier
The tribological behaviour of three different natures of titanium alloys, the α (T50), α+β (Ti-6Al-4V) and β (Ti-5553), against a steel ball counterpart was investigated for different surface conditions produced by surface severe plastic deformation (SSPD) at room and cryogenic temperatures.
Friction led to the formation of various oxides that acted as third bodies and resulted in different wear regimes referred to as stages I, II, and III. Stage I, the initial abrasive regime under which TiO2-anatase formed, was the only characteristic of the β Ti-5553 alloy behaviour. In addition, stages II and III were observed for the α T50 and α+β Ti-6Al-4V alloys. Stage II is characterised by an increase in the coefficient of friction (COF) associated with the formation of hard TiO2-rutile. Stage III corresponds to the formation of Fe-oxides induced by the steel ball abrasion. While the COF remained steady during stage III for T50, the presence of β-phase in the Ti-6Al-4V destabilised periodically the Fe-oxide layer during stage III and generated repeated sharp drops in the COF values.
Despite increasing hardness and roughness of the treated surfaces, SSPD did not modify the overall mechanisms of abrasion and improved only slightly the tribological properties.
研究了三种不同性质的钛合金--α(T50)、α+β(Ti-6Al-4V)和β(Ti-5553)--在室温和低温下通过表面剧烈塑性变形(SSPD)产生的不同表面条件下与钢球的摩擦学行为。阶段 I 是形成 TiO2-anatase 的初始磨损状态,是 β Ti-5553 合金行为的唯一特征。此外,在 α T50 和 α+β Ti-6Al-4V 合金中还观察到第二和第三阶段。第二阶段的特点是摩擦系数(COF)的增加与硬质 TiO2-Rutile 的形成有关。第三阶段与钢球磨损引起的铁氧化物的形成相对应。虽然 T50 的 COF 在第三阶段保持稳定,但 Ti-6Al-4V 中存在的 β 相在第三阶段周期性地破坏了氧化铁层的稳定性,并导致 COF 值反复急剧下降。
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引用次数: 0
A novel procedure to predict cumulative tool wear in turning based on experimental analysis 基于实验分析的车削累积刀具磨损预测新程序
IF 5.3 1区 工程技术 Q1 ENGINEERING, MECHANICAL Pub Date : 2024-10-18 DOI: 10.1016/j.wear.2024.205607
Andrea Abeni , Aldo Attanasio , José Outeiro , Gerard Poulachon
Tool wear is one of the most challenging issues in manufacturing. In cutting processes, tool-life testing procedures are defined by ISO standards. These standards give the guidelines to perform tool-life testing in terms of workpiece material, tool geometry, tool material, cutting fluid, tool wear assessment, and tool-life evaluation. For determining the useful tool-life, the standards recommend running several tool-life tests at constant cutting speed till reaching a specified value of tool wear, as defined by the selected tool-life criterion. But, in industrial applications, the approach is different. The same tool is often used to make different geometrical features on the same component using different process parameters, depending on the desired geometry and surface quality. Therefore, it is possible to state that the tool accumulates wear over the working time under different cutting conditions. In other words, the tool is subjected to cumulative tool wear. This paper aims to deepen the knowledge about cumulative tool wear, which means the tool wear generated by a combination of different process parameters. An innovative experimental procedure is proposed to determine the useful tool-life when machining a part with the same tool at different process parameters. Cumulative tool flank wear tests were performed on AISI 1045 samples by changing the cutting speed, keeping the other cutting parameters constant. The experimental cumulative flank wear evolution was compared with the theoretical one. Four different machining cycles were tested to simulate different industrial cases. The comparison revealed a good agreement between the prediction and the experimental data.
刀具磨损是制造业中最具挑战性的问题之一。在切削过程中,ISO 标准规定了刀具寿命测试程序。这些标准从工件材料、刀具几何形状、刀具材料、切削液、刀具磨损评估和刀具寿命评估等方面为刀具寿命测试提供了指导。为确定有用刀具寿命,这些标准建议在恒定切削速度下进行多次刀具寿命测试,直到达到所选刀具寿命标准规定的刀具磨损值。但在工业应用中,方法有所不同。根据所需的几何形状和表面质量,同一刀具通常用于在同一部件上使用不同的工艺参数加工不同的几何特征。因此,可以说在不同的切削条件下,刀具在工作时间内会累积磨损。换句话说,刀具的磨损是累积性的。本文旨在加深对累积刀具磨损的认识,即不同工艺参数组合产生的刀具磨损。本文提出了一种创新的实验程序,以确定在不同工艺参数下使用同一刀具加工零件时的有用刀具寿命。在保持其他切削参数不变的情况下,通过改变切削速度,对 AISI 1045 样品进行了刀具侧面累积磨损试验。实验得出的累积侧面磨损演变与理论值进行了比较。测试了四个不同的加工循环,以模拟不同的工业案例。比较结果表明,预测值与实验数据非常吻合。
{"title":"A novel procedure to predict cumulative tool wear in turning based on experimental analysis","authors":"Andrea Abeni ,&nbsp;Aldo Attanasio ,&nbsp;José Outeiro ,&nbsp;Gerard Poulachon","doi":"10.1016/j.wear.2024.205607","DOIUrl":"10.1016/j.wear.2024.205607","url":null,"abstract":"<div><div>Tool wear is one of the most challenging issues in manufacturing. In cutting processes, tool-life testing procedures are defined by ISO standards. These standards give the guidelines to perform tool-life testing in terms of workpiece material, tool geometry, tool material, cutting fluid, tool wear assessment, and tool-life evaluation. For determining the useful tool-life, the standards recommend running several tool-life tests at constant cutting speed till reaching a specified value of tool wear, as defined by the selected tool-life criterion. But, in industrial applications, the approach is different. The same tool is often used to make different geometrical features on the same component using different process parameters, depending on the desired geometry and surface quality. Therefore, it is possible to state that the tool accumulates wear over the working time under different cutting conditions. In other words, the tool is subjected to cumulative tool wear. This paper aims to deepen the knowledge about cumulative tool wear, which means the tool wear generated by a combination of different process parameters. An innovative experimental procedure is proposed to determine the useful tool-life when machining a part with the same tool at different process parameters. Cumulative tool flank wear tests were performed on AISI 1045 samples by changing the cutting speed, keeping the other cutting parameters constant. The experimental cumulative flank wear evolution was compared with the theoretical one. Four different machining cycles were tested to simulate different industrial cases. The comparison revealed a good agreement between the prediction and the experimental data.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"560 ","pages":"Article 205607"},"PeriodicalIF":5.3,"publicationDate":"2024-10-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142531157","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}
引用次数: 0
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