IF 5.3 1区工程技术 Q1 ENGINEERING, MECHANICAL

Wear

Pub Date : 2025-01-27 DOI: 10.1016/j.wear.2025.205751

Jiakun Zhang , Zaiyu Xiang , Qixiang Zhang , Shuangxi Feng , Zhou Yu , Xiaocui Wang , Jiliang Mo , Deqiang He

The tribological performance of Cu-based powder metallurgy (PM) friction materials, commonly known as friction blocks, is vital for ensuring effective braking and ride comfort in high-speed trains. Thus, it is essential to identify effective methods to enhance the tribological properties of these materials. This study proposed a floating structure design for friction materials, enhancing their deformation capacity by altering the disc spring material. This innovative approach is intended to improve the tribological performance of Cu-based PM friction materials, ensuring better braking efficiency and ride comfort in high-speed trains. Drag braking simulations were conducted on a custom-built test rig to evaluate high-speed train braking performance using four different disc spring materials. The study focused on analyzing friction-induced vibration and noise (FIVN), along with interface friction and wear behavior. A wear model incorporating dynamic effects was developed, and finite element models (FEM) based on the experimental setup and conditions were created. These models enabled coupled simulations to analyze braking interface wear and friction-induced vibrations (FIV). The results indicate that the 60SM disc spring significantly reduces FIVN, promotes uniform friction block wear, ensures consistent interface contact, and minimizes FIVN levels. In contrast, the 304 disc spring increases contact stiffness at the braking interface, which leads to abnormal wear and higher FIVN levels. Furthermore, the choice of disc spring material directly influences contact stress and deformation in both friction blocks and disc springs, thereby impacting the braking system's dynamic performance and the tribological behavior of Cu-based PM friction materials. Thus, optimizing the deformation capacity of friction materials through floating structure designs emerges as a practical strategy to enhance the tribological performance of Cu-based PM materials in high-speed train braking systems.

{"title":"A method to improve the tribological performance of Cu-based powder metallurgy friction materials for the high-speed trains braking system: Enhancement of the performance of the friction block disc spring","authors":"Jiakun Zhang , Zaiyu Xiang , Qixiang Zhang , Shuangxi Feng , Zhou Yu , Xiaocui Wang , Jiliang Mo , Deqiang He","doi":"10.1016/j.wear.2025.205751","DOIUrl":"10.1016/j.wear.2025.205751","url":null,"abstract":"<div><div>The tribological performance of Cu-based powder metallurgy (PM) friction materials, commonly known as friction blocks, is vital for ensuring effective braking and ride comfort in high-speed trains. Thus, it is essential to identify effective methods to enhance the tribological properties of these materials. This study proposed a floating structure design for friction materials, enhancing their deformation capacity by altering the disc spring material. This innovative approach is intended to improve the tribological performance of Cu-based PM friction materials, ensuring better braking efficiency and ride comfort in high-speed trains. Drag braking simulations were conducted on a custom-built test rig to evaluate high-speed train braking performance using four different disc spring materials. The study focused on analyzing friction-induced vibration and noise (FIVN), along with interface friction and wear behavior. A wear model incorporating dynamic effects was developed, and finite element models (FEM) based on the experimental setup and conditions were created. These models enabled coupled simulations to analyze braking interface wear and friction-induced vibrations (FIV). The results indicate that the 60SM disc spring significantly reduces FIVN, promotes uniform friction block wear, ensures consistent interface contact, and minimizes FIVN levels. In contrast, the 304 disc spring increases contact stiffness at the braking interface, which leads to abnormal wear and higher FIVN levels. Furthermore, the choice of disc spring material directly influences contact stress and deformation in both friction blocks and disc springs, thereby impacting the braking system's dynamic performance and the tribological behavior of Cu-based PM friction materials. Thus, optimizing the deformation capacity of friction materials through floating structure designs emerges as a practical strategy to enhance the tribological performance of Cu-based PM materials in high-speed train braking systems.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"566 ","pages":"Article 205751"},"PeriodicalIF":5.3,"publicationDate":"2025-01-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143140284","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

Investigation on the material removal mechanism of sapphire wafer by novel green slurry in semi-fixed abrasive polishing

IF 5.3 1区工程技术 Q1 ENGINEERING, MECHANICAL

Wear

Pub Date : 2025-01-27 DOI: 10.1016/j.wear.2025.205762

Guangen Zhao , Jianxiong Chen , Yongchao Xu , Cheng Peng , Qianting Wang

It is a great challenge to produce ultra-smooth surface of sapphire wafers at high material removal rate (MRR) using green slurry in semi-fixed abrasive polishing. A novel environmentally friendly polishing slurry was developed by preparing abrasives and complexing agents to improve surface quality and polishing efficiency. The SiO₂ and diamond/SiO₂ composite abrasives were successfully prepared by a simplified sol-gel strategy, exhibiting high purity, homogeneous particle size, and excellent dispersibility. Based on the semi-fixed polishing technology, the green polishing performance of sapphire wafers using different types of abrasives alone and in combination with complexing agents was investigated. The experimental results demonstrated that the novel slurry containing triisopropanolamine (TIPA) and diamond/SiO₂ composite abrasive had superior polishing performance. Compared with the traditional diamond slurry, the surface roughness of the novel slurry was reduced by 24.4 % to 6.2 nm (Ra), while the MRR was increased by 65.4 %. Through electrochemical experiments, molecular simulations, and infrared analysis, the improved polishing performance of the composite abrasives with TIPA may be attributed to the complexation of TIPA and the optimization of interfacial contact behavior. The analysis of wear debris and polished sapphire wafer surface further pointed out that the deformation reduced the indentation depth while enhancing the reactivity of the friction chemistry. The diamond/SiO₂ composite abrasives with TIPA slurry accelerated the generation and removal of the reaction layer consisting of AlOOH, Al-OH, and Al₂Si₂O₇, realizing the optimal synergy between mechanical wear and tribochemistry, which significantly improved the polishing quality.

{"title":"Investigation on the material removal mechanism of sapphire wafer by novel green slurry in semi-fixed abrasive polishing","authors":"Guangen Zhao , Jianxiong Chen , Yongchao Xu , Cheng Peng , Qianting Wang","doi":"10.1016/j.wear.2025.205762","DOIUrl":"10.1016/j.wear.2025.205762","url":null,"abstract":"<div><div>It is a great challenge to produce ultra-smooth surface of sapphire wafers at high material removal rate (MRR) using green slurry in semi-fixed abrasive polishing. A novel environmentally friendly polishing slurry was developed by preparing abrasives and complexing agents to improve surface quality and polishing efficiency. The SiO<sub>2</sub> and diamond/SiO<sub>2</sub> composite abrasives were successfully prepared by a simplified sol-gel strategy, exhibiting high purity, homogeneous particle size, and excellent dispersibility. Based on the semi-fixed polishing technology, the green polishing performance of sapphire wafers using different types of abrasives alone and in combination with complexing agents was investigated. The experimental results demonstrated that the novel slurry containing triisopropanolamine (TIPA) and diamond/SiO<sub>2</sub> composite abrasive had superior polishing performance. Compared with the traditional diamond slurry, the surface roughness of the novel slurry was reduced by 24.4 % to 6.2 nm (Ra), while the MRR was increased by 65.4 %. Through electrochemical experiments, molecular simulations, and infrared analysis, the improved polishing performance of the composite abrasives with TIPA may be attributed to the complexation of TIPA and the optimization of interfacial contact behavior. The analysis of wear debris and polished sapphire wafer surface further pointed out that the deformation reduced the indentation depth while enhancing the reactivity of the friction chemistry. The diamond/SiO<sub>2</sub> composite abrasives with TIPA slurry accelerated the generation and removal of the reaction layer consisting of AlOOH, Al-OH, and Al<sub>2</sub>Si<sub>2</sub>O<sub>7</sub>, realizing the optimal synergy between mechanical wear and tribochemistry, which significantly improved the polishing quality.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"566 ","pages":"Article 205762"},"PeriodicalIF":5.3,"publicationDate":"2025-01-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143140714","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

Modeling on cutting force considering tool flank wear in ultrasonic vibration-assisted milling Ti3Al

IF 5.3 1区工程技术 Q1 ENGINEERING, MECHANICAL

Wear

Pub Date : 2025-01-27 DOI: 10.1016/j.wear.2025.205761

Guofu Gao, Yunfei Xiang, Huai Qiao, Chenyang Wei, Guangmiao Wang, Daohui Xiang

Ti₃Al compounds have potential applications in the aerospace field because of their exceptional mechanical performance at high temperatures, while poor processability becomes the main bottleneck of their applications. This study aims to analyze the tool wear characteristics of the tool flank and their impact on cutting forces during ultrasonic vibration-assisted milling (UVAM) of Ti₃Al compounds, with the goal of optimizing cutting parameters and improving machining efficiency. Based on the oblique cutting theory, a milling force model that accounts for tool flank wear was developed. Ti₃Al workpieces were subjected to side-milling and up-milling on an UVAM platform. The wear characteristics of the tool and the variations in cutting force with respect to different milling lengths, cutting parameters, and ultrasonic amplitudes were analyzed. The results show that the wear condition of tool flank has a direct impact on cutting force. The cutting force prediction model that incorporates tool wear demonstrated higher accuracy, with average relative deviations of 9.13 % and 13.38 % for the F_x and F_y components, respectively. Adhesive wear is the primary type of tool wear throughout the machining process. Compared to conventional milling (CM), UVAM significantly reduces tool wear, with the wear rate decreasing by approximately 38.4 %, but a too-large amplitude causes additional stress and damage to the tool surface. The research demonstrates that reasonably controlling the cutting parameters and ultrasonic amplitude is effective to slow down the tool wear and lower the cutting force, resulting in good surface quality and machining efficiency.

{"title":"Modeling on cutting force considering tool flank wear in ultrasonic vibration-assisted milling Ti3Al","authors":"Guofu Gao, Yunfei Xiang, Huai Qiao, Chenyang Wei, Guangmiao Wang, Daohui Xiang","doi":"10.1016/j.wear.2025.205761","DOIUrl":"10.1016/j.wear.2025.205761","url":null,"abstract":"<div><div>Ti<sub>3</sub>Al compounds have potential applications in the aerospace field because of their exceptional mechanical performance at high temperatures, while poor processability becomes the main bottleneck of their applications. This study aims to analyze the tool wear characteristics of the tool flank and their impact on cutting forces during ultrasonic vibration-assisted milling (UVAM) of Ti<sub>3</sub>Al compounds, with the goal of optimizing cutting parameters and improving machining efficiency. Based on the oblique cutting theory, a milling force model that accounts for tool flank wear was developed. Ti<sub>3</sub>Al workpieces were subjected to side-milling and up-milling on an UVAM platform. The wear characteristics of the tool and the variations in cutting force with respect to different milling lengths, cutting parameters, and ultrasonic amplitudes were analyzed. The results show that the wear condition of tool flank has a direct impact on cutting force. The cutting force prediction model that incorporates tool wear demonstrated higher accuracy, with average relative deviations of 9.13 % and 13.38 % for the <em>F</em><sub><em>x</em></sub> and <em>F</em><sub><em>y</em></sub> components, respectively. Adhesive wear is the primary type of tool wear throughout the machining process. Compared to conventional milling (CM), UVAM significantly reduces tool wear, with the wear rate decreasing by approximately 38.4 %, but a too-large amplitude causes additional stress and damage to the tool surface. The research demonstrates that reasonably controlling the cutting parameters and ultrasonic amplitude is effective to slow down the tool wear and lower the cutting force, resulting in good surface quality and machining efficiency.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"566 ","pages":"Article 205761"},"PeriodicalIF":5.3,"publicationDate":"2025-01-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143140711","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

Particle erosion behavior of La2(ZrxCe1-x)2O7/YSZ double ceramic layers TBCs deposited by electron beam-physical vapor deposition

IF 5.3 1区工程技术 Q1 ENGINEERING, MECHANICAL

Wear

Pub Date : 2025-01-25 DOI: 10.1016/j.wear.2025.205763

Lizhe Wang, Limin He, Rujing Zhang, Zhenhua Xu, Rende Mu

La₂(Zr_xCe_1-x)₂O₇/YSZ (LZC/YSZ) double ceramic layers (DCL) thermal barrier coatings (TBCs) have attracted extensive attentions due to their low thermal conductivity and good thermal stability. Particle erosion of DCL TBCs is one of the typical degradation patterns. Here, LZC/YSZ DCL TBCs samples deposited by electron beam-physical vapor deposition (EB-PVD) underwent solid particle erosion test for different time. Characterization of microstructure evolution is implemented using correlative methods, which links together the observations and analysis from X-ray diffraction (XRD), scanning electron microscopy (SEM) and white light scanning interferometry (WLSI). The erosion rates for LZC/YSZ DCL TBCs were determined after exposure to varying durations of erosion. During the initial erosion stages, the predominant degradation mechanism involved the removal of ceramic material. This was attributed to the compaction and cracking of the near-surface columns, causing a progressive thinning of the coating in a layer-by-layer manner. This pattern of degradation also occurred at the LZC/YSZ interface, indicating a relatively good adhesive bond between the LZC and YSZ layers. In the later stages of erosion, the formation of deep cracks, erosion craters, and the emergence of horizontal cracks within the bottom of YSZ layer contributed to block spalling, consequently increasing the erosion rate.

{"title":"Particle erosion behavior of La2(ZrxCe1-x)2O7/YSZ double ceramic layers TBCs deposited by electron beam-physical vapor deposition","authors":"Lizhe Wang, Limin He, Rujing Zhang, Zhenhua Xu, Rende Mu","doi":"10.1016/j.wear.2025.205763","DOIUrl":"10.1016/j.wear.2025.205763","url":null,"abstract":"<div><div>La<sub>2</sub>(Zr<sub>x</sub>Ce<sub>1-x</sub>)<sub>2</sub>O<sub>7</sub>/YSZ (LZC/YSZ) double ceramic layers (DCL) thermal barrier coatings (TBCs) have attracted extensive attentions due to their low thermal conductivity and good thermal stability. Particle erosion of DCL TBCs is one of the typical degradation patterns. Here, LZC/YSZ DCL TBCs samples deposited by electron beam-physical vapor deposition (EB-PVD) underwent solid particle erosion test for different time. Characterization of microstructure evolution is implemented using correlative methods, which links together the observations and analysis from X-ray diffraction (XRD), scanning electron microscopy (SEM) and white light scanning interferometry (WLSI). The erosion rates for LZC/YSZ DCL TBCs were determined after exposure to varying durations of erosion. During the initial erosion stages, the predominant degradation mechanism involved the removal of ceramic material. This was attributed to the compaction and cracking of the near-surface columns, causing a progressive thinning of the coating in a layer-by-layer manner. This pattern of degradation also occurred at the LZC/YSZ interface, indicating a relatively good adhesive bond between the LZC and YSZ layers. In the later stages of erosion, the formation of deep cracks, erosion craters, and the emergence of horizontal cracks within the bottom of YSZ layer contributed to block spalling, consequently increasing the erosion rate.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"566 ","pages":"Article 205763"},"PeriodicalIF":5.3,"publicationDate":"2025-01-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143140285","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

Influencing factors on high temperature tribology

IF 5.3 1区工程技术 Q1 ENGINEERING, MECHANICAL

Wear

Pub Date : 2025-01-25 DOI: 10.1016/j.wear.2025.205758

Tobias König , Eduard Wolf , Philipp Daum , Dominik Kürten , Andreas Kailer , Martin Dienwiebel

This study investigates the influence of temperatures, normal force, displacement, frequency and sliding distance on the tribological material behaviour of an unlubricated cobalt-based material pairing, as well as the effects resulting from a change of atmosphere from ambient air to a low-oxygen CO₂/N₂/O₂-atmosphere. The subsequent identification of empirical wear correlations should enable a transfer to other material systems. Reciprocating wear tests were carried out at up to 800 °C with a cylinder-on-plate contact geometry. The test conditions and the material are based on the application as exhaust gas flap plain bearings for combustion engines.

The temperature has a major influence on the wear behaviour, as it induces the change of tribological mechanisms from abrasion to oxidation and adhesion of wear particles to the formation of a glaze layer in the HT range. The wear particles, required for the tribologically induced sintering process of the glaze layer, are already present in fully oxidised form at low temperatures of 200 °C. The formation of a wear-reducing glaze layer is therefore mainly dependent on the temperature, as this directly influences the sintering process, according to a key finding of this work. The atmospheric influence on the tribological material behaviour is dependent on the temperature related wear regime. For lower temperatures, a mechanism change from abrasion to adhesion takes place in the oxygen-reduced CO₂/N₂/O₂-atmosphere. In contrast, the formation of the glaze layer is not influenced by the change in atmosphere. Moreover, the influence of normal force, displacement and sliding distance differs between the various temperature sections and the related tribological mechanisms.

{"title":"Influencing factors on high temperature tribology","authors":"Tobias König , Eduard Wolf , Philipp Daum , Dominik Kürten , Andreas Kailer , Martin Dienwiebel","doi":"10.1016/j.wear.2025.205758","DOIUrl":"10.1016/j.wear.2025.205758","url":null,"abstract":"<div><div>This study investigates the influence of temperatures, normal force, displacement, frequency and sliding distance on the tribological material behaviour of an unlubricated cobalt-based material pairing, as well as the effects resulting from a change of atmosphere from ambient air to a low-oxygen CO<sub>2</sub>/N<sub>2</sub>/O<sub>2</sub>-atmosphere. The subsequent identification of empirical wear correlations should enable a transfer to other material systems. Reciprocating wear tests were carried out at up to 800 °C with a cylinder-on-plate contact geometry. The test conditions and the material are based on the application as exhaust gas flap plain bearings for combustion engines.</div><div>The temperature has a major influence on the wear behaviour, as it induces the change of tribological mechanisms from abrasion to oxidation and adhesion of wear particles to the formation of a glaze layer in the HT range. The wear particles, required for the tribologically induced sintering process of the glaze layer, are already present in fully oxidised form at low temperatures of 200 °C. The formation of a wear-reducing glaze layer is therefore mainly dependent on the temperature, as this directly influences the sintering process, according to a key finding of this work. The atmospheric influence on the tribological material behaviour is dependent on the temperature related wear regime. For lower temperatures, a mechanism change from abrasion to adhesion takes place in the oxygen-reduced CO<sub>2</sub>/N<sub>2</sub>/O<sub>2</sub>-atmosphere. In contrast, the formation of the glaze layer is not influenced by the change in atmosphere. Moreover, the influence of normal force, displacement and sliding distance differs between the various temperature sections and the related tribological mechanisms.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"566 ","pages":"Article 205758"},"PeriodicalIF":5.3,"publicationDate":"2025-01-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143140707","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Characterizing wear performance of tyre tread rubber

IF 5.3 1区工程技术 Q1 ENGINEERING, MECHANICAL

Wear

Pub Date : 2025-01-25 DOI: 10.1016/j.wear.2025.205754

Chen Liu, David Cebon

Understanding the wear of tyre tread rubber is important for tyre design. A ’local wear law’ is needed in models of tyre contact mechanics to quantify wear on tyres. Previous studies on local wear laws faced limitations in temperature control or low frictional power, prompting the design of a new test rig to address these issues. The new rig was designed to measure wear under varying vertical loads, sliding speeds and contact temperature, with wear quantified by the mass loss of rubber samples.

Results indicated that on different sandpapers, wear rates normalised by area and sliding distance (giving units of kg/m³) were approximately proportional to vertical pressure and changed linearly with sliding speed, with a positive intercept. This is indicative of a ’machining’ process down to zero speed. When the measure of wear was normalised by sliding time (giving units of kg/m²

\cdot

s), the wear law aligned with power laws measured in previous literature.

引用次数: 0

A comparative analysis of abrasive wear behaviors and mechanisms of pearlitic and carbide-free bainitic steels for grinding mill liners under varied impact loads

IF 5.3 1区工程技术 Q1 ENGINEERING, MECHANICAL

Wear

Pub Date : 2025-01-25 DOI: 10.1016/j.wear.2025.205765

Weiming Liu , Tao Jiang , Shizhong Wei , Liujie Xu , Chong Chen , Hua Yu , Xin Jin , Huiling Ding , Chao Zhang , Kunming Pan

A mill liner is a critical wear-resistant component in mineral crushing equipment, and its main failure mode is impact abrasive wear. This study examined carbide-free bainitic steel and pearlitic steel, which are commonly utilized in commercial liners. The wear behavior and wear mechanism of the two wear-resistant steels under different impact loads were revealed through characterization and testing of their microstructure, mechanical properties, and impact abrasive wear performance. The results indicated that under impact loads of 1, 3, and 5 J, the impact abrasive wear resistance of the carbide-free bainitic steel was superior to that of the pearlitic steel. The wear resistance of the pearlitic steel increased nearly linearly with increasing impact load, whereas the wear resistance of the carbide-free bainitic steel exhibited a nonlinear trend, initially decreasing and then increasing with higher impact loads. Under an impact load of 1 J, both samples primarily exhibited micro-cutting as the main wear mechanism, whereas the pearlitic steel demonstrated additional features such as micro-indentation and spalling. Under impact loads of 3 and 5 J, the main wear mechanisms for both samples were micro-cracking and micro-fatigue caused by abrasive impact. Compared with pearlitic steel, carbide-free bainitic steel demonstrated better resistance to delamination, especially under higher impact loads. This study provides guidance for designing tailored liner materials for different impact loads and lays theoretical foundation for extensive application of bainitic steel liners.

{"title":"A comparative analysis of abrasive wear behaviors and mechanisms of pearlitic and carbide-free bainitic steels for grinding mill liners under varied impact loads","authors":"Weiming Liu , Tao Jiang , Shizhong Wei , Liujie Xu , Chong Chen , Hua Yu , Xin Jin , Huiling Ding , Chao Zhang , Kunming Pan","doi":"10.1016/j.wear.2025.205765","DOIUrl":"10.1016/j.wear.2025.205765","url":null,"abstract":"<div><div>A mill liner is a critical wear-resistant component in mineral crushing equipment, and its main failure mode is impact abrasive wear. This study examined carbide-free bainitic steel and pearlitic steel, which are commonly utilized in commercial liners. The wear behavior and wear mechanism of the two wear-resistant steels under different impact loads were revealed through characterization and testing of their microstructure, mechanical properties, and impact abrasive wear performance. The results indicated that under impact loads of 1, 3, and 5 J, the impact abrasive wear resistance of the carbide-free bainitic steel was superior to that of the pearlitic steel. The wear resistance of the pearlitic steel increased nearly linearly with increasing impact load, whereas the wear resistance of the carbide-free bainitic steel exhibited a nonlinear trend, initially decreasing and then increasing with higher impact loads. Under an impact load of 1 J, both samples primarily exhibited micro-cutting as the main wear mechanism, whereas the pearlitic steel demonstrated additional features such as micro-indentation and spalling. Under impact loads of 3 and 5 J, the main wear mechanisms for both samples were micro-cracking and micro-fatigue caused by abrasive impact. Compared with pearlitic steel, carbide-free bainitic steel demonstrated better resistance to delamination, especially under higher impact loads. This study provides guidance for designing tailored liner materials for different impact loads and lays theoretical foundation for extensive application of bainitic steel liners.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"566 ","pages":"Article 205765"},"PeriodicalIF":5.3,"publicationDate":"2025-01-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143140279","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

Coating material loss and surface roughening due to leading edge erosion of wind turbine blades: Probabilistic analysis

IF 5.3 1区工程技术 Q1 ENGINEERING, MECHANICAL

Wear

Pub Date : 2025-01-25 DOI: 10.1016/j.wear.2025.205755

Antonios Tempelis, Leon Mishnaevsky Jr.

This study presents a novel approach for the prediction of random erosion roughness patterns of leading edge protection coatings for wind turbine blades. The predictions can be used for determining the effect on aerodynamic performance and provide decision support for repairs. The model removes coating material fragments from the surface of the blade based on a Weibull failure probability function. Input from rain erosion tests of a coating material are used to fit the parameters of the failure probability function and the predictions are validated with data from available literature. Predictions for the time required to reach full breakthrough of the coating layer are made for tip speeds between 90–120 m/s. For tip speeds larger than 100 m/s, the examined coating is predicted to experience significant damage within a few months after installation. The sequence of rain events with different rain intensities was also found to have a significant effect on the amount of surface damage. Using droplet size distributions based on measurements was predicted to lead to different coating lifetimes than when using Best’s droplet size distribution. Measurements of erosion craters from rain erosion test samples were used to define a size distribution for failed coating fragments. A machine learning approach for automatic parameter fitting based on erosion depth data from tests is also presented.

{"title":"Coating material loss and surface roughening due to leading edge erosion of wind turbine blades: Probabilistic analysis","authors":"Antonios Tempelis, Leon Mishnaevsky Jr.","doi":"10.1016/j.wear.2025.205755","DOIUrl":"10.1016/j.wear.2025.205755","url":null,"abstract":"<div><div>This study presents a novel approach for the prediction of random erosion roughness patterns of leading edge protection coatings for wind turbine blades. The predictions can be used for determining the effect on aerodynamic performance and provide decision support for repairs. The model removes coating material fragments from the surface of the blade based on a Weibull failure probability function. Input from rain erosion tests of a coating material are used to fit the parameters of the failure probability function and the predictions are validated with data from available literature. Predictions for the time required to reach full breakthrough of the coating layer are made for tip speeds between 90–120 m/s. For tip speeds larger than 100 m/s, the examined coating is predicted to experience significant damage within a few months after installation. The sequence of rain events with different rain intensities was also found to have a significant effect on the amount of surface damage. Using droplet size distributions based on measurements was predicted to lead to different coating lifetimes than when using Best’s droplet size distribution. Measurements of erosion craters from rain erosion test samples were used to define a size distribution for failed coating fragments. A machine learning approach for automatic parameter fitting based on erosion depth data from tests is also presented.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"566 ","pages":"Article 205755"},"PeriodicalIF":5.3,"publicationDate":"2025-01-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143140286","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Characterization of oxidative processes associated to low-severity tire tread wear

IF 5.3 1区工程技术 Q1 ENGINEERING, MECHANICAL

Wear

Pub Date : 2025-01-24 DOI: 10.1016/j.wear.2025.205753

C. Chanal , J. Galipaud , B. Moreaux , J.-L. Loubet , P. Sotta

As the tire tread wears throughout its lifetime, particles are generated due to small-scale fracture processes. Friction and wear may also involve physico-chemical degradation of the material. In this paper, the chemical effects associated to low-severity wear of filled Styrene Butadiene Rubber (SBR)/cis-Butadiene Rubber (BR) materials were investigated. Laboratory wear tests were performed using a home-made rotary tribometer in which intermittent sliding contacts on a slightly rough granite surface are applied. This enables imitating real conditions in terms of kinematics and dynamics of the contact for tire treads. The resulting wear patterns were analyzed through X-ray Photoelectron Spectroscopy (XPS) and Scanning Electron Microscopy (SEM). The results show that sulfur oxidation occurs concomitantly to wear. Besides, thermal measurements reveal no significant temperature increase at the sample surface during the wear tests. This suggests that the observed chemical changes are not thermally activated but are instead due to mechanical phenomena related to interface shear. Analysis of the wear debris indicates that their chemical composition is consistent with that of the wear patterns.

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引用次数: 0

Integrated approach to machinability and optimization of nitronic-50 with uncoated carbides

IF 5.3 1区工程技术 Q1 ENGINEERING, MECHANICAL

Wear

Pub Date : 2025-01-22 DOI: 10.1016/j.wear.2025.205750

Ayan Banerjee, Kalipada Maity

Nitronic-50 has been dry-turned with uncoated carbides at three distinct levels of cutting velocities, feeds and cutting depths following a face-centered central composite design. Responses in the form of tangential cutting force, tool-tip temperature, flank wear, material removal rate and surface roughness have been thoroughly studied. Wear characteristics showed prevalence of attrition, abrasion, micro-pitting, grooving and spalling as the major forms. Simulated wear was studied using Usui's tool wear criteria. Depth of cut and cutting velocity significantly influenced tangential cutting force, tool-tip temperature and MRR, while feed rate was the prime factor affecting surface roughness. Experimental outcomes showed strong agreement with predictive models, bearing low error percentages and high R-squared values validating their reliability. Further process parameters have been optimized using MCDM and hybridized MCDM integrated metaheuristic techniques. Optimization results advocate of 66.8297 m/min as cutting velocity, 0.08 mm/rev as feed and 0.1 mm as cutting depth obtained with TLBO. Least surface roughness was recorded with MOORA-based Taguchi optimized set, consisting of 100 m/min as cutting velocity, 0.08 mm/rev as feed and 0.5 mm as cutting depth, while highest material removal rate was obtained under optimized sets of MOORA or MOORA-based TLBO, both of which consisted of higher levels of parametric settings. The TLBO-optimized conditions offered reductions of up to 51.94 % in tangential cutting force, 66.67 % in tool-tip temperature, and 57.41 % in flank wear as compared to alternative optimal setups. Surface roughness was 19.64 % lower than MOORA optimization, while MRR was marginally lower, indicating productivity-tool wear trade-offs.

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引用次数: 0

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