IF 6.1 1区工程技术 Q1 ENGINEERING, MECHANICAL

Wear

Pub Date : 2026-03-15 Epub 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

Friction and wear prediction of copper-free resin-based brake materials: A hybrid PSO-FPA-BP neural network approach 无铜树脂基制动材料的摩擦磨损预测：混合PSO-FPA-BP神经网络方法

IF 6.1 1区工程技术 Q1 ENGINEERING, MECHANICAL

Wear

Pub Date : 2026-03-15 Epub Date: 2026-01-12 DOI: 10.1016/j.wear.2026.206536

Kaikui Zheng , Qing Le , Ling Pan , Jianmeng Huang

Copper-free resin-based brake materials are multicomponent composites comprising both organic and inorganic constituents. Their friction and wear behavior is governed by complex nonlinear interactions among various components and temperature, making accurate prediction through conventional approaches difficult. To overcome this challenge, the present study investigates a novel copper-free resin-based brake material reinforced with foundry waste sand, and proposes a back-propagation (BP) neural network model optimized by a hybrid Particle Swarm Optimization–Flower Pollination Algorithm (PSO-FPA), referred to as PSO-FPA-BP, for precise prediction of the material's friction and wear properties. Orthogonal analysis of variance (ANOVA) was employed to examine the correlations between the friction coefficient, wear rate, and raw material composition, with the optimal formulation determined through range analysis. The data derived from orthogonal experiments served as the training set for model development. Using the principal material components and temperature as input variables, and the friction coefficient and wear rate as outputs, the PSO-FPA-BP prediction model was constructed. Comparative evaluations against BP neural networks optimized solely by the Flower Pollination Algorithm (FPA-BP) or the Particle Swarm Optimization algorithm (PSO-BP) revealed that the PSO-FPA-BP model achieved superior predictive accuracy, with coefficients of determination (R²) of 0.879 for the friction coefficient and 0.979 for the wear rate. Furthermore, friction and wear tests were conducted using the optimized formulation to generate validation data. The results indicated that the prediction accuracy of the PSO-FPA-BP model reached 95.005 % for the friction coefficient and 88.021 % for the wear rate on the validation samples, confirming the model's strong robustness and generalization capability.

无铜树脂基制动材料是由有机和无机成分组成的多组分复合材料。它们的摩擦磨损行为受各部件之间复杂的非线性相互作用和温度的影响，难以通过传统方法进行准确预测。为了克服这一挑战，本研究研究了一种用铸造废砂增强的新型无铜树脂基制动材料，并提出了一种由混合粒子群优化-花授粉算法（PSO-FPA）优化的反向传播（BP）神经网络模型，简称PSO-FPA-BP，用于精确预测材料的摩擦和磨损性能。采用正交方差分析（ANOVA）检验摩擦系数、磨损率与原料成分的相关性，并通过极差分析确定最佳配方。正交实验得到的数据作为模型开发的训练集。以主材料成分和温度为输入变量，摩擦系数和磨损率为输出变量，构建了PSO-FPA-BP预测模型。与单纯采用授粉算法（Flower Pollination Algorithm, FPA-BP）和粒子群算法（Particle Swarm Optimization Algorithm, PSO-BP）优化的BP神经网络相比，PSO-FPA-BP模型的摩擦系数和磨损率的决定系数（R2）分别为0.879和0.979，预测精度更高。此外，使用优化后的配方进行了摩擦磨损试验，以生成验证数据。结果表明，PSO-FPA-BP模型对验证样品的摩擦系数和磨损率的预测精度分别达到95.005%和88.021%，表明该模型具有较强的鲁棒性和泛化能力。

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引用次数: 0

Cold sintering process on the tribological properties of h-BN@SiO2/PEEK composite 冷烧结工艺对h-BN@SiO2/PEEK复合材料摩擦学性能的影响

IF 6.1 1区工程技术 Q1 ENGINEERING, MECHANICAL

Wear

Pub Date : 2026-03-15 Epub Date: 2026-01-19 DOI: 10.1016/j.wear.2026.206549

Dapeng Gu , Hao Xu , Ke Liu , Chenxi Suo , Junqi Ge , Suwen Chen

To achieve the low-temperature combination of ceramics and polymers, the core-shell structure and cold sintering method are employed to prepare ceramic/polymer composites. An easy-bonding Silica (SiO₂) shell was introduced onto the surface of the hard-bonding Hexagonal boron nitride (h-BN) core by a sol-gel method to fabricate a core-shell structured h-BN@SiO₂ composite. Polyether ether ketone (PEEK) was subsequently filled into h-BN@SiO₂ to prepare h-BN@SiO₂/PEEK ceramic composite by a cold sintering method. The effects of PEEK content (20 vol%, 35 vol%, and 50 vol%), sintering temperature (205 °C, 245 °C, 285 °C, and 325 °C), and molding pressure (350 MPa, 450 MPa, and 550 MPa) on the dry tribological properties of h-BN@SiO₂/PEEK ceramic composites against GCr15 bearing steel were investigated using a ball-on-disc contact configuration. Field emission transmission electron microscopy (TEM), Energy dispersive spectrometer (EDS), Field emission scanning electron microscopy (SEM), X-ray diffraction (XRD), and Fourier transform infrared spectrometer (FTIR) were used to characterize and analyze h-BN@SiO₂ or h-BN@SiO₂/PEEK ceramic composites. The results indicate that h-BN@SiO₂/PEEK composite exhibits better tribological performance when fabricated with a PEEK content of 35 vol%, a sintering temperature of 285 °C, and a molding pressure of 450 MPa under the investigated conditions. The formation of a stable and continuous mixed lubrication layer composed of h-BN, PEEK, and SiO₂ is identified as the primary factor contributing to the enhanced friction reduction and wear resistance. Under the investigated conditions, the main wear mechanisms observed in h-BN@SiO₂/PEEK composites are adhesive wear, fatigue wear, and slight abrasive wear.

为了实现陶瓷与聚合物的低温结合，采用核壳结构和冷烧结方法制备陶瓷/聚合物复合材料。采用溶胶-凝胶法将易成键二氧化硅（SiO2）壳层引入硬成键六方氮化硼（h-BN）核表面，制备了核-壳结构h-BN@SiO2复合材料。随后将聚醚醚酮（PEEK）填充到h-BN@SiO2中，采用冷烧结法制备h-BN@SiO2/PEEK陶瓷复合材料。研究了PEEK含量（20 vol%、35 vol%和50 vol%）、烧结温度（205°C、245°C、285°C和325°C）和成型压力（350 MPa、450 MPa和550 MPa）对h-BN@SiO2/PEEK陶瓷复合材料与GCr15轴承钢干摩擦性能的影响。采用场发射透射电镜（TEM）、能谱仪（EDS）、场发射扫描电镜（SEM）、x射线衍射仪（XRD）和傅里叶变换红外光谱仪（FTIR）对h-BN@SiO2或h-BN@SiO2/PEEK陶瓷复合材料进行了表征和分析。结果表明，在PEEK含量为35 vol%、烧结温度为285℃、成型压力为450 MPa的条件下，h-BN@SiO2/PEEK复合材料具有较好的摩擦学性能。由h-BN、PEEK和SiO2组成的稳定连续的混合润滑层的形成是增强减摩性和耐磨性的主要因素。在实验条件下，h-BN@SiO2/PEEK复合材料的主要磨损机制为黏着磨损、疲劳磨损和轻微磨粒磨损。

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引用次数: 0

Mechanical and tribological properties of Al-20Si-5Fe-2Ni composites reinforced by Cu-coated Mo2BC ceramic cu包覆Mo2BC陶瓷增强Al-20Si-5Fe-2Ni复合材料的力学和摩擦学性能

IF 6.1 1区工程技术 Q1 ENGINEERING, MECHANICAL

Wear

Pub Date : 2026-03-15 Epub Date: 2026-01-19 DOI: 10.1016/j.wear.2026.206551

Shuai Wang , Zhiyuan Zhang , Yu Cai , Xianjuan Pang , Long You , Chenfei Song , Sanming Du , Yongzhen Zhang

In this paper, Al-20Si-5Fe-2Ni composites reinforced with varying contents of Mo₂BC and Cu-coated Mo₂BC were fabricated via vacuum hot-press sintering. The influence of Cu-coated Mo₂BC content on the mechanical and tribological properties of the composites was systematically examined. Results revealed that the Cu coating on Mo₂BC ceramic particles reacted with the aluminum alloy matrix during sintering, leading to the formation of Al₂Cu interfacial bridges. The incorporation of Cu-coated Mo₂BC significantly enhanced the overall mechanical properties of the composites, which was attributed to the synergistic effects of interfacial bridging strengthening and the pinning effect provided by the Mo₂BC ceramic particles. Moreover, the tribological performance of the Al-20Si-5Fe-2Ni composites was markedly improved. When sliding against GCr15 bearing steel, the primary wear mechanisms of the unreinforced alloy included adhesive, fatigue, and abrasive wear. With the addition of up to 20 wt% Cu-coated Mo₂BC, a smooth and continuous oxide film formed on the worn surface, which exerted a lubricating effect and reduced wear. However, as the content of Cu-coated Mo₂BC further increased to 30 wt%, agglomeration of Mo₂BC particles became evident. Under applied shear stresses during sliding, these agglomerated particles were prone to fracture and disperse within the wear track, ultimately resulting in an increased friction coefficient and higher wear rate.

本文采用真空热压烧结法制备了不同Mo2BC含量的Al-20Si-5Fe-2Ni复合材料和cu包覆Mo2BC复合材料。研究了cu包覆Mo2BC含量对复合材料力学性能和摩擦学性能的影响。结果表明，Mo2BC陶瓷颗粒表面的Cu涂层在烧结过程中与铝合金基体发生反应，形成Al2Cu界面桥；cu包覆Mo2BC的加入显著提高了复合材料的整体力学性能，这是由于界面桥接强化和Mo2BC陶瓷颗粒提供的钉住效应的协同作用。此外，Al-20Si-5Fe-2Ni复合材料的摩擦学性能也得到了显著改善。当与GCr15轴承钢滑动时，非增强合金的主要磨损机制包括粘接磨损、疲劳磨损和磨料磨损。添加高达20%的cu包覆Mo2BC，磨损表面形成光滑连续的氧化膜，发挥润滑作用，减少磨损。然而，随着cu包覆Mo2BC的含量进一步增加到30 wt%， Mo2BC颗粒的团聚现象变得明显。在滑动过程中施加的剪切应力作用下，这些团聚颗粒容易破裂并分散在磨损轨迹内，最终导致摩擦系数增加，磨损率提高。

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引用次数: 0

Improving the tribological and anti-corrosion performance of LPBF-processed GH3230 superalloy by post-treatment 通过后处理提高lpbf加工的GH3230高温合金的摩擦学和防腐性能

IF 6.1 1区工程技术 Q1 ENGINEERING, MECHANICAL

Wear

Pub Date : 2026-03-15 Epub Date: 2026-01-21 DOI: 10.1016/j.wear.2026.206560

Xiaohang Liu , Xueping Guo , Qilin Zhang , Shengbin Dai , Jiangqi Zhu , Bingwen Lu , Changri Xiong , Hao Qiu , Ting Yu , Xingchen Yan

The poor tribological performance and susceptibility to corrosion of as-printed nickel-based superalloys produced by laser powder bed fusion (LPBF) limit their application in demanding environments, such as the unlubricated, high-temperature components of aerospace engines. To address this challenge, this study aims to enhance the wear and corrosion resistance of LPBF-fabricated GH3230 superalloy through tailored post-processing. Specimens were subjected to solution treatment (ST) and hot isostatic pressing (HIP), and their microstructure, dry sliding wear behavior against a Si₃N₄ counter body, and electrochemical corrosion performance were systematically investigated. Results indicate that both ST and HIP promoted recrystallization and the formation of coarse carbides, completely transforming the initial molten pool structure. The HIP-treated alloy exhibited the lowest friction coefficient (0.69) and wear rate (3.23 × 10⁻⁵ mm³/(N·m)), which is attributed to the synergistic effect of coarse carbides and high-density dislocations that facilitated the formation of a work-hardened layer, thereby reducing the actual contact area. Furthermore, the HIP treatment enabled the formation of a more stable and protective passive film, resulting in superior corrosion resistance. This work demonstrates that HIP is an effective post-processing strategy for achieving a synergistic improvement in tribological and anti-corrosion properties, providing critical insights for the performance optimization of additively manufactured superalloys in severe service conditions.

激光粉末床熔合（LPBF）生产的镍基高温合金的摩擦学性能差，易腐蚀，限制了其在苛刻环境中的应用，如航空发动机的无润滑高温部件。为了解决这一挑战，本研究旨在通过定制后处理来提高lpbf制造的GH3230高温合金的耐磨损和耐腐蚀性能。对试样进行固溶处理（ST）和热等静压（HIP），系统地研究了试样的微观结构、对Si3N4反体的干滑动磨损行为和电化学腐蚀性能。结果表明：ST和HIP都促进了再结晶和粗碳化物的形成，完全改变了初始熔池结构；摩擦系数（0.69）和磨损率（3.23 × 10−5 mm3/(N·m)）最低，这是由于粗碳化物和高密度位错的协同作用，促进了加工硬化层的形成，从而减少了实际接触面积。此外，HIP处理能够形成更稳定和保护性的钝化膜，从而具有更好的耐腐蚀性。这项工作表明，HIP是一种有效的后处理策略，可以实现摩擦学和防腐性能的协同改进，为增材制造高温合金在恶劣使用条件下的性能优化提供关键见解。

{"title":"Improving the tribological and anti-corrosion performance of LPBF-processed GH3230 superalloy by post-treatment","authors":"Xiaohang Liu , Xueping Guo , Qilin Zhang , Shengbin Dai , Jiangqi Zhu , Bingwen Lu , Changri Xiong , Hao Qiu , Ting Yu , Xingchen Yan","doi":"10.1016/j.wear.2026.206560","DOIUrl":"10.1016/j.wear.2026.206560","url":null,"abstract":"<div><div>The poor tribological performance and susceptibility to corrosion of as-printed nickel-based superalloys produced by laser powder bed fusion (LPBF) limit their application in demanding environments, such as the unlubricated, high-temperature components of aerospace engines. To address this challenge, this study aims to enhance the wear and corrosion resistance of LPBF-fabricated GH3230 superalloy through tailored post-processing. Specimens were subjected to solution treatment (ST) and hot isostatic pressing (HIP), and their microstructure, dry sliding wear behavior against a Si<sub>3</sub>N<sub>4</sub> counter body, and electrochemical corrosion performance were systematically investigated. Results indicate that both ST and HIP promoted recrystallization and the formation of coarse carbides, completely transforming the initial molten pool structure. The HIP-treated alloy exhibited the lowest friction coefficient (0.69) and wear rate (3.23 × 10<sup>−5</sup> mm<sup>3</sup>/(N·m)), which is attributed to the synergistic effect of coarse carbides and high-density dislocations that facilitated the formation of a work-hardened layer, thereby reducing the actual contact area. Furthermore, the HIP treatment enabled the formation of a more stable and protective passive film, resulting in superior corrosion resistance. This work demonstrates that HIP is an effective post-processing strategy for achieving a synergistic improvement in tribological and anti-corrosion properties, providing critical insights for the performance optimization of additively manufactured superalloys in severe service conditions.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"589 ","pages":"Article 206560"},"PeriodicalIF":6.1,"publicationDate":"2026-03-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146079451","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

Tribological compatibility investigation of multiwall carbon nanotubes/nickel coatings sliding against silicon nitride under dry friction and oil lubrication 干摩擦和油润滑条件下多壁碳纳米管/镍涂层与氮化硅的摩擦学相容性研究

IF 6.1 1区工程技术 Q1 ENGINEERING, MECHANICAL

Wear

Pub Date : 2026-03-15 Epub Date: 2026-01-26 DOI: 10.1016/j.wear.2026.206564

Lupeng Wu , Haifeng Xue , Ke Zhang , Tianxiang Li , Wei Gao , Le Gu , Yongtao Zhang

Multiwall carbon nanotubes reinforced nickle (MWCNTs/Ni) coatings were electrodeposited in electrolyte solution containing carboxylated MWCNTs with dimensions of 285–427 nm. Surface morphology and hardness analysis determined 3 g/L MWCNTs as the optical addition concentration under low current density of 1 Adm⁻². Based on friction and wear behaviors, the tribological compatibility of Ni coating sliding against silicon nitride was improved by using MWCNTs as lubrication reinforcements. 50.6 and 44.4 % of friction and wear reduction was achieved under dry friction at 1214 MPa and 0.089 m/s while 35.8 % and 24.2 % of that was accomplished under oil lubrication. Micro-protrudes containing MWCNTs were crushed because of the high contact stress caused by coarse surface during sliding and hereby MWCNTs were released into oil. The improved tribological properties were attributed to the synergistic mechanism of MWCNTs serve as solid lubricants inside coatings and lubrication additives in oil.

在含有尺寸为285-427 nm羧化MWCNTs的电解质溶液中电沉积多壁碳纳米管增强镍（MWCNTs/Ni）涂层。表面形貌和硬度分析确定，在1 Adm−2低电流密度下，光学添加浓度为3g /L MWCNTs。基于摩擦磨损行为，采用MWCNTs作为润滑增强剂，改善了Ni涂层与氮化硅的摩擦相容性。在1214 MPa和0.089 m/s的干摩擦条件下，摩擦磨损减少率分别为50.6%和44.4%，而油润滑条件下的减少率分别为35.8%和24.2%。含有MWCNTs的微突起在滑动过程中由于表面粗糙而产生高接触应力而被压碎，MWCNTs释放到油中。MWCNTs作为涂层内部的固体润滑剂和油中润滑添加剂的协同作用，提高了涂层的摩擦学性能。

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引用次数: 0

Tribological properties of gradient-structured TiAlSiN coatings: A comparative study with homogeneous coatings under a wide range of load-speed conditions 梯度结构TiAlSiN涂层的摩擦学性能：与均匀涂层在大范围载荷-速度条件下的比较研究

IF 6.1 1区工程技术 Q1 ENGINEERING, MECHANICAL

Wear

Pub Date : 2026-03-15 Epub Date: 2026-01-21 DOI: 10.1016/j.wear.2026.206559

Lianggang Ji , Hanlian Liu , Chuanzhen Huang , Guanqun Wang , Xuefei Liu , Jinfu Zhao , Longhua Xu

To investigate the influence of gradient structure on the tribological properties of coatings, this study compares the dry sliding behavior of gradient TiAlSiN, homogeneous TiAlSiN, and TiAlN coatings against GCr15 steel balls under loads of 10–40 N and sliding speeds of 10–40 m/min. The wear mechanisms were revealed through multi-scale characterization. Results show that the wear rates of all three coatings increase with increasing load and speed, while the gradient coating exhibits a more stable friction coefficient and a gentler increase in wear rate. Under conditions of a 40 N load and a 20 m/min sliding speed, its wear rate is reduced by 17.2 % and 41.3 % compared to homogeneous TiAlSiN and TiAlN coatings, respectively. In terms of failure modes, homogeneous TiAlSiN exhibits brittle spalling, while TiAlN suffers from poor wear resistance due to low hardness. The superior performance of the gradient coating originates from its gradual microstructural and mechanical transitions. Finite element modeling (FEM) confirms that this design effectively mitigates stress concentrations, leading to enhanced load-bearing capacity and a reduced risk of interfacial delamination. Abrasive wear is the dominant mechanism for all coatings under low load and speed, while the synergistic effect of adhesive wear and oxidative wear becomes predominant under high load and speed. This study confirms that gradient structure design can significantly enhance wear resistance of coating, providing theoretical support for coating development under extreme operating conditions.

为了研究梯度结构对涂层摩擦学性能的影响，本研究比较了梯度TiAlSiN、均匀TiAlSiN和TiAlN涂层在10-40 N载荷和10-40 m/min滑动速度下对GCr15钢球的干滑动行为。通过多尺度表征揭示了磨损机理。结果表明，三种涂层的磨损率均随载荷和速度的增加而增加，而梯度涂层的摩擦系数更稳定，磨损率的增加更平缓。在载荷为40 N、滑动速度为20 m/min的条件下，其磨损率比均相TiAlSiN和TiAlN涂层分别降低了17.2%和41.3%。在失效模式方面，均质TiAlSiN表现为脆性剥落，而TiAlN由于硬度低，耐磨性较差。梯度涂层的优异性能源于其逐渐的微观组织和力学转变。有限元模型（FEM）证实，这种设计有效地减轻了应力集中，从而提高了承载能力，降低了界面分层的风险。在低负荷和低速下，磨料磨损是各涂层的主要磨损机制，而在高负荷和高速下，粘结磨损和氧化磨损的协同作用成为主要作用机制。本研究证实了梯度结构设计可以显著提高涂层的耐磨性，为极端工况下涂层的开发提供了理论支持。

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引用次数: 0

Addition of Al anodizing waste in a commercial friction material in an industrial symbiosis perspective 工业共生视角下铝阳极氧化废料在工业摩擦材料中的添加

IF 6.1 1区工程技术 Q1 ENGINEERING, MECHANICAL

Wear

Pub Date : 2026-03-15 Epub Date: 2026-01-24 DOI: 10.1016/j.wear.2026.206553

G.S. Gehlen , F. Valentini , A.P. Nogueira , R. Masciocchi , A. Barbieri , G. Straffelini

This study investigates the incorporation of anodizing aluminum waste (AAW), primarily aluminum hydroxide, into commercial brake pad friction materials. Four formulations were evaluated: a reference benchmark, one with 12 % unsieved AAW, and two with 6 % and 12 % sieved AAW. Samples were produced by hot pressing and characterized in terms of wear, friction behavior, and particulate matter (PM) emissions using a sub-scale dynamometer and a 168-cycle braking protocol based on the AK Master standard. To assess the environmental implications of AAW addition and the associated drying step, a life cycle assessment (LCA) was also conducted. The results revealed that increasing AAW content led to larger friction coefficient fluctuations and higher sensitivity to pressure and sliding speed, with the 12 % AAW formulations showing the greatest instability. The mean coefficient of friction under mild braking conditions decreased with AAW incorporation. In terms of wear, the 6 % AAW formulation achieved performance comparable to the reference, whereas 12 % AAW increased pad wear; disc wear remained unaffected across all compositions. Importantly, PM emissions from AAW-containing materials were similar to or lower than those of the reference, regardless of AAW content or sieving. LCA demonstrated that replacing alumina with AAW consistently reduced environmental impacts across all categories. Overall, among the tested compositions, the 6 % AAW formulation provided the best compromise between tribological stability and environmental benefits, supporting both the technical feasibility and the sustainability potential of incorporating AAW into friction material manufacturing within an industrial symbiosis framework.

本研究探讨了阳极氧化废铝（AAW）（主要是氢氧化铝）在商用刹车片摩擦材料中的应用。评估了四种配方：一个参考基准，一个未经筛选的12%的AAW，两个分别筛选6%和12%的AAW。样品通过热压生产，并使用亚尺度测力仪和基于AK Master标准的168循环制动协议，对磨损、摩擦行为和颗粒物（PM）排放进行了表征。为了评估添加AAW及其相关干燥步骤的环境影响，还进行了生命周期评估（LCA）。结果表明，AAW含量的增加导致摩擦系数波动更大，对压力和滑动速度的敏感性更高，其中12%的AAW配方表现出最大的不稳定性。轻度制动条件下的平均摩擦系数随着AAW的加入而降低。在磨损方面，6% AAW配方达到了与参考配方相当的性能，而12% AAW增加了衬垫磨损；磁盘磨损在所有组合中都不受影响。重要的是，无论AAW含量或筛分如何，含AAW材料的PM排放量与参考材料相似或低于参考材料。LCA证明，用AAW代替氧化铝可以持续减少所有类别的环境影响。总体而言，在所测试的组合物中，6% AAW配方在摩擦学稳定性和环境效益之间提供了最佳折衷，支持在工业共生框架内将AAW纳入摩擦材料制造的技术可行性和可持续性潜力。

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引用次数: 0

Wear stage evolution and failure mechanism of hard chromium-coated calender rolls during continuous lithium-ion battery electrode calendering 锂离子电池电极连续压延过程中硬铬压延辊磨损阶段演变及失效机理

IF 6.1 1区工程技术 Q1 ENGINEERING, MECHANICAL

Wear

Pub Date : 2026-03-15 Epub Date: 2026-01-14 DOI: 10.1016/j.wear.2026.206537

Jingyu Fan , Xipeng Xin , Qingdong Liu , Yifeng Xu , Yiqiu Zhu , Hu Chen , Wei Chen , Xiaofeng Zhao , Xuefeng Song

The wear mechanisms and life cycle evolution of hard chromium-coated rolls during lithium-ion battery electrode calendering remain underexplored. In this study, a modified ball-on-disk configuration was employed to simulate the long-term sliding contact (360 h) between hard chromium coatings and LiFePO₄ (LFP) electrode sheets. A non-linear, four-stage wear evolution law was identified: (1) Running-in (0–120 h), characterized by mild abrasion protected by the native oxide film; (2) Stable wear (120–170 h), marked by oxide breakdown and substrate exposure; (3) Severe wear (170–270 h), driven by matrix-mediated adhesion, where carbon-rich binder accumulation formed protrusions that induced fatigue shear fracture and deep pitting; and (4) Secondary stable wear (270–360 h), featuring a cyclic competition between tribo-oxidative regeneration and fatigue spallation. The failure mechanism is attributed to the synergy between binder-driven adhesion and third-body abrasion caused by hard oxide debris. These findings highlight that maintaining the integrity of the surface Cr₂O₃ layer is critical for suppressing adhesive wear and optimizing roll durability in battery manufacturing.

锂离子电池电极压延过程中硬铬包覆辊的磨损机理和生命周期演变尚未得到充分研究。在这项研究中，采用改进的球盘结构来模拟硬铬涂层与LiFePO4 （LFP）电极片之间的长期滑动接触（360小时）。结果表明：(1)磨合（0 ~ 120 h）以天然氧化膜保护的轻度磨损为特征；(2)稳定磨损（120-170小时），以氧化物击穿和衬底暴露为标志；(3)重度磨损（170 ~ 270 h），由基体介导的黏附驱动，富碳粘结剂积累形成突出物，诱发疲劳剪切断裂和深点蚀；(4)二次稳定磨损（270 ~ 360 h），表现为摩擦氧化再生和疲劳剥落之间的循环竞争。破坏机理是粘结剂驱动的粘结和硬氧化碎屑造成的第三体磨损共同作用的结果。这些发现强调，在电池制造中，保持表面Cr2O3层的完整性对于抑制胶粘剂磨损和优化轧辊耐久性至关重要。

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引用次数: 0

Measurement of grit wear in abrasive c-BN electroplated tipped blades for gas turbines applications 燃气轮机用c-BN电镀磨料叶片的磨粒磨损测量

IF 6.1 1区工程技术 Q1 ENGINEERING, MECHANICAL

Wear

Pub Date : 2026-03-15 Epub Date: 2026-01-13 DOI: 10.1016/j.wear.2026.206538

A. Parody Martin , M.B. Marshall

The increasing use of ceramic abradable seal systems in the High-Pressure Turbine section of gas turbines, aimed at improving efficiency and reducing fuel consumption, introduces new challenges in performance evaluation. This work proposes a standard method to quantify wear on c-BN electroplated tipped blades, which function as abrasive coatings on rotor blades. The approach relies on 3D metrology scanner to capture surface data of the blade and converting them into measurable parameters that allow for consistent comparison between blades from rig testing. Key metrics include grit density, the volume occupied by abrasive particles, and the corresponding void volume and void density resulting from wear. An additional parameter is proposed to account for debris accumulation and its effect on the proposed wear-related metrics. The results demonstrate consistent trends across the proposed parameters, both in pristine and tested blades, regardless of their initial grit density as well as with grit wear patterns. The proposed Positive Volume Variation (PVV) and Grit Density Variation (GDV) metrics exhibited a strong mutual correlation (r = 0.950), a result supported by their shared underlying physical basis. In contrast, the Mean Height Variation (MHV), typically applied to bare blades, demonstrated weaker correlations with both PVV (r = 0.893) and GDV (r = 0.745).

为了提高燃气轮机的效率和降低燃油消耗，高压涡轮部分越来越多地使用陶瓷耐磨密封系统，这给性能评估带来了新的挑战。这项工作提出了一种标准方法来量化c-BN电镀尖端叶片的磨损，其功能是转子叶片的磨料涂层。该方法依靠3D测量扫描仪捕获叶片表面数据，并将其转换为可测量参数，以便在钻机测试中对叶片进行一致的比较。关键指标包括磨粒密度、磨料颗粒占据的体积，以及由磨损产生的相应空隙体积和空隙密度。提出了一个额外的参数来解释碎片堆积及其对拟议的磨损相关指标的影响。结果表明，无论初始磨粒密度和磨粒磨损模式如何，在原始和测试叶片中，所提出的参数都具有一致的趋势。正体积变化（PVV）和颗粒密度变化（GDV）指标具有很强的相互相关性（r = 0.950），这一结果得到了它们共同的潜在物理基础的支持。相比之下，通常应用于裸叶片的平均高度变化（MHV）与PVV （r = 0.893）和GDV （r = 0.745）的相关性较弱。

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