Forming maraging-steel deposits on railway crossing surfaces via laser directed energy deposition can extend the service life, but suffer the unbalanced wear and RCF resistance. This study employs induction heat treatment for in-situ microstructural tailoring of 18Ni300 deposits, achieving synergistic enhancement of wear and RCF resistance through precise control of nanoprecipitates and reversed austenite (RA'). With increasing temperature, RA' nucleation sites shift from HAGBs to LAGBs, accompanied by increased volume fraction and grain coarsening; nanoprecipitates evolve from coherent η-Ni3Ti (500 °C) to semi-coherent η-Ni3Ti and Ni3Mo (600 °C), and finally to incoherent Laves-Fe2Mo (700 °C). Optimal synergy between wear and RCF resistance emerges at 600 °C, attributed to strengthening via dislocation pinning by semi-coherent nanoprecipitates and stress dissipation through plastic flow of nano-sized RA'.
{"title":"Synergistically improving the wear and rolling contact fatigue properties of laser-directed energy deposited 18Ni300 by controlling the nanoprecipitate and austenite","authors":"Beibei Zhu, Gaofeng Xu, Li Meng, Xu Liu, Qianwu Hu, Xiaoyan Zeng","doi":"10.1016/j.wear.2026.206517","DOIUrl":"10.1016/j.wear.2026.206517","url":null,"abstract":"<div><div>Forming maraging-steel deposits on railway crossing surfaces via laser directed energy deposition can extend the service life, but suffer the unbalanced wear and RCF resistance. This study employs induction heat treatment for in-situ microstructural tailoring of 18Ni300 deposits, achieving synergistic enhancement of wear and RCF resistance through precise control of nanoprecipitates and reversed austenite (RA'). With increasing temperature, RA' nucleation sites shift from HAGBs to LAGBs, accompanied by increased volume fraction and grain coarsening; nanoprecipitates evolve from coherent η-Ni<sub>3</sub>Ti (500 °C) to semi-coherent η-Ni<sub>3</sub>Ti and Ni<sub>3</sub>Mo (600 °C), and finally to incoherent Laves-Fe<sub>2</sub>Mo (700 °C). Optimal synergy between wear and RCF resistance emerges at 600 °C, attributed to strengthening via dislocation pinning by semi-coherent nanoprecipitates and stress dissipation through plastic flow of nano-sized RA'.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"588 ","pages":"Article 206517"},"PeriodicalIF":6.1,"publicationDate":"2026-01-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145897880","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-01-05DOI: 10.1016/j.wear.2026.206514
Min Zhang , Caoyuan Hu , Jiliang Mo , Qixiang Zhang , Zhongrong Zhou
High-speed trains experience severe wear of brake pads when operating on lines with long ramps. Researching the wear progression of brake pads under these conditions is essential for the safe functioning of the train. The braking conditions on long ramps are complex and variable, and the tribological behavior between brake pads and brake discs is intricate, having a significant impact on the evolution of the brake pad's wear interface. In this study, scaled-down braking tests were conducted. Meanwhile, finite element models and numerical models were established. These models aimed to analyze the wear evolution law and vibration response characteristics of brake pad friction blocks under long ramp conditions. The test results indicate that different braking conditions lead to distinct eccentric wear angles, which not only alter the contact state but also exert a significant impact on the vibration intensity of the system. The finite element simulation results indicate that both excessively large and small uneven wear angles can cause rapid wear of the friction blocks and intensify friction vibration. A small uneven wear angle results in stress concentration at the cut-in edge, increasing the uneven wear angle. Conversely, a large uneven wear angle leads to stress concentration at the cut-out edge, reducing the uneven wear angle. Numerical simulation results show that changes in contact stiffness due to uneven wear are more likely to trigger unstable vibrations under low braking forces. Different combinations of braking speed and braking pressure also significantly affect the system's stability. The analysis and research results are significant for theoretical and practical value, revealing wear interface evolution patterns of train brake friction blocks on long ramps.
{"title":"Wear interface evolution and its impact on vibration of high-speed train brake friction blocks under long ramps","authors":"Min Zhang , Caoyuan Hu , Jiliang Mo , Qixiang Zhang , Zhongrong Zhou","doi":"10.1016/j.wear.2026.206514","DOIUrl":"10.1016/j.wear.2026.206514","url":null,"abstract":"<div><div>High-speed trains experience severe wear of brake pads when operating on lines with long ramps. Researching the wear progression of brake pads under these conditions is essential for the safe functioning of the train. The braking conditions on long ramps are complex and variable, and the tribological behavior between brake pads and brake discs is intricate, having a significant impact on the evolution of the brake pad's wear interface. In this study, scaled-down braking tests were conducted. Meanwhile, finite element models and numerical models were established. These models aimed to analyze the wear evolution law and vibration response characteristics of brake pad friction blocks under long ramp conditions. The test results indicate that different braking conditions lead to distinct eccentric wear angles, which not only alter the contact state but also exert a significant impact on the vibration intensity of the system. The finite element simulation results indicate that both excessively large and small uneven wear angles can cause rapid wear of the friction blocks and intensify friction vibration. A small uneven wear angle results in stress concentration at the cut-in edge, increasing the uneven wear angle. Conversely, a large uneven wear angle leads to stress concentration at the cut-out edge, reducing the uneven wear angle. Numerical simulation results show that changes in contact stiffness due to uneven wear are more likely to trigger unstable vibrations under low braking forces. Different combinations of braking speed and braking pressure also significantly affect the system's stability. The analysis and research results are significant for theoretical and practical value, revealing wear interface evolution patterns of train brake friction blocks on long ramps.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"588 ","pages":"Article 206514"},"PeriodicalIF":6.1,"publicationDate":"2026-01-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145940642","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-01-05DOI: 10.1016/j.wear.2026.206520
Simon Skurka , Radovan Galas , Jiaxin Li , Honghao Wang , Milan Omasta , Haohao Ding , Wenjian Wang , Ivan Krupka , Martin Hartl
Top-of-rail (TOR) products are used to optimise friction and reduce wear in the wheel–rail contact. However, their performance is affected by the presence of oxide layers naturally formed on the rail surface and by other environmental contaminants such as water. In this study, two types of TOR products (one friction modifier and one TOR lubricant) were tested under dry and wet conditions on both clean and oxidised specimens. In addition, some specimens were preconditioned to form pre-existing cracks, allowing a comparison between undamaged and damaged surfaces. The investigation focused on traction (CoT), wear rate, and rolling contact fatigue (RCF). The results showed that, with respect to CoT, water influenced the TOR lubricant much more than the friction modifier, as it extended its retentivity and led to extremely low friction levels (CoT down to 0.05). Both products effectively reduced wear and prevented crack initiation. However, when pre-existing cracks were present, the combination of water and the liquid base of TOR products accelerated crack propagation and caused severe spalling. Interestingly, oxidation also contributed to crack growth, as oxide formation inside the crack induced internal pressure that promoted secondary crack propagation.
{"title":"Performance of top-of-rail products under contaminated conditions with pre-existing cracks: Impacts on traction and surface damage","authors":"Simon Skurka , Radovan Galas , Jiaxin Li , Honghao Wang , Milan Omasta , Haohao Ding , Wenjian Wang , Ivan Krupka , Martin Hartl","doi":"10.1016/j.wear.2026.206520","DOIUrl":"10.1016/j.wear.2026.206520","url":null,"abstract":"<div><div>Top-of-rail (TOR) products are used to optimise friction and reduce wear in the wheel–rail contact. However, their performance is affected by the presence of oxide layers naturally formed on the rail surface and by other environmental contaminants such as water. In this study, two types of TOR products (one friction modifier and one TOR lubricant) were tested under dry and wet conditions on both clean and oxidised specimens. In addition, some specimens were preconditioned to form pre-existing cracks, allowing a comparison between undamaged and damaged surfaces. The investigation focused on traction (CoT), wear rate, and rolling contact fatigue (RCF). The results showed that, with respect to CoT, water influenced the TOR lubricant much more than the friction modifier, as it extended its retentivity and led to extremely low friction levels (CoT down to 0.05). Both products effectively reduced wear and prevented crack initiation. However, when pre-existing cracks were present, the combination of water and the liquid base of TOR products accelerated crack propagation and caused severe spalling. Interestingly, oxidation also contributed to crack growth, as oxide formation inside the crack induced internal pressure that promoted secondary crack propagation.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"588 ","pages":"Article 206520"},"PeriodicalIF":6.1,"publicationDate":"2026-01-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145979282","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-01-05DOI: 10.1016/j.wear.2026.206516
Maslinda Kamarudin, Zaini Ahmad, Mohd Nasir Tamin
Fretting wear is a dominant failure mechanism in stranded steel wire ropes subjected to cyclic tension-tension fatigue. The aim of this study is to improve the fatigue life prediction of the newly designed 1 × 7 drawn steel wire ropes. A damage-based fretting wear model was developed to predict the fretting-induced wear at the wire-to-wire contact region. The model incorporates experimentally measured parameters, including the adhesion shear strength of bonded micro-peaks (10.75 MPa), the residual modulus of the wire material affected by the mean stress, and the evolution of fretted surface hardness (up to 7340 MPa). The model coefficient, = 0.10 and critical damage index for discrete material element removal, 0.90 are established through calibration of Finite Element (FE)-calculated wear depth with measured values. Partial validation of the model is demonstrated by similar FE-predicted and measured wear depths of 45 ± 7 μm after 1.5 × 105 cycles at an orientation angle of 45°. A fracture criterion based on arc-elliptical surface crack propagation was developed using fracture mechanics principles, where failure occurs once the stress intensity factor reaches the fracture toughness of the material (25 MPa√m). The corresponding critical energy dissipation at fracture was determined to be 34 ± 1 J. This result aligned with the practical threshold for rope replacement at a one-third wire diameter wear depth. The outcomes of this study serve a mechanistic understanding of fretting-induced damage accumulation in steel wire ropes, enabling predictive failure modeling without the need for full-scale rope testing.
{"title":"Fretting wear damage model for stranded steel wire ropes","authors":"Maslinda Kamarudin, Zaini Ahmad, Mohd Nasir Tamin","doi":"10.1016/j.wear.2026.206516","DOIUrl":"10.1016/j.wear.2026.206516","url":null,"abstract":"<div><div>Fretting wear is a dominant failure mechanism in stranded steel wire ropes subjected to cyclic tension-tension fatigue. The aim of this study is to improve the fatigue life prediction of the newly designed 1 × 7 drawn steel wire ropes. A damage-based fretting wear model was developed to predict the fretting-induced wear at the wire-to-wire contact region. The model incorporates experimentally measured parameters, including the adhesion shear strength of bonded micro-peaks (10.75 MPa), the residual modulus of the wire material affected by the mean stress, and the evolution of fretted surface hardness (up to 7340 MPa). The model coefficient, <span><math><mrow><msub><mi>c</mi><mi>f</mi></msub></mrow></math></span> = 0.10 and critical damage index for discrete material element removal, <span><math><mrow><msub><mi>D</mi><mi>c</mi></msub><mo>=</mo></mrow></math></span> 0.90 are established through calibration of Finite Element (FE)-calculated wear depth with measured values. Partial validation of the model is demonstrated by similar FE-predicted and measured wear depths of 45 ± 7 μm after 1.5 × 10<sup>5</sup> cycles at an orientation angle of 45°. A fracture criterion based on arc-elliptical surface crack propagation was developed using fracture mechanics principles, where failure occurs once the stress intensity factor reaches the fracture toughness of the material (25 MPa√m). The corresponding critical energy dissipation at fracture was determined to be 34 ± 1 J. This result aligned with the practical threshold for rope replacement at a one-third wire diameter wear depth. The outcomes of this study serve a mechanistic understanding of fretting-induced damage accumulation in steel wire ropes, enabling predictive failure modeling without the need for full-scale rope testing.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"588 ","pages":"Article 206516"},"PeriodicalIF":6.1,"publicationDate":"2026-01-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145940634","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-01-05DOI: 10.1016/j.wear.2026.206523
Yang Qin , Yuan Wang , Honghao Wang , Shuyue Zhang , Xin Lu , Hudong Xue , Wenjian Wang , Enrico Meli , Roger Lewis , Zhongrong Zhou , Haohao Ding
This study investigated the wear and RCF behaviours of a lath-like (1380B) bainitic rail steel and a granular bainitic rail steel (1250B) in low-temperature environments through rolling contact tests, using a pearlitic rail steel (U75VH) for comparison. Results showed that as temperature decreased, overall wear increased markedly, while average crack length and depth in all three steels became smaller. Among the steels, pearlitic rail steel consistently demonstrated the highest wear resistance and strongest resistance to crack initiation. At ambient temperature, lath-like bainitic rail steel performed better in resisting wear than the granular one; however, at −40 °C the opposite occurred, since the granular bainitic rail steel exhibited higher plastic deformation capacity. The lath-like bainitic rail steel also developed a few long cracks at low temperature. The superior low-temperature wear resistance of granular bainitic rail steel was attributed to differences in transformation behaviour compared with lath-like bainitic rail steel. Furthermore, fragments generated from multi-layer cracks were observed in both bainitic steels under low temperature, caused by brittle fracture and subsequent extrusion and twisting of the material between cracks. In contrast, no such fragments formed in pearlitic rail steel, which retained relatively high plasticity even in cold environments and thus avoided brittle fracture. These findings highlight the distinct wear and RCF responses of rail steels of different microstructures, and reveal the temperature-dependent mechanisms governing their tribological performance.
{"title":"Wear and RCF damage behaviours of bainitic rail steels under low temperature environments","authors":"Yang Qin , Yuan Wang , Honghao Wang , Shuyue Zhang , Xin Lu , Hudong Xue , Wenjian Wang , Enrico Meli , Roger Lewis , Zhongrong Zhou , Haohao Ding","doi":"10.1016/j.wear.2026.206523","DOIUrl":"10.1016/j.wear.2026.206523","url":null,"abstract":"<div><div>This study investigated the wear and RCF behaviours of a lath-like (1380B) bainitic rail steel and a granular bainitic rail steel (1250B) in low-temperature environments through rolling contact tests, using a pearlitic rail steel (U75VH) for comparison. Results showed that as temperature decreased, overall wear increased markedly, while average crack length and depth in all three steels became smaller. Among the steels, pearlitic rail steel consistently demonstrated the highest wear resistance and strongest resistance to crack initiation. At ambient temperature, lath-like bainitic rail steel performed better in resisting wear than the granular one; however, at −40 °C the opposite occurred, since the granular bainitic rail steel exhibited higher plastic deformation capacity. The lath-like bainitic rail steel also developed a few long cracks at low temperature. The superior low-temperature wear resistance of granular bainitic rail steel was attributed to differences in transformation behaviour compared with lath-like bainitic rail steel. Furthermore, fragments generated from multi-layer cracks were observed in both bainitic steels under low temperature, caused by brittle fracture and subsequent extrusion and twisting of the material between cracks. In contrast, no such fragments formed in pearlitic rail steel, which retained relatively high plasticity even in cold environments and thus avoided brittle fracture. These findings highlight the distinct wear and RCF responses of rail steels of different microstructures, and reveal the temperature-dependent mechanisms governing their tribological performance.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"588 ","pages":"Article 206523"},"PeriodicalIF":6.1,"publicationDate":"2026-01-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145940635","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-30DOI: 10.1016/j.wear.2025.206473
Qiang Wang, Jin Wang, Nan Li, Wenjuan Niu, Nan Guo, Shukai Ge, Liangliang Huang
Laser assisted cold spray (LACS) is an emerging solid-state deposition technique integrating cold spray (CS) and laser heating advantages, for fabricating components with low oxidation and high densification. However, the inherently low laser absorptivity of aluminum (Al) alloy powders limits thermal-assisted plastic deformation and overall coating performance in LACS. This study developed a micro-nano composite powder by incorporating Nano-Al2O3 particles (0–3 wt %) into 7075 Al alloy powder to enhance laser absorption and optimize coating quality. Results showed increasing Al2O3 led to a rougher powder surface, enhancing laser absorptivity from 60.91 % to 77.84 %. Deposition efficiency first increased then decreased, peaking at 62.3 % before dropping to 31.7 %. Nano-Al2O3 promoted localized heat absorption and enhanced particle plastic deformation, reducing porosity from 2.73 % to 0.69 %. Microhardness increased significantly from 117.46 HV0.2 to 161.51 HV0.2 with increasing nanoparticle content. Tribological tests revealed the 3 wt % Al2O3 coating showed a 52.9 % lower wear rate than pure 7075 Al when sliding against GCr15 steel ball. Adding Nano-Al2O3 shifted the wear mechanism from severe adhesive wear to mild adhesive combined with abrasive wear, with oxidative wear throughout. This study demonstrated a feasible surface modification strategy to enhance laser energy utilization and coating performance in LACS, offering a new pathway for wear-resistant Al alloy coatings.
{"title":"Balancing friction and wear properties in Nano-Al2O3 strengthened 7075 Al alloys fabricated by laser assisted cold spray","authors":"Qiang Wang, Jin Wang, Nan Li, Wenjuan Niu, Nan Guo, Shukai Ge, Liangliang Huang","doi":"10.1016/j.wear.2025.206473","DOIUrl":"10.1016/j.wear.2025.206473","url":null,"abstract":"<div><div>Laser assisted cold spray (LACS) is an emerging solid-state deposition technique integrating cold spray (CS) and laser heating advantages, for fabricating components with low oxidation and high densification. However, the inherently low laser absorptivity of aluminum (Al) alloy powders limits thermal-assisted plastic deformation and overall coating performance in LACS. This study developed a micro-nano composite powder by incorporating Nano-Al<sub>2</sub>O<sub>3</sub> particles (0–3 wt %) into 7075 Al alloy powder to enhance laser absorption and optimize coating quality. Results showed increasing Al<sub>2</sub>O<sub>3</sub> led to a rougher powder surface, enhancing laser absorptivity from 60.91 % to 77.84 %. Deposition efficiency first increased then decreased, peaking at 62.3 % before dropping to 31.7 %. Nano-Al<sub>2</sub>O<sub>3</sub> promoted localized heat absorption and enhanced particle plastic deformation, reducing porosity from 2.73 % to 0.69 %. Microhardness increased significantly from 117.46 HV<sub>0.2</sub> to 161.51 HV<sub>0.2</sub> with increasing nanoparticle content. Tribological tests revealed the 3 wt % Al<sub>2</sub>O<sub>3</sub> coating showed a 52.9 % lower wear rate than pure 7075 Al when sliding against GCr15 steel ball. Adding Nano-Al<sub>2</sub>O<sub>3</sub> shifted the wear mechanism from severe adhesive wear to mild adhesive combined with abrasive wear, with oxidative wear throughout. This study demonstrated a feasible surface modification strategy to enhance laser energy utilization and coating performance in LACS, offering a new pathway for wear-resistant Al alloy coatings.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"588 ","pages":"Article 206473"},"PeriodicalIF":6.1,"publicationDate":"2025-12-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145979281","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-26DOI: 10.1016/j.wear.2025.206502
Xiaobing Zhang , Yongtao Wang , Xiaohe Zhang
Special mechanical equipment, such as rocket engines, high-speed vehicles, and gun barrels, suffers serious erosion and damage to their material surfaces under extreme working conditions of high temperature, high pressure, and high velocity. Investigating erosion and wear is of great significance in improving the service life of mechanical equipment. Taking the barrel of a gun as an example, the mechanism of erosion is clarified by summarizing the thermal-chemical-mechanical factors that affect the service life of mechanical equipment. The literature of the last fifteen years is analyzed to obtain the key directions of erosion research. Recent advances in coatings, protective materials, and erosion-resistant groove structure are summarized. Then, advances in prediction methods for barrel erosion are outlined in terms of heat transfer and erosion simulation. Prediction models that consider multi-physical field coupling, such as the flow-solid-thermal three-phase coupling model, have higher precision. Finally, future challenges and recommendations for research on resistance to erosion of gun barrels and aeroengines are presented. The study of erosion mechanisms, anti-erosion techniques, and erosion prediction techniques is crucial for enhancing the performance of guns, which not only improves the service life of guns but also provides important references for other engineering applications in extreme environments.
{"title":"Advances in erosion and wear of barrels: Inhibition strategies, predictive models, and future challenges","authors":"Xiaobing Zhang , Yongtao Wang , Xiaohe Zhang","doi":"10.1016/j.wear.2025.206502","DOIUrl":"10.1016/j.wear.2025.206502","url":null,"abstract":"<div><div>Special mechanical equipment, such as rocket engines, high-speed vehicles, and gun barrels, suffers serious erosion and damage to their material surfaces under extreme working conditions of high temperature, high pressure, and high velocity. Investigating erosion and wear is of great significance in improving the service life of mechanical equipment. Taking the barrel of a gun as an example, the mechanism of erosion is clarified by summarizing the thermal-chemical-mechanical factors that affect the service life of mechanical equipment. The literature of the last fifteen years is analyzed to obtain the key directions of erosion research. Recent advances in coatings, protective materials, and erosion-resistant groove structure are summarized. Then, advances in prediction methods for barrel erosion are outlined in terms of heat transfer and erosion simulation. Prediction models that consider multi-physical field coupling, such as the flow-solid-thermal three-phase coupling model, have higher precision. Finally, future challenges and recommendations for research on resistance to erosion of gun barrels and aeroengines are presented. The study of erosion mechanisms, anti-erosion techniques, and erosion prediction techniques is crucial for enhancing the performance of guns, which not only improves the service life of guns but also provides important references for other engineering applications in extreme environments.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"587 ","pages":"Article 206502"},"PeriodicalIF":6.1,"publicationDate":"2025-12-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145842285","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-26DOI: 10.1016/j.wear.2025.206482
Marcin Kowalski , Ayush Khurana , Michael Weil , Anna Neus Igual Muñoz , Stefano Mischler
Tribocorrosion of hydrogen-embrittled steel is a critical concern for materials, particularly used in applications involving high mechanical stress and corrosive conditions. Hydrogen uptake by steel structures, induced by an electrochemical process, can cause degradation of mechanical properties and induce cracks. It is widely known as hydrogen embrittlement. This study investigates the combined effects of mechanical wear and electrochemical corrosion on hydrogen-charged C45CE carbon steel, in the presence and absence of surface film. The tribocorrosion behavior of hydrogen-charged steel is evaluated through tests in corrosive solutions, accompanied by microstructural analysis. The method of hydrogen charging in carbon steel was carried out electrochemically under galvanostatic conditions in a 0.5M Na2S solution for 24 h. The tribocorrosion tests were done in a reciprocating tribometer in a borate solution under well-controlled mechanical and electrochemical conditions, allowing for imposing a specific surface chemistry. Dry wear tests were also carried out in the same tribological configuration.
Results show that hydrogen reduces the fracture energy of the hydrogen-charged steel by 50 % despite no differences in hardness were observed. Hydrogen charging neither modifies the grain structure of the steel. The tribocorrosion results show that the hydrogen uptake has an impact on the steel degradation (hydrogen blocks deformation, increases the strain accumulation, and higher subsurface recrystallization was observed) when no passive film is formed on the steel (cathodic conditions). The main effect of hydrogen is grain refinement. In the presence of surface films (passive conditions), no difference was observed between the tribocorrosion behaviour of the charged and non-charged samples. When imposing passive conditions, hydrogen intake into the material can be oxidized, thus its effect on the tribocorrosion response is minimized. The surface of the material was embrittled by the presence of the passive film, regardless of the hydrogen charging.
{"title":"Effect of hydrogen charging on the tribocorrosion performance of C45CE steel","authors":"Marcin Kowalski , Ayush Khurana , Michael Weil , Anna Neus Igual Muñoz , Stefano Mischler","doi":"10.1016/j.wear.2025.206482","DOIUrl":"10.1016/j.wear.2025.206482","url":null,"abstract":"<div><div>Tribocorrosion of hydrogen-embrittled steel is a critical concern for materials, particularly used in applications involving high mechanical stress and corrosive conditions. Hydrogen uptake by steel structures, induced by an electrochemical process, can cause degradation of mechanical properties and induce cracks. It is widely known as hydrogen embrittlement. This study investigates the combined effects of mechanical wear and electrochemical corrosion on hydrogen-charged C45CE carbon steel, in the presence and absence of surface film. The tribocorrosion behavior of hydrogen-charged steel is evaluated through tests in corrosive solutions, accompanied by microstructural analysis. The method of hydrogen charging in carbon steel was carried out electrochemically under galvanostatic conditions in a 0.5M Na<sub>2</sub>S solution for 24 h. The tribocorrosion tests were done in a reciprocating tribometer in a borate solution under well-controlled mechanical and electrochemical conditions, allowing for imposing a specific surface chemistry. Dry wear tests were also carried out in the same tribological configuration.</div><div>Results show that hydrogen reduces the fracture energy of the hydrogen-charged steel by 50 % despite no differences in hardness were observed. Hydrogen charging neither modifies the grain structure of the steel. The tribocorrosion results show that the hydrogen uptake has an impact on the steel degradation (hydrogen blocks deformation, increases the strain accumulation, and higher subsurface recrystallization was observed) when no passive film is formed on the steel (cathodic conditions). The main effect of hydrogen is grain refinement. In the presence of surface films (passive conditions), no difference was observed between the tribocorrosion behaviour of the charged and non-charged samples. When imposing passive conditions, hydrogen intake into the material can be oxidized, thus its effect on the tribocorrosion response is minimized. The surface of the material was embrittled by the presence of the passive film, regardless of the hydrogen charging.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"588 ","pages":"Article 206482"},"PeriodicalIF":6.1,"publicationDate":"2025-12-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145897879","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-25DOI: 10.1016/j.wear.2025.206501
Beata Białobrzeska
This study presents an evaluation of the abrasive wear of various grades of cast steel in relation to their mechanical properties and microstructure. Experimental values of volumetric wear were compared with values calculated using the classical Archard model, with a particular focus on the validity of employing a constant wear coefficient. It was found that, for high-hardness cast steels with a martensitic microstructure, the model showed good agreement with experimental data (differences up to ±14 %). For materials with greater ductility and a ferritic–pearlitic microstructure, the discrepancies reached as much as 66 %, indicating the need to modify the model by incorporating microstructural characteristics. To correlate mechanical properties with wear resistance, regression analysis and discriminant analysis were applied. Regression analysis demonstrated a correlation between wear resistance and both hardness and yield strength, whereas no clear relationships were found for parameters describing ductility. Discriminant analysis, however, indicated that hardness and percentage elongation after fracture had the greatest influence on the wear behaviour. To relate the type of microstructure to wear resistance, correspondence analysis was employed. The results enabled the ranking of microstructures according to increasing wear resistance. It was thus confirmed that the microstructures providing the highest wear resistance are lower bainite with martensite and precipitates of finely dispersed primary carbides.
{"title":"Prediction of cast steel three-body abrasive wear by multivariate analysis","authors":"Beata Białobrzeska","doi":"10.1016/j.wear.2025.206501","DOIUrl":"10.1016/j.wear.2025.206501","url":null,"abstract":"<div><div>This study presents an evaluation of the abrasive wear of various grades of cast steel in relation to their mechanical properties and microstructure. Experimental values of volumetric wear were compared with values calculated using the classical Archard model, with a particular focus on the validity of employing a constant wear coefficient. It was found that, for high-hardness cast steels with a martensitic microstructure, the model showed good agreement with experimental data (differences up to ±14 %). For materials with greater ductility and a ferritic–pearlitic microstructure, the discrepancies reached as much as 66 %, indicating the need to modify the model by incorporating microstructural characteristics. To correlate mechanical properties with wear resistance, regression analysis and discriminant analysis were applied. Regression analysis demonstrated a correlation between wear resistance and both hardness and yield strength, whereas no clear relationships were found for parameters describing ductility. Discriminant analysis, however, indicated that hardness and percentage elongation after fracture had the greatest influence on the wear behaviour. To relate the type of microstructure to wear resistance, correspondence analysis was employed. The results enabled the ranking of microstructures according to increasing wear resistance. It was thus confirmed that the microstructures providing the highest wear resistance are lower bainite with martensite and precipitates of finely dispersed primary carbides.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"588 ","pages":"Article 206501"},"PeriodicalIF":6.1,"publicationDate":"2025-12-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145940638","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-24DOI: 10.1016/j.wear.2025.206486
Jian Zhang , Dianxiu Xia , Han Zhang , R.D.K. Misra , Shouren Wang , Lin Cui , Xiucheng Li
An innovative multiscale microstructural approach based on a secondary quenching heat treatment was adopted to increase resistance to fretting wear in a bearing steel. In this regard, the mechanisms associated with fretting wear are discussed. The wear-resistance was enabled by synergistic grain refinement and precipitation strengthening. By designing a dual-stage quenching process and employing multiscale characterization techniques including scanning electron microscopy (SEM), electron backscatter diffraction (EBSD), and transmission electron microscopy (TEM), the study comprehensively elucidates the effects of secondary quenching on austenite grain evolution, martensitic transformation, and nanoscale precipitation. The results demonstrated that secondary quenching significantly refined the austenite grain size from 18.61 ± 0.31 μm after single quenching (880 °C) to 5.23 ± 0.09 μm, with a refinement rate of ∼72 %—and simultaneously promoted the refinement and homogenization of martensitic laths. Electron microscopy studies revealed uniform dispersion of nanoscale carbides in the secondary-quenched samples, which effectively inhibited dislocation motion and interface migration, thereby enhancing matrix strengthening. In fretting wear tests conducted using a Si3N4 (silicon nitride) ball as the counterpart, the secondary-quenched samples exhibited an 18.2 % reduction in wear volume (down to (2.34 ± 0.03) × 106 μm3) compared to the single-quenched (880 °C) samples, together with noticeable reduction in both friction coefficient and wear rate. Surface morphology observations revealed smoother wear scars with significantly reduced spalling and cracking. Further analysis showed that secondary quenching facilitated the formation of a stable dynamic oxide film, reducing interfacial shear strength and shifting the dominant wear mechanism from brittle spalling to an oxidative–abrasive composite mode. This study provides both theoretical foundation and guidelines for microstructural design and performance optimization of high-reliability bearing materials.
{"title":"Mechanism of increased resistance to fretting wear of bearing steel achieved through multiscale microstructural control","authors":"Jian Zhang , Dianxiu Xia , Han Zhang , R.D.K. Misra , Shouren Wang , Lin Cui , Xiucheng Li","doi":"10.1016/j.wear.2025.206486","DOIUrl":"10.1016/j.wear.2025.206486","url":null,"abstract":"<div><div>An innovative multiscale microstructural approach based on a secondary quenching heat treatment was adopted to increase resistance to fretting wear in a bearing steel. In this regard, the mechanisms associated with fretting wear are discussed. The wear-resistance was enabled by synergistic grain refinement and precipitation strengthening. By designing a dual-stage quenching process and employing multiscale characterization techniques including scanning electron microscopy (SEM), electron backscatter diffraction (EBSD), and transmission electron microscopy (TEM), the study comprehensively elucidates the effects of secondary quenching on austenite grain evolution, martensitic transformation, and nanoscale precipitation. The results demonstrated that secondary quenching significantly refined the austenite grain size from 18.61 ± 0.31 μm after single quenching (880 °C) to 5.23 ± 0.09 μm, with a refinement rate of ∼72 %—and simultaneously promoted the refinement and homogenization of martensitic laths. Electron microscopy studies revealed uniform dispersion of nanoscale carbides in the secondary-quenched samples, which effectively inhibited dislocation motion and interface migration, thereby enhancing matrix strengthening. In fretting wear tests conducted using a Si<sub>3</sub>N<sub>4</sub> (silicon nitride) ball as the counterpart, the secondary-quenched samples exhibited an 18.2 % reduction in wear volume (down to (2.34 ± 0.03) × 10<sup>6</sup> μm<sup>3</sup>) compared to the single-quenched (880 °C) samples, together with noticeable reduction in both friction coefficient and wear rate. Surface morphology observations revealed smoother wear scars with significantly reduced spalling and cracking. Further analysis showed that secondary quenching facilitated the formation of a stable dynamic oxide film, reducing interfacial shear strength and shifting the dominant wear mechanism from brittle spalling to an oxidative–abrasive composite mode. This study provides both theoretical foundation and guidelines for microstructural design and performance optimization of high-reliability bearing materials.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"587 ","pages":"Article 206486"},"PeriodicalIF":6.1,"publicationDate":"2025-12-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145842280","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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