Pub Date : 2024-10-09DOI: 10.1016/j.wear.2024.205589
K. Oldknow , R. Stock , E. Vollebregt
This paper revisits a comprehensive data set generated in a prior test program using a full-scale wheel-rail test rig. The test program evaluated premium and standard grade rail steels with respect to wear and rolling contact fatigue (RCF). The current work evaluates the evolution of rail profiles throughout the test cases, taking advantage of the database of wheel and rail profiles that were collected. Contact conditions are modelled using the CONTACT library, including recent developments in the handling of conformal geometries and interfacial layers. Observations are made regarding the relative characteristics of rail profiles for each steel type, as they evolve with accumulated wheel passes, on the basis of the computed contact conditions.
{"title":"Effects of rail hardness on transverse profile evolution and computed contact conditions in a full-scale wheel-rail test rig evaluation","authors":"K. Oldknow , R. Stock , E. Vollebregt","doi":"10.1016/j.wear.2024.205589","DOIUrl":"10.1016/j.wear.2024.205589","url":null,"abstract":"<div><div>This paper revisits a comprehensive data set generated in a prior test program using a full-scale wheel-rail test rig. The test program evaluated premium and standard grade rail steels with respect to wear and rolling contact fatigue (RCF). The current work evaluates the evolution of rail profiles throughout the test cases, taking advantage of the database of wheel and rail profiles that were collected. Contact conditions are modelled using the CONTACT library, including recent developments in the handling of conformal geometries and interfacial layers. Observations are made regarding the relative characteristics of rail profiles for each steel type, as they evolve with accumulated wheel passes, on the basis of the computed contact conditions.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"560 ","pages":"Article 205589"},"PeriodicalIF":5.3,"publicationDate":"2024-10-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142531162","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}
Pub Date : 2024-10-05DOI: 10.1016/j.wear.2024.205583
Eric Ramalho Ferreira de Carvalho , Tahiana Francisca da Conceição Hermenegildo , Nicolau Apoena Castro , Anderson Clayton Alves de Melo , Salete Martins Alves
Turning of hardened tool steels has posed a significant challenge for machining professionals. Usually, hardened tool steels are machined under dry with ceramic or PCBN inserts. However, dry machining imposes a condition where high cutting temperatures are developed, which becomes prohibitive when the part's geometric and dimensional accuracy is required. On the other hand, using mineral oil-based cutting fluid has encountered increasing restrictions because of its unsustainable nature. In this context, developing new sustainable lubri-cooling techniques, such as using vegetable oils blended with nanoparticles, could be an appropriate alternative. Thus, the main objective of this study was to investigate the performance of three different vegetable oil-based nanolubricants blended with three different nanoparticles (CuO, a-C:H, and CuO + a-C:H), applied under MQL when machining a quenched and tempered AISI D6 tool steel. For this purpose, facing turning trials were performed using solid PCBN inserts with the following cutting parameters: Vc = 100 m/min, ap = 0.3 mm, and f = 0.1 mm/rev. For comparison, facing turning tests were performed under dry and pure vegetable oil (without nanoparticles) and applied under MQL. Output variables included average surface roughness (Ra), flank wear (VBC), wear mechanisms of the cutting edge, chip shape, and chip compression ratio (Rc). The results showed that the vegetable oil-based nanolubricants applied under MQL improved the tribological conditions in the chip-tool and workpiece-tool interfaces, mainly in the case of CuO + a-C:H nanolubricant. In this case, it enhanced the lubricating action of the vegetable oil, decreasing cutting tool wear probably because of the combination of rolling mechanism, - provided by the CuO nanoparticles, and the formation of a protective film, supplied by the a-C:H nanoparticles.
{"title":"Evaluation of lubrication mechanism of hybrid nanolubricants in turning hardened AISI D6 tool steel","authors":"Eric Ramalho Ferreira de Carvalho , Tahiana Francisca da Conceição Hermenegildo , Nicolau Apoena Castro , Anderson Clayton Alves de Melo , Salete Martins Alves","doi":"10.1016/j.wear.2024.205583","DOIUrl":"10.1016/j.wear.2024.205583","url":null,"abstract":"<div><div>Turning of hardened tool steels has posed a significant challenge for machining professionals. Usually, hardened tool steels are machined under dry with ceramic or PCBN inserts. However, dry machining imposes a condition where high cutting temperatures are developed, which becomes prohibitive when the part's geometric and dimensional accuracy is required. On the other hand, using mineral oil-based cutting fluid has encountered increasing restrictions because of its unsustainable nature. In this context, developing new sustainable lubri-cooling techniques, such as using vegetable oils blended with nanoparticles, could be an appropriate alternative. Thus, the main objective of this study was to investigate the performance of three different vegetable oil-based nanolubricants blended with three different nanoparticles (CuO, a-C:H, and CuO + a-C:H), applied under MQL when machining a quenched and tempered AISI D6 tool steel. For this purpose, facing turning trials were performed using solid PCBN inserts with the following cutting parameters: V<sub>c</sub> = 100 m/min, a<sub>p</sub> = 0.3 mm, and f = 0.1 mm/rev. For comparison, facing turning tests were performed under dry and pure vegetable oil (without nanoparticles) and applied under MQL. Output variables included average surface roughness (R<sub>a</sub>), flank wear (VB<sub>C</sub>), wear mechanisms of the cutting edge, chip shape, and chip compression ratio (R<sub>c</sub>). The results showed that the vegetable oil-based nanolubricants applied under MQL improved the tribological conditions in the chip-tool and workpiece-tool interfaces, mainly in the case of CuO + a-C:H nanolubricant. In this case, it enhanced the lubricating action of the vegetable oil, decreasing cutting tool wear probably because of the combination of rolling mechanism, - provided by the CuO nanoparticles, and the formation of a protective film, supplied by the a-C:H nanoparticles.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"558 ","pages":"Article 205583"},"PeriodicalIF":5.3,"publicationDate":"2024-10-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142424960","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 : 2024-10-04DOI: 10.1016/j.wear.2024.205588
Yi Liu , Rui Xu , Yanhui Zhang , Jianli Wang , Shanhong Wan , Liuyang Bai
This work investigates the wear behavior of nickel-based alloy during ultrasonic vibration-assisted machining (UVAM) by combining molecular dynamics simulation and thermodynamic theory. The research reveals that the tangential force exhibits periodic variations during UVAM, with a period half of the vibration period. Tangential force and total resistance decrease due to the synergistic effect of vibration-induced softening and thermal softening. A deeper understanding of the total resistance variation during the UVAM process can be achieved by the dimensionless resistance coefficient, which is difficult for the traditional friction coefficient (CoF). The Bejan number elucidates the contributions of the thermal softening and vibration-induced softening effects in the wear process. The findings highlight that the vibration-induced softening effect dominates when adjusting the amplitude for the active control of friction. In contrast, when the frequency is modulated, the contributions of vibration-induced softening and thermal softening effects are nearly equivalent. Furthermore, the wear mode transitions with increasing vibration frequency, characterized by the Strouhal number (Srw). The vibration wear mode attains dominance when Srw > 1.88. This work provides essential theoretical guidance to gain insight into the wear behavior in UVAM to optimize the machining performance.
{"title":"Insights into vibration-induced softening effect: A thermodynamic approach","authors":"Yi Liu , Rui Xu , Yanhui Zhang , Jianli Wang , Shanhong Wan , Liuyang Bai","doi":"10.1016/j.wear.2024.205588","DOIUrl":"10.1016/j.wear.2024.205588","url":null,"abstract":"<div><div>This work investigates the wear behavior of nickel-based alloy during ultrasonic vibration-assisted machining (UVAM) by combining molecular dynamics simulation and thermodynamic theory. The research reveals that the tangential force exhibits periodic variations during UVAM, with a period half of the vibration period. Tangential force and total resistance decrease due to the synergistic effect of vibration-induced softening and thermal softening. A deeper understanding of the total resistance variation during the UVAM process can be achieved by the dimensionless resistance coefficient, which is difficult for the traditional friction coefficient (CoF). The Bejan number elucidates the contributions of the thermal softening and vibration-induced softening effects in the wear process. The findings highlight that the vibration-induced softening effect dominates when adjusting the amplitude for the active control of friction. In contrast, when the frequency is modulated, the contributions of vibration-induced softening and thermal softening effects are nearly equivalent. Furthermore, the wear mode transitions with increasing vibration frequency, characterized by the Strouhal number (<em>Sr</em><sub><em>w</em></sub>). The vibration wear mode attains dominance when <em>Sr</em><sub><em>w</em></sub> > 1.88. This work provides essential theoretical guidance to gain insight into the wear behavior in UVAM to optimize the machining performance.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"558 ","pages":"Article 205588"},"PeriodicalIF":5.3,"publicationDate":"2024-10-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142424959","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}
This study investigates laser-cladded high entropy alloy (HEA) coatings on high-speed train axles to enhance wear resistance under specific fretting conditions. Axles in humid and acidic environments absorb hydrogen, leading to accumulation in grain boundaries, which weakens their structure and causes damage under alternating stress. Despite this, the impact of hydrogen damage on the fretting wear behavior of HEA coatings has not been explored. To address this, we performed fretting wear tests on a laser-cladded FeCoCrNiMo0.2 coating and a GCr15 steel ball friction system, evaluating their performance before and after hydrogen exposure. The results of the study indicate that under a constant load of Fn = 10N and a displacement amplitude of D = 50 μm, the friction coefficient, maximum wear depth, wear volume, and wear rate increased when the system was in the hydrogen charging state compared to the non-hydrogen charging state. Specifically, the friction coefficient increased from 0.60 to 0.93, the maximum wear depth increased from 2.82 μm to 3.63 μm, the wear volume increased from 14.106 × 104μm3 to 22.098 × 104μm3, and the wear rate increased from 28.213 × 10−6 mm/Nm to 36.600 × 10−6 mm/Nm. Under the hydrogen charging state, the friction coefficient, maximum wear depth, wear volume, and wear rate all increased. This is due to hydrogen damage, including the formation of pitting pits and cracks on the surface of the coating, stress concentration, and brittle failure caused by hydrogen infiltration into the material. The presence of hydrogen makes the surface of the coating more prone to detachment, resulting in finer wear debris, deeper grooves, and increased oxidation. These factors accelerate the wear of the coating. This finding will contribute to the development and improvement of advanced surface modification techniques for materials in the hydrogen environment.
{"title":"Effects of hydrogen on the fretting wear behavior of laser cladded FeCoCrNiMo0.2 high entropy alloy coating","authors":"Junjun Jin , Zhiyi Zhang , Bing Chen , Xiangyang Wu , Feifei Qiu , Zhenghong Fu , Wenjing Chen , Guoqing Gou","doi":"10.1016/j.wear.2024.205587","DOIUrl":"10.1016/j.wear.2024.205587","url":null,"abstract":"<div><div>This study investigates laser-cladded high entropy alloy (HEA) coatings on high-speed train axles to enhance wear resistance under specific fretting conditions. Axles in humid and acidic environments absorb hydrogen, leading to accumulation in grain boundaries, which weakens their structure and causes damage under alternating stress. Despite this, the impact of hydrogen damage on the fretting wear behavior of HEA coatings has not been explored. To address this, we performed fretting wear tests on a laser-cladded FeCoCrNiMo<sub>0.2</sub> coating and a GCr15 steel ball friction system, evaluating their performance before and after hydrogen exposure. The results of the study indicate that under a constant load of F<sub>n</sub> = 10N and a displacement amplitude of D = 50 μm, the friction coefficient, maximum wear depth, wear volume, and wear rate increased when the system was in the hydrogen charging state compared to the non-hydrogen charging state. Specifically, the friction coefficient increased from 0.60 to 0.93, the maximum wear depth increased from 2.82 μm to 3.63 μm, the wear volume increased from 14.106 × 10<sup>4</sup>μm<sup>3</sup> to 22.098 × 10<sup>4</sup>μm<sup>3</sup>, and the wear rate increased from 28.213 × 10<sup>−6</sup> mm/Nm to 36.600 × 10<sup>−6</sup> mm/Nm. Under the hydrogen charging state, the friction coefficient, maximum wear depth, wear volume, and wear rate all increased. This is due to hydrogen damage, including the formation of pitting pits and cracks on the surface of the coating, stress concentration, and brittle failure caused by hydrogen infiltration into the material. The presence of hydrogen makes the surface of the coating more prone to detachment, resulting in finer wear debris, deeper grooves, and increased oxidation. These factors accelerate the wear of the coating. This finding will contribute to the development and improvement of advanced surface modification techniques for materials in the hydrogen environment.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"560 ","pages":"Article 205587"},"PeriodicalIF":5.3,"publicationDate":"2024-10-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142445556","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 : 2024-09-30DOI: 10.1016/j.wear.2024.205585
Ester Villanueva , Iban Vicario , Joseba Albizuri , Gurutze Arruebarrena , Teresa Guraya
The present study investigates the tribological properties of a newly developed multicomponent aluminium weight-light multicomponent alloy for wear based on the Al80Mg10Si5Cu5 system for lightweight automotive applications, especially back drum discs. The samples were manufactured by High-Pressure Die Casting (HPDC) employing cast alloy returns and secondary aluminium ingots and were tested at room temperature (RT) and 200 °C. It has been observed that the Al80Mg10Si5Cu5 alloy offers a higher hardness and wear resistance at RT and especially at 200 °C compared with the AlSi9Cu3 reference alloy (x10 times reduction in wear rate). The impact of maintaining the external surface layer (skin) of HPDC cast parts has been studied for the ball-on disc test, showing improved tribological properties and the possibility of avoiding the machining of contact surfaces. The as-cast Al80Mg10Si5Cu alloy with the surface layer showed a wear rate coefficient of 5 × 10−4 mm3/N.m2 at RT, a 50 % lower than that of the sample without skin. Solution heat-treated samples (72 h at 440 °C, water quenching at 75 °C, and natural aging) with the surface layer showed a wear rate coefficient of 11 × 10−4 mm3/N.m2, approximately 20 % lower than the sample without a surface layer. The wear rate of AlSi9Cu3 alloy decreased by more than 50 % in the samples without skin at RT. At 200 °C, wear rate coefficients were lower in the samples with the surface layer.
{"title":"Wear properties of a new Al80Mg10Si5Cu5 multicomponent alloy","authors":"Ester Villanueva , Iban Vicario , Joseba Albizuri , Gurutze Arruebarrena , Teresa Guraya","doi":"10.1016/j.wear.2024.205585","DOIUrl":"10.1016/j.wear.2024.205585","url":null,"abstract":"<div><div>The present study investigates the tribological properties of a newly developed multicomponent aluminium weight-light multicomponent alloy for wear based on the Al80Mg10Si5Cu5 system for lightweight automotive applications, especially back drum discs. The samples were manufactured by High-Pressure Die Casting (HPDC) employing cast alloy returns and secondary aluminium ingots and were tested at room temperature (RT) and 200 °C. It has been observed that the Al80Mg10Si5Cu5 alloy offers a higher hardness and wear resistance at RT and especially at 200 °C compared with the AlSi9Cu3 reference alloy (x10 times reduction in wear rate). The impact of maintaining the external surface layer (skin) of HPDC cast parts has been studied for the ball-on disc test, showing improved tribological properties and the possibility of avoiding the machining of contact surfaces. The as-cast Al80Mg10Si5Cu alloy with the surface layer showed a wear rate coefficient of 5 × 10<sup>−4</sup> mm<sup>3</sup>/N.m<sup>2</sup> at RT, a 50 % lower than that of the sample without skin. Solution heat-treated samples (72 h at 440 °C, water quenching at 75 °C, and natural aging) with the surface layer showed a wear rate coefficient of 11 × 10<sup>−4</sup> mm<sup>3</sup>/N.m<sup>2</sup>, approximately 20 % lower than the sample without a surface layer. The wear rate of AlSi9Cu3 alloy decreased by more than 50 % in the samples without skin at RT. At 200 °C, wear rate coefficients were lower in the samples with the surface layer.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"558 ","pages":"Article 205585"},"PeriodicalIF":5.3,"publicationDate":"2024-09-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142424527","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}
Pub Date : 2024-09-30DOI: 10.1016/j.wear.2024.205586
Xibo Shao , Haoyi Xu , Minghui Lang , Xueqi Gu , Jianxi Liu , Xianzong Wang , Long Wang , Jun Yang
As a solid lubricating material with excellent anti-friction and anti-wear performance, MoS2 is prone to oxidation in high temperature and atmospheric environment, which leads to the deterioration of lubricating performance and the decrease of service life. The addition of nano-particle oxides can improve the high-temperature lubricating performance of MoS2-based solid lubricating materials to some extent, but the effects of different nanoparticles oxides under the same test condition is still unclear. The effects of nano-particles oxides (TiO2, Cr2O3, Al2O3 and ZrO2) on the tribological performance of MoS2-based composites at 450 °C were compared. It was shown that MoS2-TiO2 exhibited the best high temperature tribological properties, and its average friction coefficient was about 0.26, which was about 26 % and 10 % lower than that of 718 substrate and MoS2, respectively. Here we attempted to propose a new concept of correlative potential to explain the lubricating difference of binary oxides under high temperature. The good tribological performance of MoS2-TiO2 at high temperature was attributed to the low correlative potential of TiO2 nanoparticles and the dense tribo-oxide layer formed at the friction interface that reduce the shearing of the rubbing interface. The research results can provide reference for the selection and design of MoS2-based composites, and also enrich the theory of high temperature tribology.
{"title":"Dependence of high temperature tribological performance of MoS2-based composites on type of oxides","authors":"Xibo Shao , Haoyi Xu , Minghui Lang , Xueqi Gu , Jianxi Liu , Xianzong Wang , Long Wang , Jun Yang","doi":"10.1016/j.wear.2024.205586","DOIUrl":"10.1016/j.wear.2024.205586","url":null,"abstract":"<div><div>As a solid lubricating material with excellent anti-friction and anti-wear performance, MoS<sub>2</sub> is prone to oxidation in high temperature and atmospheric environment, which leads to the deterioration of lubricating performance and the decrease of service life. The addition of nano-particle oxides can improve the high-temperature lubricating performance of MoS<sub>2</sub>-based solid lubricating materials to some extent, but the effects of different nanoparticles oxides under the same test condition is still unclear. The effects of nano-particles oxides (TiO<sub>2</sub>, Cr<sub>2</sub>O<sub>3</sub>, Al<sub>2</sub>O<sub>3</sub> and ZrO<sub>2</sub>) on the tribological performance of MoS<sub>2</sub>-based composites at 450 °C were compared. It was shown that MoS<sub>2</sub>-TiO<sub>2</sub> exhibited the best high temperature tribological properties, and its average friction coefficient was about 0.26, which was about 26 % and 10 % lower than that of 718 substrate and MoS<sub>2</sub>, respectively. Here we attempted to propose a new concept of correlative potential to explain the lubricating difference of binary oxides under high temperature. The good tribological performance of MoS<sub>2</sub>-TiO<sub>2</sub> at high temperature was attributed to the low correlative potential of TiO<sub>2</sub> nanoparticles and the dense tribo-oxide layer formed at the friction interface that reduce the shearing of the rubbing interface. The research results can provide reference for the selection and design of MoS<sub>2</sub>-based composites, and also enrich the theory of high temperature tribology.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"558 ","pages":"Article 205586"},"PeriodicalIF":5.3,"publicationDate":"2024-09-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142424961","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 : 2024-09-29DOI: 10.1016/j.wear.2024.205581
Yanjiang Wang , Zhi Jia , Jinjin Ji , Wenjie Lu , Dexue Liu
The tribo-oxidation layer is typically formed at the contact interface of high temperature wear, which exhibits a significant effect on the friction behavior of gradient nanostructured (GNS) materials. This study systematically investigated the wear resistance, near-surface microstructure, and compositional changes of ultra-thick GNS Inconel 625 alloy subjected to surface mechanical rolling treatment (SMRT) under high-temperature sliding wear conditions. The experimental results indicated that as the temperature increased to 500 °C, a tribo-oxidation layer was formed on the surface of the GNS sample, thereby resulting in an abnormal increase in the coefficient of friction (COF) and a rapid decrease in the wear rate. The gradient nanostructures facilitated oxidation diffusion channels, promoting the formation of a protective Cr2O3 film and spinel oxides, reducing the wear rate. At lower temperatures, a rapidly formed Cr2O3 film shielded the matrix, forming a tribo-oxidation layer composed of Cr2O3 and nickel. At 800 °C, the tribo-oxidation layer exhibited complex structures, including glaze, spinel oxide, Cr2O3, and Cr2O3/Ni mixed layers. This complexity was attributable to the oxidation diffusion rate of the gradient nanostructures and tribo-oxide layers. The findings not only elucidated the tribo-oxidation mechanism of GNS nickel-based superalloys but also offered valuable insights for designing wear-resistant materials.
{"title":"Tribo-oxidation mechanism of gradient nanostructured Inconel 625 alloy during high-temperature wear","authors":"Yanjiang Wang , Zhi Jia , Jinjin Ji , Wenjie Lu , Dexue Liu","doi":"10.1016/j.wear.2024.205581","DOIUrl":"10.1016/j.wear.2024.205581","url":null,"abstract":"<div><div>The tribo-oxidation layer is typically formed at the contact interface of high temperature wear, which exhibits a significant effect on the friction behavior of gradient nanostructured (GNS) materials. This study systematically investigated the wear resistance, near-surface microstructure, and compositional changes of ultra-thick GNS Inconel 625 alloy subjected to surface mechanical rolling treatment (SMRT) under high-temperature sliding wear conditions. The experimental results indicated that as the temperature increased to 500 °C, a tribo-oxidation layer was formed on the surface of the GNS sample, thereby resulting in an abnormal increase in the coefficient of friction (COF) and a rapid decrease in the wear rate. The gradient nanostructures facilitated oxidation diffusion channels, promoting the formation of a protective Cr<sub>2</sub>O<sub>3</sub> film and spinel oxides, reducing the wear rate. At lower temperatures, a rapidly formed Cr<sub>2</sub>O<sub>3</sub> film shielded the matrix, forming a tribo-oxidation layer composed of Cr<sub>2</sub>O<sub>3</sub> and nickel. At 800 °C, the tribo-oxidation layer exhibited complex structures, including glaze, spinel oxide, Cr<sub>2</sub>O<sub>3</sub>, and Cr<sub>2</sub>O<sub>3</sub>/Ni mixed layers. This complexity was attributable to the oxidation diffusion rate of the gradient nanostructures and tribo-oxide layers. The findings not only elucidated the tribo-oxidation mechanism of GNS nickel-based superalloys but also offered valuable insights for designing wear-resistant materials.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"558 ","pages":"Article 205581"},"PeriodicalIF":5.3,"publicationDate":"2024-09-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142357538","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 : 2024-09-27DOI: 10.1016/j.wear.2024.205582
E. Irazu, U. Alonso, B. Izquierdo, L. Godino
C/SiC Ceramic Matrix Composites (CMCs) have been identified as a key material for improving high-speed braking systems and aerospace components as they offer low density, and high specific strength at high temperatures. Grinding is often used for the machining stage due to the high hardness, heterogeneity, and brittle nature of CMSs. Previous studies have explored the effect of grinding parameters, but most of them do not indicate whether they have used the same grinding wheel for all tests. In fact, there is limited understanding of how wear impacts process performance over the grinding wheel's lifespan. In this work, the effect of grinding wheel wear on cutting forces is addressed and grinding wheel topography is analyzed with the objective of identifying a parameter that allows to quantify grinding wheel wear in a non-destructive way. Results have shown that, after a short conditioning stage, cutting forces increase approximately linearly with the machined length. For the machining conditions analyzed, normal forces increase 200 % in the first machined meter (first stage), then rise 17 % per meter thereafter (second stage). Tangential forces rise 300 % in first meter and then climb 27 % per meter subsequently. In this second stage, force ratio approaches a constant value and the generation of flat surfaces on the diamond grains is the dominating wear mechanism. Under such conditions, 3D surface roughness parameters Sa, Sq, Spk and Sku have been proven to be useful for monitoring wheel wear.
{"title":"Grinding of C/SiC ceramic matrix composites: Influence of grinding parameters on tool wear","authors":"E. Irazu, U. Alonso, B. Izquierdo, L. Godino","doi":"10.1016/j.wear.2024.205582","DOIUrl":"10.1016/j.wear.2024.205582","url":null,"abstract":"<div><div>C/SiC Ceramic Matrix Composites (CMCs) have been identified as a key material for improving high-speed braking systems and aerospace components as they offer low density, and high specific strength at high temperatures. Grinding is often used for the machining stage due to the high hardness, heterogeneity, and brittle nature of CMSs. Previous studies have explored the effect of grinding parameters, but most of them do not indicate whether they have used the same grinding wheel for all tests. In fact, there is limited understanding of how wear impacts process performance over the grinding wheel's lifespan. In this work, the effect of grinding wheel wear on cutting forces is addressed and grinding wheel topography is analyzed with the objective of identifying a parameter that allows to quantify grinding wheel wear in a non-destructive way. Results have shown that, after a short conditioning stage, cutting forces increase approximately linearly with the machined length. For the machining conditions analyzed, normal forces increase 200 % in the first machined meter (first stage), then rise 17 % per meter thereafter (second stage). Tangential forces rise 300 % in first meter and then climb 27 % per meter subsequently. In this second stage, force ratio approaches a constant value and the generation of flat surfaces on the diamond grains is the dominating wear mechanism. Under such conditions, 3D surface roughness parameters Sa, Sq, Spk and Sku have been proven to be useful for monitoring wheel wear.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"558 ","pages":"Article 205582"},"PeriodicalIF":5.3,"publicationDate":"2024-09-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142424958","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}
Pub Date : 2024-09-26DOI: 10.1016/j.wear.2024.205584
Jiayuan Yan , Chunxia Wu , Yongxing Liu , Wangfei Shen , Xiaoliang Zhang , Ping Li , Guangshuo Wang , Zehu Wang , Hongwei Che , Yanming Wang
Composite nano-lubricating fillers have attracted much attention due to their excellent synergistic effect. In this study, MoS2 nanoflowers composed of two-dimensional nanosheets were synthesized by precise control of hydrothermal conditions. Using the "bridging" effect of dopamine, the flower-like MoS2 was assembled with MXene to form a unique compound filler. This distinctive structure perfectly retained the shape of the MoS2 flower. The impacts of compound fillers on the thermodynamic, mechanistic, and frictional properties of polyimide (PI) coatings were scrutinized. The formation of the compound fillers between MXene and MoS2 effectively improve the interface compatibility of individual materials in the PI matrix. The compound fillers can enhance the thermodynamic stability and mechanical properties of PI. It is noteworthy that the frictional coefficient of the PI/(MoS2:MXene = 4:6) compound coating decreased by 47.2 %, and the attrition rate reduced by 98.5 % compared to the pure PI coating. The compound lubricating filler prepared by the combination of two types of two-dimensional lubrication fillers has an important application prospect in the field of wear resistance of polymer materials.
{"title":"Synergetic enhancement of wear resistance of polyimide coatings through the integration of MoS2 nanoflowers and MXene nanosheets","authors":"Jiayuan Yan , Chunxia Wu , Yongxing Liu , Wangfei Shen , Xiaoliang Zhang , Ping Li , Guangshuo Wang , Zehu Wang , Hongwei Che , Yanming Wang","doi":"10.1016/j.wear.2024.205584","DOIUrl":"10.1016/j.wear.2024.205584","url":null,"abstract":"<div><div>Composite nano-lubricating fillers have attracted much attention due to their excellent synergistic effect. In this study, MoS<sub>2</sub> nanoflowers composed of two-dimensional nanosheets were synthesized by precise control of hydrothermal conditions. Using the \"bridging\" effect of dopamine, the flower-like MoS<sub>2</sub> was assembled with MXene to form a unique compound filler. This distinctive structure perfectly retained the shape of the MoS<sub>2</sub> flower. The impacts of compound fillers on the thermodynamic, mechanistic, and frictional properties of polyimide (PI) coatings were scrutinized. The formation of the compound fillers between MXene and MoS<sub>2</sub> effectively improve the interface compatibility of individual materials in the PI matrix. The compound fillers can enhance the thermodynamic stability and mechanical properties of PI. It is noteworthy that the frictional coefficient of the PI/(MoS<sub>2</sub>:MXene = 4:6) compound coating decreased by 47.2 %, and the attrition rate reduced by 98.5 % compared to the pure PI coating. The compound lubricating filler prepared by the combination of two types of two-dimensional lubrication fillers has an important application prospect in the field of wear resistance of polymer materials.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"558 ","pages":"Article 205584"},"PeriodicalIF":5.3,"publicationDate":"2024-09-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142357536","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 : 2024-09-21DOI: 10.1016/j.wear.2024.205580
Yanjie Du, Yuwen Sun
Cutter wear is an unavoidable issue during the milling of difficult-to-machine materials such as Ti6Al4V, which severely affects cutting performance and surface quality. Especially in multi-axis milling, the complex and irregular contact area between cutter and workpiece increases the difficulty of wear prediction. This paper proposes a flank wear prediction model of bull-nose cutter in the multi-axis milling process of Ti6Al4V with TiAlN coated inserts. The cutter workpiece engagement (CWE) zone is analyzed and the wear contact length of cutting edge is obtained, which reveals the uneven distribution characteristics of flank wear. After that, by analyzing the geometric profile properties of cutter wear in multi-axis milling, abrasive and adhesive wear, a flank wear prediction model that takes coating hardness and cutting temperature model into account is established. The proposed model is calibrated and validated by the multi-axis milling experiment of Ti6Al4V with TiAlN coated inserts. The results show that the novel wear model has high accuracy with an average percentage error of 12.76 % and can accurately and quickly predict flank wear in multi-axis milling of Ti6Al4V. Finally, the cutter wear mechanism and chip formation are analyzed, which show that the main wear mechanism is abrasive wear and adhesive wear, and there was no obvious oxidation wear.
{"title":"Mechanism analysis and prediction of bull-nose cutter wear in multi-axis milling of Ti6Al4V with TiAlN coated inserts","authors":"Yanjie Du, Yuwen Sun","doi":"10.1016/j.wear.2024.205580","DOIUrl":"10.1016/j.wear.2024.205580","url":null,"abstract":"<div><div>Cutter wear is an unavoidable issue during the milling of difficult-to-machine materials such as Ti6Al4V, which severely affects cutting performance and surface quality. Especially in multi-axis milling, the complex and irregular contact area between cutter and workpiece increases the difficulty of wear prediction. This paper proposes a flank wear prediction model of bull-nose cutter in the multi-axis milling process of Ti6Al4V with TiAlN coated inserts. The cutter workpiece engagement (CWE) zone is analyzed and the wear contact length of cutting edge is obtained, which reveals the uneven distribution characteristics of flank wear. After that, by analyzing the geometric profile properties of cutter wear in multi-axis milling, abrasive and adhesive wear, a flank wear prediction model that takes coating hardness and cutting temperature model into account is established. The proposed model is calibrated and validated by the multi-axis milling experiment of Ti6Al4V with TiAlN coated inserts. The results show that the novel wear model has high accuracy with an average percentage error of 12.76 % and can accurately and quickly predict flank wear in multi-axis milling of Ti6Al4V. Finally, the cutter wear mechanism and chip formation are analyzed, which show that the main wear mechanism is abrasive wear and adhesive wear, and there was no obvious oxidation wear.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"558 ","pages":"Article 205580"},"PeriodicalIF":5.3,"publicationDate":"2024-09-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142314555","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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