Pub Date : 2025-12-24DOI: 10.1016/j.wear.2025.206481
Yiwen Zhou , Jiang Bi , Dehua Liu , Zhuoyun Yang , Guojiang Dong , Yuhang Li , Xiangdong Jia
H13 hot-work die steel is susceptible to oxidative spalling during high-temperature service, while conventional treatments struggle to balance strength and toughness. In this study, an AlCoCrFeNi high-entropy alloy coating was fabricated via laser cladding, with an innovative dual-phase strengthening system incorporating. The composite coating exhibits superior performance: average microhardness reaches 596.9 (±8.4) HV0.2 (2.8 × higher than the substrate); at 600 °C, the wear rate ((3.86 ± 0.15) × 10−5 mm3 N−1 m−1) decreases by 70.2 % compared to H13 steel; corrosion current density (3.34 × 10−7 A/cm2) is 45 % lower than the base coating. The strengthening mechanisms originate from B4C-derived dispersion hardening and Y2O3-enhanced oxidation resistance. This work proposes a multi-scale synergistic strategy for prolonging mold service life and establishes a theoretical foundation for coatings under extreme conditions.
{"title":"High-temperature wear behavior and mechanical properties of laser-clad AlCoCrFeNi HEA coatings on H13 steel co-strengthened by B4C/Y2O3","authors":"Yiwen Zhou , Jiang Bi , Dehua Liu , Zhuoyun Yang , Guojiang Dong , Yuhang Li , Xiangdong Jia","doi":"10.1016/j.wear.2025.206481","DOIUrl":"10.1016/j.wear.2025.206481","url":null,"abstract":"<div><div>H13 hot-work die steel is susceptible to oxidative spalling during high-temperature service, while conventional treatments struggle to balance strength and toughness. In this study, an AlCoCrFeNi high-entropy alloy coating was fabricated via laser cladding, with an innovative dual-phase strengthening system incorporating. The composite coating exhibits superior performance: average microhardness reaches 596.9 (±8.4) HV<sub>0.2</sub> (2.8 × higher than the substrate); at 600 °C, the wear rate ((3.86 ± 0.15) × 10<sup>−5</sup> mm<sup>3</sup> N<sup>−1</sup> m<sup>−1</sup>) decreases by 70.2 % compared to H13 steel; corrosion current density (3.34 × 10<sup>−7</sup> A/cm<sup>2</sup>) is 45 % lower than the base coating. The strengthening mechanisms originate from B<sub>4</sub>C-derived dispersion hardening and Y<sub>2</sub>O<sub>3</sub>-enhanced oxidation resistance. This work proposes a multi-scale synergistic strategy for prolonging mold service life and establishes a theoretical foundation for coatings under extreme conditions.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"587 ","pages":"Article 206481"},"PeriodicalIF":6.1,"publicationDate":"2025-12-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145842283","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 : 2025-12-23DOI: 10.1016/j.wear.2025.206493
Lassi Raami , Kati Valtonen , Marco Wendler , Pasi Peura
Cavitation erosion of AISI 420 grade stainless steels was investigated after different heat treatments. The steels were subjected to 20 h of cavitation erosion using an ultrasonic vibratory apparatus. The mass losses were measured, and the results were compared with material properties. The eroded surfaces were examined with X-ray diffraction, scanning electron microscopy and optical profilometry. The results suggest that the cavitation erosion resistance is heavily dependent on the carbon content and the performed heat treatment. While for 0.2 C grade the best results were achieved in as-quenched condition, quenching and partitioning should be used when the carbon content is higher. During cavitation present retained austenite transforms into martensite, which hardens the surface and reduces the cavitation erosion rate. Thus, elimination of retained austenite with cryogenic treatment is not beneficial. If the steel is quenched without partitioning or tempering, the resulting microstructure may become brittle, eventually leading to high erosion rate. The results indicate that even short partitioning heat treatment can effectively reduce the martensite brittleness without sacrificing hardness or cavitation erosion resistance.
{"title":"Effect of heat treatments on the cavitation erosion evolution of AISI 420 stainless steels","authors":"Lassi Raami , Kati Valtonen , Marco Wendler , Pasi Peura","doi":"10.1016/j.wear.2025.206493","DOIUrl":"10.1016/j.wear.2025.206493","url":null,"abstract":"<div><div>Cavitation erosion of AISI 420 grade stainless steels was investigated after different heat treatments. The steels were subjected to 20 h of cavitation erosion using an ultrasonic vibratory apparatus. The mass losses were measured, and the results were compared with material properties. The eroded surfaces were examined with X-ray diffraction, scanning electron microscopy and optical profilometry. The results suggest that the cavitation erosion resistance is heavily dependent on the carbon content and the performed heat treatment. While for 0.2 C grade the best results were achieved in as-quenched condition, quenching and partitioning should be used when the carbon content is higher. During cavitation present retained austenite transforms into martensite, which hardens the surface and reduces the cavitation erosion rate. Thus, elimination of retained austenite with cryogenic treatment is not beneficial. If the steel is quenched without partitioning or tempering, the resulting microstructure may become brittle, eventually leading to high erosion rate. The results indicate that even short partitioning heat treatment can effectively reduce the martensite brittleness without sacrificing hardness or cavitation erosion resistance.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"587 ","pages":"Article 206493"},"PeriodicalIF":6.1,"publicationDate":"2025-12-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145842281","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 : 2025-12-23DOI: 10.1016/j.wear.2025.206487
Jaimie L. Daure , Matthew J. Carrington , Daniel Kóti , Philip H. Shipway , D. Graham McCartney , David A. Stewart
This paper describes the development of a novel heat treatment to significantly improve the high temperature galling behaviour of austenitic iron-based hardfacings. The alloy examined in this work is hot isostatically pressed (HIPed) Tristelle 5183 (T-5183) which is comprised of an austenitic matrix with (Cr, Fe)7C3 and NbC hard phases. In the HIPed condition, the galling pressure, was bounded as 211 MPa < < 317 MPa at room temperature, but this fell to < 53 MPa at 100 °C. In the as-HIPed state, the (Cr, Fe)7C3 fraction was significantly smaller than its equilibrium value due to its sluggish nucleation and growth kinetics during HIPing, with this resulting in a commensurate supersaturation of carbon in solution in the austenitic matrix. This carbon supersaturation results in an increase in the austenite stacking fault energy (SFE) and it is suggested that this in turn results in reduced resistance to galling at elevated temperatures. An extended high temperature heat treatment of the alloy has resulted in the following: (i) an increase in the carbide particle size; (ii) an increase in the volume fraction of carbide; (iii) a commensurate reduction in the carbon content of the austenite and thus a reduction in its SFE. Following heat treatment, the room temperature galling pressure remained bounded as 211 MPa < < 317 MPa (i.e. no significant improvement in galling resistance was observed); however, the heat treatment resulted in a significant increase in the elevated temperature capability of the alloy with the galling pressure being again bounded as 211 MPa < < 317 MPa at temperatures as high as 300 °C. Given the temperature-sensitivity of the observed improvements in galling behaviour and the temperature-sensitivity of the SFE of the austenitic matrix, it is argued that it is the change in austenite SFE associated with the heat treatment that is the dominant influence in the observed improvement in the galling resistance of this alloy.
In light of a review of relevant adjacent literature related to the destabilisation of high chromium cast irons, it is argued that the heat treatment method proposed here for improving high temperature galling capability has general applicability to any ferrous system composed of austenite and complex carbides (including hardfacings) and is generalisable to a variety of methods of manufacture (e.g. HIPing, weld and laser cladding, casting etc).
{"title":"Significant improvement in elevated temperature galling resistance of austenitic iron-based hard-facings through heat treatment","authors":"Jaimie L. Daure , Matthew J. Carrington , Daniel Kóti , Philip H. Shipway , D. Graham McCartney , David A. Stewart","doi":"10.1016/j.wear.2025.206487","DOIUrl":"10.1016/j.wear.2025.206487","url":null,"abstract":"<div><div>This paper describes the development of a novel heat treatment to significantly improve the high temperature galling behaviour of austenitic iron-based hardfacings. The alloy examined in this work is hot isostatically pressed (HIPed) Tristelle 5183 (T-5183) which is comprised of an austenitic matrix with (Cr, Fe)<sub>7</sub>C<sub>3</sub> and NbC hard phases. In the HIPed condition, the galling pressure, <span><math><mrow><msub><mi>σ</mi><mi>g</mi></msub></mrow></math></span> was bounded as 211 MPa < <span><math><mrow><msub><mi>σ</mi><mi>g</mi></msub></mrow></math></span> < 317 MPa at room temperature, but this fell to <span><math><mrow><msub><mi>σ</mi><mi>g</mi></msub></mrow></math></span> < 53 MPa at 100 °C. In the as-HIPed state, the (Cr, Fe)<sub>7</sub>C<sub>3</sub> fraction was significantly smaller than its equilibrium value due to its sluggish nucleation and growth kinetics during HIPing, with this resulting in a commensurate supersaturation of carbon in solution in the austenitic matrix. This carbon supersaturation results in an increase in the austenite stacking fault energy (SFE) and it is suggested that this in turn results in reduced resistance to galling at elevated temperatures. An extended high temperature heat treatment of the alloy has resulted in the following: (i) an increase in the carbide particle size; (ii) an increase in the volume fraction of carbide; (iii) a commensurate reduction in the carbon content of the austenite and thus a reduction in its SFE. Following heat treatment, the room temperature galling pressure remained bounded as 211 MPa < <span><math><mrow><msub><mi>σ</mi><mi>g</mi></msub></mrow></math></span> < 317 MPa (i.e. no significant improvement in galling resistance was observed); however, the heat treatment resulted in a significant increase in the elevated temperature capability of the alloy with the galling pressure being again bounded as 211 MPa < <span><math><mrow><msub><mi>σ</mi><mi>g</mi></msub></mrow></math></span> < 317 MPa at temperatures as high as 300 °C. Given the temperature-sensitivity of the observed improvements in galling behaviour and the temperature-sensitivity of the SFE of the austenitic matrix, it is argued that it is the change in austenite SFE associated with the heat treatment that is the dominant influence in the observed improvement in the galling resistance of this alloy.</div><div>In light of a review of relevant adjacent literature related to the destabilisation of high chromium cast irons, it is argued that the heat treatment method proposed here for improving high temperature galling capability has general applicability to any ferrous system composed of austenite and complex carbides (including hardfacings) and is generalisable to a variety of methods of manufacture (e.g. HIPing, weld and laser cladding, casting etc).</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"587 ","pages":"Article 206487"},"PeriodicalIF":6.1,"publicationDate":"2025-12-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145842288","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 the influence of polyurethane acrylate (PUA) content on the cavitation resistance of UV-cured epoxy acrylate (EPA)-PUA polymer networks. Four blends containing 0, 15, 30, and 45 wt% PUA were prepared and characterized to understand the relationship between mechanical properties and cavitation resistance. Thermogravimetric analysis (TGA), dynamic mechanical analysis (DMA), and nanoindentation were used to confirm that increasing PUA content in the epoxy matrix enhanced material deformability. Cavitation tests performed according to ASTM G32 revealed that increasing PUA content improved cavitation resistance, as evidenced by longer incubation periods before surface damage and fewer pits and cracks. Notably, nanoindentation conducted on cavitated surfaces showed a hardening effect during the incubation phase, particularly in the 45 % PUA blend, which was attributed to plastic deformation induced by cavitation. These findings highlight the role of material deformability in absorbing energy from collapsing bubble, making UV-cured EPA-PUA blends promising candidates for applications requiring polymeric coatings resistant to cavitation erosion.
{"title":"Enhanced ultrasonic cavitation resistance of photopolymerizable acrylate resins through increased proportion of polyurethane acrylate in the blend","authors":"Mohammed Bendimerad , Sylvain Giljean , Marie-José Pac , Cyril Marsiquet , Gautier Schrodj , Loïc Vidal , Dominique Zwingelstein , Jacques Lalevée , Laurent Vonna","doi":"10.1016/j.wear.2025.206492","DOIUrl":"10.1016/j.wear.2025.206492","url":null,"abstract":"<div><div>This study investigates the influence of polyurethane acrylate (PUA) content on the cavitation resistance of UV-cured epoxy acrylate (EPA)-PUA polymer networks. Four blends containing 0, 15, 30, and 45 wt% PUA were prepared and characterized to understand the relationship between mechanical properties and cavitation resistance. Thermogravimetric analysis (TGA), dynamic mechanical analysis (DMA), and nanoindentation were used to confirm that increasing PUA content in the epoxy matrix enhanced material deformability. Cavitation tests performed according to ASTM <span><span>G32</span><svg><path></path></svg></span> revealed that increasing PUA content improved cavitation resistance, as evidenced by longer incubation periods before surface damage and fewer pits and cracks. Notably, nanoindentation conducted on cavitated surfaces showed a hardening effect during the incubation phase, particularly in the 45 % PUA blend, which was attributed to plastic deformation induced by cavitation. These findings highlight the role of material deformability in absorbing energy from collapsing bubble, making UV-cured EPA-PUA blends promising candidates for applications requiring polymeric coatings resistant to cavitation erosion.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"587 ","pages":"Article 206492"},"PeriodicalIF":6.1,"publicationDate":"2025-12-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145842284","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 : 2025-12-23DOI: 10.1016/j.wear.2025.206488
Liang Fang , Xiaogang Xu , Anjun Li , Zhenbo Wang , Qiang Li
Hydraulic cavitation erosion is a prevalent form of wear in fluid engineering, which primarily results from the mechanical effects of cavity collapse. However, a precise understanding of the dynamic pitting process has been lacking. Coupled synchronized cavitation-erosion experiments with high-fidelity compressible cavitation simulations in a Venturi, this study investigates the mechanical pitting mechanism. The results definitively demonstrate that pitting originates solely from detached cavity collapse, and is irrelevant to attached cavity development and movement. The collapse process is revealed to be progressive, evolving through three successive physical stages: the initial isolated cavity collapse stage, the core large cavity collapse stage where extreme pressure arises from the spatiotemporal superposition of collapse-induced shocks, and the subsequent rebound cavity collapse stage characterized by multiple pressure peaks. Specifically, quantitative analysis attributes differential pitting severity to these three stages: the large cavity collapse stage is the core pitting source, the rebound cavity collapse stage is a significant contributor, while the isolated cavity collapse stage presents only minor supplementary pitting. Moreover, the study clarifies that the potential pitting risk from cavity shedding is not direct but attributable to the collapse of shedding-induced isolated cavities; however, the actual damage is negligible due to low pressure amplitude and distribution density. Additionally, pitting severity worsens nonlinearly with cavitation aggravation, underscoring that preventing severe cavitation is paramount for mitigating damage.
{"title":"Mechanical pitting mechanism of hydraulic cavitation erosion in a venturi: A coupled experimental-numerical investigation","authors":"Liang Fang , Xiaogang Xu , Anjun Li , Zhenbo Wang , Qiang Li","doi":"10.1016/j.wear.2025.206488","DOIUrl":"10.1016/j.wear.2025.206488","url":null,"abstract":"<div><div>Hydraulic cavitation erosion is a prevalent form of wear in fluid engineering, which primarily results from the mechanical effects of cavity collapse. However, a precise understanding of the dynamic pitting process has been lacking. Coupled synchronized cavitation-erosion experiments with high-fidelity compressible cavitation simulations in a Venturi, this study investigates the mechanical pitting mechanism. The results definitively demonstrate that pitting originates solely from detached cavity collapse, and is irrelevant to attached cavity development and movement. The collapse process is revealed to be progressive, evolving through three successive physical stages: the initial isolated cavity collapse stage, the core large cavity collapse stage where extreme pressure arises from the spatiotemporal superposition of collapse-induced shocks, and the subsequent rebound cavity collapse stage characterized by multiple pressure peaks. Specifically, quantitative analysis attributes differential pitting severity to these three stages: the large cavity collapse stage is the core pitting source, the rebound cavity collapse stage is a significant contributor, while the isolated cavity collapse stage presents only minor supplementary pitting. Moreover, the study clarifies that the potential pitting risk from cavity shedding is not direct but attributable to the collapse of shedding-induced isolated cavities; however, the actual damage is negligible due to low pressure amplitude and distribution density. Additionally, pitting severity worsens nonlinearly with cavitation aggravation, underscoring that preventing severe cavitation is paramount for mitigating damage.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"587 ","pages":"Article 206488"},"PeriodicalIF":6.1,"publicationDate":"2025-12-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145808363","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 : 2025-12-23DOI: 10.1016/j.wear.2025.206490
Haiyue Yu , Kaixin Sun , Jianfeng Song , Junqiu Zhang , Zhiwu Han
Erosion wear impairs the mechanical strength of flow components, severely restricting machinery, energy, and related industrial development. Bionics offers new solutions to the problem of wear. Drawing inspiration from Mammillaria hahniana cactus petals, this study proposes a new bionic model: a symmetrical biconical structure. Multiple bionic petal models were fabricated using fused deposition modelling (FDM) technology. Gas-solid erosion tests were conducted using gravel particles of different sizes at various angles of erosion. Tests have shown that the biconical structure exhibits superior erosion resistance at high angles (≥60°), achieving a maximum erosion wear rate reduction of 45.9 % compared to other samples. Computational fluid dynamics (CFD) analysis was used to study the flow patterns and the way the particles moved. The biconical structure's unique streamlined shape prevents the boundary layer from separating, guiding the particles to slip directionally along the cone surface. This reduces the normal impact and sliding friction between the particles and the sample surface. Meanwhile, tensile and compression tests showed that the front and back ends of the biconical structure could support each other, enabling the structure to resist plastic deformation during erosion. Additionally, the overall structural strength of the biconical samples increased, particularly with regard to compressive loads. This study overcomes the shortcomings of conventional erosion-resistant structures, which are limited to a single function. The synergistic effect of erosion and deformation resistance is achieved through ‘flow field regulation - particle motion guidance - stress dispersion’, which enriches the theoretical system in the field of bionic wear resistance.
{"title":"Bionic synergistic enhancement of erosive wear resistance with mechanical properties","authors":"Haiyue Yu , Kaixin Sun , Jianfeng Song , Junqiu Zhang , Zhiwu Han","doi":"10.1016/j.wear.2025.206490","DOIUrl":"10.1016/j.wear.2025.206490","url":null,"abstract":"<div><div>Erosion wear impairs the mechanical strength of flow components, severely restricting machinery, energy, and related industrial development. Bionics offers new solutions to the problem of wear. Drawing inspiration from <em>Mammillaria hahniana</em> cactus petals, this study proposes a new bionic model: a symmetrical biconical structure. Multiple bionic petal models were fabricated using fused deposition modelling (FDM) technology. Gas-solid erosion tests were conducted using gravel particles of different sizes at various angles of erosion. Tests have shown that the biconical structure exhibits superior erosion resistance at high angles (≥60°), achieving a maximum erosion wear rate reduction of 45.9 % compared to other samples. Computational fluid dynamics (CFD) analysis was used to study the flow patterns and the way the particles moved. The biconical structure's unique streamlined shape prevents the boundary layer from separating, guiding the particles to slip directionally along the cone surface. This reduces the normal impact and sliding friction between the particles and the sample surface. Meanwhile, tensile and compression tests showed that the front and back ends of the biconical structure could support each other, enabling the structure to resist plastic deformation during erosion. Additionally, the overall structural strength of the biconical samples increased, particularly with regard to compressive loads. This study overcomes the shortcomings of conventional erosion-resistant structures, which are limited to a single function. The synergistic effect of erosion and deformation resistance is achieved through ‘flow field regulation - particle motion guidance - stress dispersion’, which enriches the theoretical system in the field of bionic wear resistance.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"587 ","pages":"Article 206490"},"PeriodicalIF":6.1,"publicationDate":"2025-12-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145842279","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 : 2025-12-19DOI: 10.1016/j.wear.2025.206485
Peishuo Zhang , Hongjun Wang , Yubin Yue
The poor machinability of Ti–6Al–4V poses challenges to notch wear prediction during ball-end milling, including complex mechanism modeling and heavy reliance on sensors. Existing data-driven approaches often suffer from limited interpretability and high monitoring costs. To address these issues, this study proposes a hybrid mechanism and data-driven method for predicting notch wear. A geometric model of the ball-end cutting edge was constructed, and the cutting edge micro-element force feature (CFF) and the effective cutting edge length feature (ECEF) were derived using polar coordinate projection and interpolation algorithms. These two features were identified as core drivers of notch wear, with clear mechanistic links. The derived features were then used to train predictive models based on ensemble learning, kernel methods, and artificial neural networks. All predictive models achieved a coefficient of determination () consistently exceeding 0.97, demonstrating robust generalization across multiple modeling paradigms, the Random Forest (RF) model stood out with optimal performance ( = 0.998). Further integrating the random forest algorithm with recursive feature elimination, feature optimization achieved a 50.2% improvement in computational efficiency while retaining 99.84% of the original model’s predictive capability. Finally, based on wear mechanism decoupling and ablation experiments, a cross-scale framework combining geometry, mechanics, and data was established. The results indicated that force-induced thermal cyclic load plays a dominant role in the notch wear process, while abrasive wear acts as an auxiliary factor, and the contribution of the former is 3.6 times that of the latter. This framework offers a new paradigm for wear prediction that is both mechanistically interpretable and practically applicable, with significant potential for high-end manufacturing sectors such as aerospace.
{"title":"Sensorless prediction of notch wear in Ti–6Al–4V ball-end milling based on cutting edge geometry and thermo-mechanical coupling","authors":"Peishuo Zhang , Hongjun Wang , Yubin Yue","doi":"10.1016/j.wear.2025.206485","DOIUrl":"10.1016/j.wear.2025.206485","url":null,"abstract":"<div><div>The poor machinability of Ti–6Al–4V poses challenges to notch wear prediction during ball-end milling, including complex mechanism modeling and heavy reliance on sensors. Existing data-driven approaches often suffer from limited interpretability and high monitoring costs. To address these issues, this study proposes a hybrid mechanism and data-driven method for predicting notch wear. A geometric model of the ball-end cutting edge was constructed, and the cutting edge micro-element force feature (CFF) and the effective cutting edge length feature (ECEF) were derived using polar coordinate projection and interpolation algorithms. These two features were identified as core drivers of notch wear, with clear mechanistic links. The derived features were then used to train predictive models based on ensemble learning, kernel methods, and artificial neural networks. All predictive models achieved a coefficient of determination (<span><math><msup><mrow><mi>R</mi></mrow><mrow><mn>2</mn></mrow></msup></math></span>) consistently exceeding 0.97, demonstrating robust generalization across multiple modeling paradigms, the Random Forest (RF) model stood out with optimal performance (<span><math><msup><mrow><mi>R</mi></mrow><mrow><mn>2</mn></mrow></msup></math></span> = 0.998). Further integrating the random forest algorithm with recursive feature elimination, feature optimization achieved a 50.2% improvement in computational efficiency while retaining 99.84% of the original model’s predictive capability. Finally, based on wear mechanism decoupling and ablation experiments, a cross-scale framework combining geometry, mechanics, and data was established. The results indicated that force-induced thermal cyclic load plays a dominant role in the notch wear process, while abrasive wear acts as an auxiliary factor, and the contribution of the former is 3.6 times that of the latter. This framework offers a new paradigm for wear prediction that is both mechanistically interpretable and practically applicable, with significant potential for high-end manufacturing sectors such as aerospace.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"587 ","pages":"Article 206485"},"PeriodicalIF":6.1,"publicationDate":"2025-12-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145842287","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}
In biomedical machining, proper tool wear monitoring is required as surface integrity and dimensional accuracy have a direct impact on the way of the implants to work and the safety of patients. Traditional monitoring methods that are based on single-modality data do not usually identify the presence of the subtle wear development in a complex cutting environment. In this research, the authors introduce a deep-learning methodology based on multimodality as Thermo-Edge Attention Network (TEA-Net) consisting of the fusion of thermal images, line maps, and statistical wear detection to obtain accurate tool-wear separation. The model uses multi-head attention to focus on local wear areas and combines similarities of complementary cues of various data modalities using a common fusion point. Experimental analyses on Austenitic Stainless Steel 316L (SS316L) and Zirconia (ZrO2) machining tools show that TEA-Net can be evaluated at 82.5 and 88.4 classification accuracy on direct comparison with conventional machine-learning models, and with standard convolutional networks, respectively, with 15-percent higher accuracy. This framework also has a high capability of discrimination whose Area Under the Receiver Operating Characteristic Curve (AUC) exceed 0.97 therefore showing the reliability in both ductile and brittle materials. The findings show that multimodal integration has a significant positive effect on interpretability and prediction stability despite the scanty data quantity. TEA-Net is therefore an effective and timely solution to intelligent tool-wear saving and predictive maintenance in biomedical manufacturing sector.
{"title":"TEA-net: A multimodal deep learning framework for tool wear classification in biomedical machining","authors":"Phanindra Addepalli , Lavanya Addepalli , Vidya Sagar S.D , Worapong Sawangsri , Saiful Anwar Che Ghani , Jaime Lloret","doi":"10.1016/j.wear.2025.206484","DOIUrl":"10.1016/j.wear.2025.206484","url":null,"abstract":"<div><div>In biomedical machining, proper tool wear monitoring is required as surface integrity and dimensional accuracy have a direct impact on the way of the implants to work and the safety of patients. Traditional monitoring methods that are based on single-modality data do not usually identify the presence of the subtle wear development in a complex cutting environment. In this research, the authors introduce a deep-learning methodology based on multimodality as Thermo-Edge Attention Network (TEA-Net) consisting of the fusion of thermal images, line maps, and statistical wear detection to obtain accurate tool-wear separation. The model uses multi-head attention to focus on local wear areas and combines similarities of complementary cues of various data modalities using a common fusion point. Experimental analyses on Austenitic Stainless Steel 316L (SS316L) and Zirconia (ZrO<sub>2</sub>) machining tools show that TEA-Net can be evaluated at 82.5 and 88.4 classification accuracy on direct comparison with conventional machine-learning models, and with standard convolutional networks, respectively, with 15-percent higher accuracy. This framework also has a high capability of discrimination whose Area Under the Receiver Operating Characteristic Curve (AUC) exceed 0.97 therefore showing the reliability in both ductile and brittle materials. The findings show that multimodal integration has a significant positive effect on interpretability and prediction stability despite the scanty data quantity. TEA-Net is therefore an effective and timely solution to intelligent tool-wear saving and predictive maintenance in biomedical manufacturing sector.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"587 ","pages":"Article 206484"},"PeriodicalIF":6.1,"publicationDate":"2025-12-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145808362","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}
A dual ceramics (32.5 wt%B4C-32.5 wt%WC)-T55 coating was fabricated via laser direction energy deposition on TC4, achieving α/β-Ti matrix with dispersed B4C, WC, W2C, TiB, and TiC phases, yielding ultrahigh hardness (1956.3 HV0.2 vs. 412.6 HV0.2 in 32.5 wt%B4C-T55). Both coatings exhibited abrasive-surface fatigue-tribochemical hybrid wear with coefficient of friction 0.46–0.60. The dual-ceramic coating demonstrated lower wear rate (∼10−11-10−12 mm3/(N·m)) and counterbody damage (lg(WDED) + lg(WBall) = -14.51) than single-ceramic (−10.39), attributed to WC-induced phase optimization. Wear mechanisms transitioned from coating spallation (B4C-T55/Si3N4) to counterbody abrasion (B4C-WC-T55/Si3N4). Results confirm dual-ceramic design enhances wear resistance via microstructure tailoring.
Pub Date : 2025-12-17DOI: 10.1016/j.wear.2025.206480
Liangying Yin , Tingyu Zhang , Feiteng Xv , Yang Yu , Shenghua Zhang , Yanli Wang
The selection of materials for hydraulic turbine blades, which suffer from premature failure due to the synergistic interplay of mechanical wear and electrochemical corrosion in sediment-laden water, remains a significant challenge. This study focuses on 11Cr4NiMo low-carbon martensitic stainless steel and aims to elucidate the role of heat-treatment-induced microstructure, particularly reversed austenite, in governing the tribocorrosion mechanisms of low-carbon martensitic stainless steels under a custom triboelectrochemical setup with a silicon nitride (Si3N4) counterpart in a 3.5 wt% NaCl solution. The results demonstrate that the microstructure, containing 6.54 % reverted austenite, provides optimal performance, reducing wear volume and corrosion current density by approximately 31 % compared to tempered martensite. This superior resistance is attributed to a novel dual mechanism: reversed austenite facilitates the rapid regeneration of a continuous, Cr-rich passive film, maintaining a “repassivation rate > wear rate” balance to impede Cl− attack; and (2) It coordinates plastic deformation to alleviate stress concentration, maintaining passivation film integrity, ultimately resulting in mild abrasive wear. In contrast, martensitic structures, due to strain localization and slow regeneration of passivation films post-rupture, are prone to delamination, leading to layered-oxidative composite wear. This work establishes that microstructural engineering for synergistic passivation and deformation capacity, rather than pursuing high hardness alone, is the key to enhancing tribocorrosion resistance in demanding aqueous environments.
{"title":"Microstructure-dependent tribocorrosion mechanisms of low-carbon martensitic stainless steel","authors":"Liangying Yin , Tingyu Zhang , Feiteng Xv , Yang Yu , Shenghua Zhang , Yanli Wang","doi":"10.1016/j.wear.2025.206480","DOIUrl":"10.1016/j.wear.2025.206480","url":null,"abstract":"<div><div>The selection of materials for hydraulic turbine blades, which suffer from premature failure due to the synergistic interplay of mechanical wear and electrochemical corrosion in sediment-laden water, remains a significant challenge. This study focuses on 11Cr4NiMo low-carbon martensitic stainless steel and aims to elucidate the role of heat-treatment-induced microstructure, particularly reversed austenite, in governing the tribocorrosion mechanisms of low-carbon martensitic stainless steels under a custom triboelectrochemical setup with a silicon nitride (Si<sub>3</sub>N<sub>4</sub>) counterpart in a 3.5 wt% NaCl solution. The results demonstrate that the microstructure, containing 6.54 % reverted austenite, provides optimal performance, reducing wear volume and corrosion current density by approximately 31 % compared to tempered martensite. This superior resistance is attributed to a novel dual mechanism: reversed austenite facilitates the rapid regeneration of a continuous, Cr-rich passive film, maintaining a “repassivation rate > wear rate” balance to impede Cl<sup>−</sup> attack; and (2) It coordinates plastic deformation to alleviate stress concentration, maintaining passivation film integrity, ultimately resulting in mild abrasive wear. In contrast, martensitic structures, due to strain localization and slow regeneration of passivation films post-rupture, are prone to delamination, leading to layered-oxidative composite wear. This work establishes that microstructural engineering for synergistic passivation and deformation capacity, rather than pursuing high hardness alone, is the key to enhancing tribocorrosion resistance in demanding aqueous environments.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"587 ","pages":"Article 206480"},"PeriodicalIF":6.1,"publicationDate":"2025-12-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145808361","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}
扫码关注我们
求助内容：
应助结果提醒方式：
京公网安备 11010802042870号