IF 6.1 1区工程技术 Q1 ENGINEERING, MECHANICAL

Wear

Pub Date : 2025-12-23 DOI: 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.

水力空化冲刷是流体工程中常见的一种磨损形式，其主要原因是空化塌陷的力学效应。然而，对动态点蚀过程的精确理解一直缺乏。在文丘里腔中进行了高保真可压缩空化模拟的同步空化-侵蚀耦合实验，研究了机械点蚀机理。结果明确地表明，点蚀完全是由离体空腔塌陷引起的，与附体空腔的发育和运动无关。崩塌过程是一个渐进的过程，经历了三个连续的物理阶段：最初的孤立空腔崩塌阶段、崩塌冲击时空叠加产生极端压力的核心大空腔崩塌阶段和随后以多重压力峰为特征的反弹空腔崩塌阶段。具体而言，定量分析将不同程度的点蚀归因于这三个阶段：大空腔塌陷阶段是核心点蚀源，反弹空腔塌陷阶段是重要的点蚀源，而孤立空腔塌陷阶段只出现少量的补充点蚀。此外，该研究还阐明了空腔脱落的潜在点蚀风险不是直接的，而是可归因于脱落引起的孤立空腔的崩溃；但由于压力幅值和分布密度较低，实际损伤可以忽略不计。此外，随着空化的加剧，点蚀的严重程度呈非线性恶化，这表明防止严重的空化对于减轻损害至关重要。

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引用次数: 0

Bionic synergistic enhancement of erosive wear resistance with mechanical properties 仿生协同增强机械性能的耐冲蚀磨损性能

IF 6.1 1区工程技术 Q1 ENGINEERING, MECHANICAL

Wear

Pub Date : 2025-12-23 DOI: 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.

冲蚀磨损损害了流动部件的机械强度，严重制约了机械、能源和相关工业的发展。仿生学为磨损问题提供了新的解决方案。本研究从哺乳动物（Mammillaria hahniana）仙人掌花瓣中获得灵感，提出了一种新的仿生模型：对称的双圆锥形结构。采用熔融沉积建模（FDM）技术制备了多个仿生花瓣模型。采用不同粒径的砾石颗粒在不同的冲蚀角度下进行气固冲蚀试验。试验表明，双锥形结构在高角度（≥60°）下具有优异的抗冲蚀性能，与其他样品相比，最大冲蚀磨损率降低45.9%。采用计算流体力学（CFD）分析研究了颗粒的流动模式和运动方式。双锥结构独特的流线型防止边界层分离，引导颗粒沿锥面定向滑动。这减少了颗粒和样品表面之间的正常冲击和滑动摩擦。同时，拉伸和压缩试验表明，双锥结构前后端可以相互支撑，使结构能够抵抗侵蚀时的塑性变形。此外，双锥形试样的整体结构强度增加，特别是在压缩载荷方面。这项研究克服了传统的抗侵蚀结构局限于单一功能的缺点。通过“流场调节-颗粒运动引导-应力分散”实现抗冲蚀和抗变形的协同效应，丰富了仿生耐磨领域的理论体系。

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引用次数: 0

Sensorless prediction of notch wear in Ti–6Al–4V ball-end milling based on cutting edge geometry and thermo-mechanical coupling 基于切削刃几何和热-力耦合的Ti-6Al-4V球头铣削缺口磨损无传感器预测

IF 6.1 1区工程技术 Q1 ENGINEERING, MECHANICAL

Wear

Pub Date : 2025-12-19 DOI: 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 (

R^{2}

) consistently exceeding 0.97, demonstrating robust generalization across multiple modeling paradigms, the Random Forest (RF) model stood out with optimal performance (

R^{2}

= 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.

Ti-6Al-4V合金的切削性能较差，给球端铣削过程中的缺口磨损预测带来了挑战，包括复杂的机理建模和对传感器的严重依赖。现有的数据驱动方法往往存在可解释性有限和监测成本高的问题。为了解决这些问题，本研究提出了一种混合机制和数据驱动的方法来预测缺口磨损。建立了球端切削刃的几何模型，利用极坐标投影和插值算法推导了切削刃微单元力特征（CFF）和有效切削刃长度特征（ECEF）。这两个特征被确定为缺口磨损的核心驱动因素，具有明确的机械联系。然后使用衍生的特征来训练基于集成学习、核方法和人工神经网络的预测模型。所有预测模型的决定系数（R2）均超过0.97，显示了多种建模范式的鲁棒泛化，其中随机森林（RF）模型表现最优（R2 = 0.998）。进一步将随机森林算法与递归特征消除相结合，特征优化的计算效率提高了50.2%，同时保留了原模型99.84%的预测能力。最后，基于磨损机理解耦和烧蚀实验，建立了几何、力学和数据相结合的跨尺度框架。结果表明：力致热循环载荷在缺口磨损过程中起主导作用，磨料磨损起辅助作用，前者的贡献是后者的3.6倍；该框架为磨损预测提供了一种新的范式，既具有机械可解释性，又具有实际应用价值，在航空航天等高端制造领域具有巨大潜力。

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引用次数: 0

TEA-net: A multimodal deep learning framework for tool wear classification in biomedical machining TEA-net：生物医学加工中刀具磨损分类的多模态深度学习框架

IF 6.1 1区工程技术 Q1 ENGINEERING, MECHANICAL

Wear

Pub Date : 2025-12-19 DOI: 10.1016/j.wear.2025.206484

Phanindra Addepalli , Lavanya Addepalli , Vidya Sagar S.D , Worapong Sawangsri , Saiful Anwar Che Ghani , Jaime Lloret

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.

在生物医学加工中，由于表面完整性和尺寸精度直接影响到植入物的工作方式和患者的安全，因此需要适当的刀具磨损监测。基于单模态数据的传统监测方法通常不能识别复杂切削环境中细微磨损发展的存在。在这项研究中，作者引入了一种基于多模态的深度学习方法，即热边缘注意网络（TEA-Net），该方法由热图像、线形图和统计磨损检测的融合组成，以获得准确的工具磨损分离。该模型使用多头关注来关注局部磨损区域，并使用一个共同的融合点将各种数据模式的互补线索的相似性结合起来。对奥氏体不锈钢316L （SS316L）和氧化锆（ZrO2）加工工具的实验分析表明，与传统机器学习模型和标准卷积网络进行直接比较，TEA-Net的分类准确率分别为82.5和88.4，准确率提高了15%。该框架还具有较高的识别能力，其接收工作特征曲线下面积（AUC）超过0.97，因此在韧性和脆性材料中都显示出可靠性。结果表明，在数据量不足的情况下，多模态积分对可解释性和预测稳定性有显著的正向影响。因此，TEA-Net是生物医学制造领域智能工具磨损节省和预测性维护的有效及时的解决方案。

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引用次数: 0

Influence of WCp addition (1:1 ratio) on the dry wear behavior of in-situ synthesized B4C-Ti DEDed hardfacing against Si3N4 counterbody WCp添加量（1:1）对原位合成B4C-Ti DEDed堆焊面对Si3N4 counterbody干磨损行为的影响

IF 6.1 1区工程技术 Q1 ENGINEERING, MECHANICAL

Wear

Pub Date : 2025-12-19 DOI: 10.1016/j.wear.2025.206479

Huabing Gao , Wenjun Zhu , Chunhuan Guo , Wei Chen , Fengchun Jiang

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 HV_0.2 vs. 412.6 HV_0.2 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(W_DED) + lg(W_Ball) = -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.

采用激光定向能沉积方法在TC4上制备了双晶陶瓷(32.5 wt%B4C-32.5 wt%WC)-T55涂层，得到了具有分散的B4C、WC、W2C、TiB和TiC相的α/β-Ti基体，获得了超高的硬度（32.5 wt%B4C-T55中的1956.3 HV0.2比412.6 HV0.2）。两种涂层均表现为磨粒-表面疲劳-摩擦化学混合磨损，摩擦系数为0.46 ~ 0.60。由于wc诱导的相优化，双陶瓷涂层的磨损率（~ 10−11-10−12 mm3/(N·m)）和反体损伤(lg（WDED) + lg(WBall) = -14.51）低于单陶瓷涂层（- 10.39）。磨损机制由涂层脱落（B4C-T55/Si3N4）转变为对位体磨损（B4C-WC-T55/Si3N4）。结果表明，双陶瓷设计通过微观结构定制提高了耐磨性。

引用次数: 0

Microstructure-dependent tribocorrosion mechanisms of low-carbon martensitic stainless steel 低碳马氏体不锈钢摩擦腐蚀机理研究

IF 6.1 1区工程技术 Q1 ENGINEERING, MECHANICAL

Wear

Pub Date : 2025-12-17 DOI: 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.

水轮机叶片的材料选择仍然是一个重大挑战，因为在含沙水中，机械磨损和电化学腐蚀的协同相互作用会导致叶片过早失效。本研究的重点是11Cr4NiMo低碳马氏体不锈钢，旨在阐明热处理诱导的微观结构，特别是反奥氏体，在与氮化硅（Si3N4）在3.5 wt% NaCl溶液中定制摩擦电化学设置下控制低碳马氏体不锈钢摩擦腐蚀机制的作用。结果表明，与回火马氏体相比，含6.54%回火奥氏体的组织提供了最佳性能，磨损体积和腐蚀电流密度减少了约31%。这种优异的电阻归因于一种新的双重机制：反向奥氏体促进了连续的富cr钝化膜的快速再生，保持了“再钝化率和磨损率”的平衡，以阻止Cl -的攻击；(2)协调塑性变形，缓解应力集中，保持钝化膜的完整性，最终产生轻度磨粒磨损。相反，马氏体组织由于应变局部化和断裂后钝化膜再生缓慢，容易发生脱层，导致层状氧化复合磨损。这项工作表明，在苛刻的水环境中，提高耐摩擦腐蚀性能的关键是通过微观结构工程来实现协同钝化和变形能力，而不仅仅是追求高硬度。

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引用次数: 0

Clam shell waste as a filler ingredient for sustainable brake pad friction materials 蛤壳废料作为填充物成分可用于可持续刹车片摩擦材料

IF 6.1 1区工程技术 Q1 ENGINEERING, MECHANICAL

Wear

Pub Date : 2025-12-17 DOI: 10.1016/j.wear.2025.206465

Gustavo da Silva Gehlen , Davide Carlevaris , Giovanni Straffelini , Stefano Gialanella

Waste clam shell was evaluated as an eco-friendly filler ingredient for brake friction materials and was compared with standard filler, like calcite and barite. The raw shell crystalline structure, morphology, and thermal stability were characterized. It was subsequently milled to 25–45 μm and incorporated into brake pad formulations in concentrations of 15 wt% and 30 wt%. Pin-on-disc tests at room temperature, 200 °C, and 400 °C under mild wear conditions were conducted. Seashell and calcite obtained coefficient of friction (CoF) similar to barite at room temperature and at 200 °C. At 400 °C, 15 wt% seashell or calcite reduced the CoF with respect to barite, whereas 30 wt% increased the CoF. Wear coefficients increased with temperature. Samples containing only barite showed the lowest wear at room temperature. On the other hand, at 400 °C samples with 15 wt% seashell or calcite showed the lowest wear, with seashell being equivalent to calcite and outperforming barite. Seashell and calcite formed a protective tribofilm on the disc at elevated temperature, which reduced disc wear. The emissions were found to be proportional to the wear of the samples. Life cycle assessment showed that replacing calcite for seashell reduces the environmental impact over all categories. Overall, seashell powder had comparable performance to calcite and barite, and 15 wt% seashell offered the best balance between friction stability, wear resistance, and emissions. This highlights the potential of seashell waste as a sustainable filler in friction materials.

对废蛤壳作为一种环保的制动摩擦材料填料进行了评价，并与方解石、重晶石等标准填料进行了比较。表征了原壳的晶体结构、形貌和热稳定性。随后，将其研磨至25-45 μm，并以15% wt%和30% wt%的浓度加入刹车片配方中。在室温、200°C和400°C轻度磨损条件下进行销盘试验。在室温和200℃下，贝壳和方解石的摩擦系数（CoF）与重晶石相似。在400°C时，相对于重晶石，15%的贝壳或方解石降低了CoF，而30%的贝壳或方解石增加了CoF。磨损系数随温度升高而增大。仅含重晶石的样品在室温下的磨损最小。另一方面，在400°C时，含有15%海贝或方解石的样品显示出最低的磨损，海贝与方解石相当，优于重晶石。在高温下，贝壳和方解石在圆盘上形成保护性摩擦膜，减少了圆盘的磨损。发现排放量与样品的磨损成正比。生命周期评价结果表明，以方解石代替贝类可减少各类环境影响。总的来说，贝壳粉的性能与方解石和重晶石相当，15%的贝壳粉在摩擦稳定性、耐磨性和排放之间取得了最佳平衡。这突出了贝壳废物作为摩擦材料可持续填料的潜力。

{"title":"Clam shell waste as a filler ingredient for sustainable brake pad friction materials","authors":"Gustavo da Silva Gehlen , Davide Carlevaris , Giovanni Straffelini , Stefano Gialanella","doi":"10.1016/j.wear.2025.206465","DOIUrl":"10.1016/j.wear.2025.206465","url":null,"abstract":"<div><div>Waste clam shell was evaluated as an eco-friendly filler ingredient for brake friction materials and was compared with standard filler, like calcite and barite. The raw shell crystalline structure, morphology, and thermal stability were characterized. It was subsequently milled to 25–45 μm and incorporated into brake pad formulations in concentrations of 15 wt% and 30 wt%. Pin-on-disc tests at room temperature, 200 °C, and 400 °C under mild wear conditions were conducted. Seashell and calcite obtained coefficient of friction (CoF) similar to barite at room temperature and at 200 °C. At 400 °C, 15 wt% seashell or calcite reduced the CoF with respect to barite, whereas 30 wt% increased the CoF. Wear coefficients increased with temperature. Samples containing only barite showed the lowest wear at room temperature. On the other hand, at 400 °C samples with 15 wt% seashell or calcite showed the lowest wear, with seashell being equivalent to calcite and outperforming barite. Seashell and calcite formed a protective tribofilm on the disc at elevated temperature, which reduced disc wear. The emissions were found to be proportional to the wear of the samples. Life cycle assessment showed that replacing calcite for seashell reduces the environmental impact over all categories. Overall, seashell powder had comparable performance to calcite and barite, and 15 wt% seashell offered the best balance between friction stability, wear resistance, and emissions. This highlights the potential of seashell waste as a sustainable filler in friction materials.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"586 ","pages":"Article 206465"},"PeriodicalIF":6.1,"publicationDate":"2025-12-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145798152","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Tribological synergy between extreme pressure and copper oleate based additives under boundary lubrication 边界润滑下极压和油酸铜基添加剂之间的摩擦学协同作用

IF 6.1 1区工程技术 Q1 ENGINEERING, MECHANICAL

Wear

Pub Date : 2025-12-16 DOI: 10.1016/j.wear.2025.206478

Borja Armendariz-Molinero , Francesco Pagano , José Tomás San-José-Lombera , Lucia Pisarova , Josef Brenner , Emna Charfi , Ichiro Minami

One of the current trends in tribology is reducing oil viscosity to minimize the hydrodynamic losses. However, the reduction of viscosity could lead to harsher tribological operating conditions and consequently higher wear and lower durability of gears and bearings. For this reason, new additive technology is essential. One promising approach involves smart additive design based on synergy between existing additives. This paper combined copper oleate with Sulfur and Phosphorus extreme-pressure additives showing a remarkable reduction on friction and a novel synergistic effect on wear using an ISO VG 46 base oil. Based on SEM/EDS and XPS analyses on the wear scars, a plausible mechanism for this synergy was proposed. Finally, to assess the anti-wear properties of this synergy, a fully formulated commercial ISO VG 320 synthetic gear oil was tested under the same tribological conditions, showing that the formulation developed in this work was even able to provide superior protection.

当前摩擦学的发展趋势之一是降低油的粘度，以尽量减少流体动力损失。然而，粘度的降低可能会导致更苛刻的摩擦学操作条件，从而导致齿轮和轴承的更高磨损和更低的耐久性。因此，新的增材技术是必不可少的。一种有前途的方法是基于现有添加剂之间的协同作用进行智能添加剂设计。本文将油酸铜与硫和磷极压添加剂结合使用，在ISO VG 46基础油中显示出显著的摩擦降低和新型的协同磨损效应。通过对磨损痕的SEM/EDS和XPS分析，提出了这种协同作用的合理机制。最后，为了评估这种协同作用的抗磨性能，在相同的摩擦学条件下测试了一种完全配方的商用ISO VG 320合成齿轮油，结果表明，在这项工作中开发的配方甚至能够提供更好的保护。

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引用次数: 0

Molecular dynamics analysis of friction wear in gray cast iron brake discs: an atom-scale investigation of graphite/matrix interface behavior 灰口铸铁制动盘摩擦磨损的分子动力学分析：石墨/基体界面行为的原子尺度研究

IF 6.1 1区工程技术 Q1 ENGINEERING, MECHANICAL

Wear

Pub Date : 2025-12-15 DOI: 10.1016/j.wear.2025.206477

Yanjie Liu , Kaikui Zheng , Zhiying Ren

The friction and wear behavior of gray cast iron brake discs is closely related to its microstructure and the interaction at the graphite/iron matrix interface. However, due to limitations in testing conditions, the microscopic mechanism of this interface during the braking process remains unclear. This study employed molecular dynamics simulations to investigate the nanoscale tribological behavior of a graphite-embedded gray cast iron model. Through multidimensional analysis encompassing friction force, grinding mark depth, phase transformation behavior, internal deformation, stress-strain distribution, temperature variation, bond length, and potential energy, which revealed graphite's dual role: acting as a solid lubricant to reduce friction force while simultaneously serving as a stress concentration source that promotes the formation of grinding debris. The study demonstrates that graphite flakes undergo significant out-of-plane bending and wrinkling under the combined action of normal load and shear force, effectively dissipating energy and influencing the plastic strain distribution of the surrounding matrix. The graphite-iron interface, characterized by low shear strength, becomes a preferred slip plane but also represents a vulnerable region for crack initiation and propagation. Furthermore, graphite's exceptionally high in-plane thermal conductivity enables rapid dissipation of frictional heat, reducing peak temperatures and mitigating localized thermal damage. Experiments confirm that crack propagation along the graphite/matrix interface leads to graphite flake pull-out and the formation of micro-exfoliation pits. This study reveals the friction and wear mechanisms of gray cast iron brake discs at the atomic scale.

灰铸铁制动盘的摩擦磨损性能与其微观组织和石墨/铁基体界面的相互作用密切相关。然而，由于试验条件的限制，该界面在制动过程中的微观机理尚不清楚。本研究采用分子动力学模拟研究了石墨灰铸铁模型的纳米级摩擦学行为。通过摩擦力、磨痕深度、相变行为、内部变形、应力应变分布、温度变化、键长、势能等多维度分析，揭示了石墨的双重作用：作为固体润滑剂减少摩擦力，同时作为应力集中源促进磨屑的形成。研究表明，在法向载荷和剪切力的共同作用下，石墨薄片发生了明显的面外弯曲和起皱，有效地耗散了能量，影响了周围基体的塑性应变分布。石墨-铁界面具有低剪切强度的特点，成为首选滑移面，但也是裂纹萌生和扩展的脆弱区域。此外，石墨异常高的面内导热系数使摩擦热迅速消散，降低峰值温度，减轻局部热损伤。实验证实，裂纹沿石墨/基体界面扩展，导致石墨薄片拉出，形成微剥落坑。本研究揭示了灰口铸铁制动盘在原子尺度上的摩擦磨损机理。

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引用次数: 0

A new experimental technique for assessing impact-sliding wear resistance of materials for non-synchronous transmissions 一种评估非同步传动材料冲击滑动磨损性能的新实验技术

IF 6.1 1区工程技术 Q1 ENGINEERING, MECHANICAL

Wear

Pub Date : 2025-12-15 DOI: 10.1016/j.wear.2025.206476

Maria Wojtowicz, Urban Wiklund, Robin Elo, Staffan Jacobson

Non-synchronous transmission can reduce the weight and increase efficiency of electrical heavy vehicles, with great potential to increase the vehicle range and load capacity. However, it comes at a cost, also increasing missed gear shifts resulting in impact-sliding wear. In this work, a new test rig is presented, allowing accelerated wear testing of component materials that need to withstand numerous severe impact-sliding events, with each event simulating a missed gear shift. The test rig enables controlled variation and measurement of important parameters such as relative velocity, normal load, impact depth and impact force. Demonstrator tests show that it is possible to distinguish between small alloying differences of relevant materials, and quickly reach numbers of impact-sliding events that real components would experience in years of operation. The wear mechanisms of rig tested samples are compared to, and mimic, real industrial testing of non-synchronous transmission, showing a complex process including a wide impact surface with extruded material on the edges, formation of tongues in the impact direction, delamination, spalling, and both small and large fractures. The acceleration of the test, with a high frequency of high energy impacts and pre-shaped impact geometry results in a full test taking hours instead of months. Additionally, the control of test parameters and the sample size enables both detailed wear studies and screening of candidate materials, facilitating much quicker development of materials and surface treatments to withstand severe impact-sliding events.

非同步传动可以减轻电动重型汽车的重量，提高效率，在增加车辆续航里程和载重能力方面具有很大的潜力。然而，这是有代价的，也增加了错过换挡导致冲击滑动磨损。在这项工作中，提出了一种新的试验台，可以加速对需要承受许多严重冲击滑动事件的部件材料的磨损测试，每个事件都模拟错过的换挡。该试验台能够控制重要参数的变化和测量，如相对速度、法向载荷、冲击深度和冲击力。演示试验表明，它可以区分相关材料的微小合金差异，并迅速达到真实部件在多年运行中所经历的冲击滑动事件的数量。将钻机测试样品的磨损机理与非同步变速器的实际工业测试进行了比较和模拟，显示了一个复杂的过程，包括边缘有挤压材料的宽冲击面，在冲击方向上形成舌状物，分层，剥落以及大小断裂。测试的加速，加上高频率的高能冲击和预成型的冲击几何形状，使得整个测试只需几个小时，而不是几个月。此外，测试参数和样本量的控制可以进行详细的磨损研究和候选材料的筛选，从而促进材料和表面处理的更快开发，以承受严重的冲击滑动事件。

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引用次数: 0

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