As a transformative engineering discipline, additive manufacturing has greatly improved rapid prototyping by dramatically reducing lead times, enabling mass production of complex material types and shapes, and offering unparalleled functionalities in intended applications. In this study, the material and tribological properties of 316L austenitic stainless steel produced through the laser-directed energy deposition (LDED) method are examined at multiple length scales. These analyses include material and tribological characterization, particularly on LDED-induced defects such as cavities containing unfused powders, porosities at micro-to-macro scales, and oxide-rich inclusions. Extensive wear tests using a linear reciprocating wear machine were carried out to evaluate how these defects influence the wear behavior of LDED-printed 316L against hardened 52100 steel balls under dry sliding conditions, specifically targeting the defective regions. The results revealed that oxide-rich inclusions, with a high average Vickers hardness of 855 HV, substantially impair the wear performance of steel balls used, increasing the volumetric wear loss of balls by approximately 130 %. This emphasizes the need to minimize such defects during LDED for superior tribological performance.
{"title":"Effect of chemical and structural defects on the tribological performance of additively manufactured 316L stainless steel: Micro-to-macroscale characterization","authors":"Erfan Salehi , Cagatay Yelkarasi , Puskar Pathak , Venkat Selvamanickam , Amrutha Dinesh , Mathew Kuttolamadom , Ali Erdemir","doi":"10.1016/j.wear.2025.206450","DOIUrl":"10.1016/j.wear.2025.206450","url":null,"abstract":"<div><div>As a transformative engineering discipline, additive manufacturing has greatly improved rapid prototyping by dramatically reducing lead times, enabling mass production of complex material types and shapes, and offering unparalleled functionalities in intended applications. In this study, the material and tribological properties of 316L austenitic stainless steel produced through the laser-directed energy deposition (LDED) method are examined at multiple length scales. These analyses include material and tribological characterization, particularly on LDED-induced defects such as cavities containing unfused powders, porosities at micro-to-macro scales, and oxide-rich inclusions. Extensive wear tests using a linear reciprocating wear machine were carried out to evaluate how these defects influence the wear behavior of LDED-printed 316L against hardened 52100 steel balls under dry sliding conditions, specifically targeting the defective regions. The results revealed that oxide-rich inclusions, with a high average Vickers hardness of 855 HV, substantially impair the wear performance of steel balls used, increasing the volumetric wear loss of balls by approximately 130 %. This emphasizes the need to minimize such defects during LDED for superior tribological performance.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"586 ","pages":"Article 206450"},"PeriodicalIF":6.1,"publicationDate":"2025-12-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145693390","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 : 2025-12-04DOI: 10.1016/j.wear.2025.206448
Jianpeng Wu , Ao Ding , Wenya Shu , Heyan Li , Liyong Wang , Chengbing Yang
As a key element in the power transmission of heavy machinery, the wet friction component is essential for maintaining the safe and stable operation of mechanical systems. Its frictional behaviour directly influences transmission efficiency, which makes the study of its wear-related failure particularly important. In particular, the steel disc is composed of 65Mn steel, whereas the friction disc is fabricated from a copper-based powder metallurgy material. This study develops an elastohydrodynamic lubrication (EDL) model based on the microscopic contact characteristics under mixed lubrication, aiming to explore the interface topography and coefficient of friction (COF) of a circularly micro-textured friction component. Furthermore, a statistical model of microscopic wear failure probability (MWFP) is established using a limit state function and Monte Carlo simulation to analyse the microscopic wear failure of the friction component. Test data are used to validate the accuracy of both models. The results show that the EDL model accurately predicts the interface morphology and overall COF of the friction component, while the MWFP effectively estimates the probability of wear failure. Finally, this study examines the surface wear mechanisms exhibited by the micro-textured friction components during testing, particularly copper transfer and self-healing behaviour within the friction material.
{"title":"Microscopic wear failure probability analysis of multiform micro-textured friction component under mixed lubrication","authors":"Jianpeng Wu , Ao Ding , Wenya Shu , Heyan Li , Liyong Wang , Chengbing Yang","doi":"10.1016/j.wear.2025.206448","DOIUrl":"10.1016/j.wear.2025.206448","url":null,"abstract":"<div><div>As a key element in the power transmission of heavy machinery, the wet friction component is essential for maintaining the safe and stable operation of mechanical systems. Its frictional behaviour directly influences transmission efficiency, which makes the study of its wear-related failure particularly important. In particular, the steel disc is composed of 65Mn steel, whereas the friction disc is fabricated from a copper-based powder metallurgy material. This study develops an elastohydrodynamic lubrication (EDL) model based on the microscopic contact characteristics under mixed lubrication, aiming to explore the interface topography and coefficient of friction (COF) of a circularly micro-textured friction component. Furthermore, a statistical model of microscopic wear failure probability (MWFP) is established using a limit state function and Monte Carlo simulation to analyse the microscopic wear failure of the friction component. Test data are used to validate the accuracy of both models. The results show that the EDL model accurately predicts the interface morphology and overall COF of the friction component, while the MWFP effectively estimates the probability of wear failure. Finally, this study examines the surface wear mechanisms exhibited by the micro-textured friction components during testing, particularly copper transfer and self-healing behaviour within the friction material.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"586 ","pages":"Article 206448"},"PeriodicalIF":6.1,"publicationDate":"2025-12-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145798150","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 : 2025-12-03DOI: 10.1016/j.wear.2025.206437
Qi Sun , Qian Yang , Haowen Tang , Yuanyu Zhu , Pengfei Yang , Minhao Zhu
In this paper, the impacts of tangential and impact-sliding fretting on the damage behavior of 316L steel in lead-bismuth eutectic at 420 °C were comparatively analyzed, with particular emphasis on the microstructural evolution. The results revealed that abrasive and delamination wear represent the primary damage mechanisms in both fretting modes. However, delamination wear contributes more significantly under tangential fretting, leading to a higher average damage volume. This phenomenon is attributed to fretting-induced dynamic recrystallization beneath the contact interface during tangential fretting. In this mode, significant heat accumulation at the contact interface exceeds the threshold temperature for dynamic recrystallization. Based on these findings, a potential damage evolution model for these two fretting modes is proposed.
{"title":"Comparative study on microstructural evolution and damage behavior of 316L steel under tangential and impact-sliding fretting in liquid lead-bismuth eutectic","authors":"Qi Sun , Qian Yang , Haowen Tang , Yuanyu Zhu , Pengfei Yang , Minhao Zhu","doi":"10.1016/j.wear.2025.206437","DOIUrl":"10.1016/j.wear.2025.206437","url":null,"abstract":"<div><div>In this paper, the impacts of tangential and impact-sliding fretting on the damage behavior of 316L steel in lead-bismuth eutectic at 420 °C were comparatively analyzed, with particular emphasis on the microstructural evolution. The results revealed that abrasive and delamination wear represent the primary damage mechanisms in both fretting modes. However, delamination wear contributes more significantly under tangential fretting, leading to a higher average damage volume. This phenomenon is attributed to fretting-induced dynamic recrystallization beneath the contact interface during tangential fretting. In this mode, significant heat accumulation at the contact interface exceeds the threshold temperature for dynamic recrystallization. Based on these findings, a potential damage evolution model for these two fretting modes is proposed.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"586 ","pages":"Article 206437"},"PeriodicalIF":6.1,"publicationDate":"2025-12-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145693394","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 : 2025-12-03DOI: 10.1016/j.wear.2025.206447
Lingling Liu , Xianhui Wang , Hangyu Li , Yuan Fei , Hang Zhang , Zhiren Xue
To unveil the effect of intrinsic material properties, eroded morphology evolution, and electric load characteristics on the bouncing arc behavior of Ag-based contact materials, electrical contact tests were performed on Ag-8wt.%Ni, Ag-8wt.%SnO2, and Ag-4wt.%SnO2-4wt.%Ni contact materials under resistive and inductive loads of 18, 24, and 30 V. The arc duration, eroded morphology, and bounce characteristics were analyzed, and the correlation between contact bounce and arc behavior for the Ag-based contact materials was established. It is found that different arc states are present during each bouncing process and thus exert a profound impact on the make-arc duration. A larger bounce height is observed for the Ag-8wt.%Ni contact material because of its high elastic limit. However, for the Ag-8wt.%SnO2 contact material, greater bouncing energy loss arises from the stress concentration on SnO2 particles. Moreover, good bonding between the Ag matrix and the eroded layer is beneficial to bounce, whereas separation of the eroded layer gives rise to bouncing energy loss, thereby decreasing the bounce. Additionally, because temperature rise and stress release occur at the contact spots due to the rapid response to current, a small bounce height is observed under the resistive load and at higher voltage. In contrast, a large bounce height occurs under the inductive load without the presence of a sharply increased current.
为了揭示材料特性、侵蚀形态演变和电负载特性对ag基触点材料弹跳电弧行为的影响，在Ag-8wt上进行了电触点试验。%倪,Ag-8wt。%SnO2, ag -4wt, %SnO2-4wt。%Ni触点材料在18、24和30 V的电阻性和感性负载下。分析了银基触点材料的电弧持续时间、侵蚀形貌和回弹特性，建立了触点回弹与电弧行为的相关性。研究发现，在每次弹跳过程中，电弧状态都不同，从而对造弧时间产生深远的影响。Ag-8wt的弹跳高度更大。Ni接触材料因其高弹性极限。然而，对于Ag-8wt。在SnO2接触材料中，由于应力集中在SnO2颗粒上，弹跳能损失较大。此外，银基体与侵蚀层之间良好的结合有利于弹跳，而侵蚀层的分离会导致弹跳能量的损失，从而降低弹跳。此外，由于对电流的快速响应导致接触点温度升高和应力释放，因此在电阻负载和较高电压下观察到较小的弹跳高度。相反，在没有急剧增加电流的情况下，在感应负载下会出现较大的反弹高度。
{"title":"Correlation of contact bounce and arc behavior for Ag-based contact materials under resistive and inductive load","authors":"Lingling Liu , Xianhui Wang , Hangyu Li , Yuan Fei , Hang Zhang , Zhiren Xue","doi":"10.1016/j.wear.2025.206447","DOIUrl":"10.1016/j.wear.2025.206447","url":null,"abstract":"<div><div>To unveil the effect of intrinsic material properties, eroded morphology evolution, and electric load characteristics on the bouncing arc behavior of Ag-based contact materials, electrical contact tests were performed on Ag-8wt.%Ni, Ag-8wt.%SnO<sub>2</sub>, and Ag-4wt.%SnO<sub>2</sub>-4wt.%Ni contact materials under resistive and inductive loads of 18, 24, and 30 V. The arc duration, eroded morphology, and bounce characteristics were analyzed, and the correlation between contact bounce and arc behavior for the Ag-based contact materials was established. It is found that different arc states are present during each bouncing process and thus exert a profound impact on the make-arc duration. A larger bounce height is observed for the Ag-8wt.%Ni contact material because of its high elastic limit. However, for the Ag-8wt.%SnO<sub>2</sub> contact material, greater bouncing energy loss arises from the stress concentration on SnO<sub>2</sub> particles. Moreover, good bonding between the Ag matrix and the eroded layer is beneficial to bounce, whereas separation of the eroded layer gives rise to bouncing energy loss, thereby decreasing the bounce. Additionally, because temperature rise and stress release occur at the contact spots due to the rapid response to current, a small bounce height is observed under the resistive load and at higher voltage. In contrast, a large bounce height occurs under the inductive load without the presence of a sharply increased current.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"586 ","pages":"Article 206447"},"PeriodicalIF":6.1,"publicationDate":"2025-12-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145658705","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 : 2025-12-03DOI: 10.1016/j.wear.2025.206442
Martin Tockner , Tanja Stiller , Paul Staudinger , Michael Fasching , Kartik Pondicherry , Andreas Hausberger , Florian Grün , Thomas Schwarz
Fretting wear is a critical failure mechanism in elastomer seals used in dynamic systems, particularly under low-amplitude, high-frequency loading. In such conditions, localized surface damage progresses rapidly, with temperature exerting a significant influence on both mechanical behavior and wear processes. Low temperatures, especially during machine start-up, can dramatically affect the performance and longevity of sealing components. Despite this, experimental studies under sub-ambient conditions remain scarce, largely due to the technical complexity of cooling test setups.
To address this gap, we present a novel fretting test setup and method for elastomeric materials that enables controlled sub-ambient measurements. The novel measurement system for a modular compact rheometer (MCR) is based on a rotational Ball-on-Plate (BoP) configuration, where a steel ball serves as a counterpart against an elastomeric plate. The setup is especially designed for elastomeric materials, replicating realistic conditions in automotive, energy, or aerospace applications. Thermoplastic polyurethane (TPU) was investigated as a representative elastomer. A parameter study revealed that temperature is the dominant factor affecting fretting behavior. Between 10 °C and 80 °C, dissipated energy decreased by 75 %, and the hysteresis (Force-Displacement-diagram) angle was halved. These trends correlate well with DMA-derived viscoelastic properties and emphasize the high temperature sensitivity of TPU. At lower temperatures, stiffer material behavior promoted the formation of wear pits in shear-dominated zones of the contact area, particularly in the partial-slip regions. Higher normal forces increased energy dissipation and surface damage, while load duration had a negligible effect on hysteresis shape but contributed to progressive surface damage and wear.
The developed test setup enhances the investigation capabilities of fretting wear of elastomeric materials considering realistic conditions and offers a deeper understanding of temperature-dependent behavior and fretting wear mechanisms. These findings provide a basis for optimizing materials of sealing systems and improving durability, while also enhancing the understanding of the temperature-dependent fretting behavior of TPU.
{"title":"Fretting behavior of TPU under sub-ambient to elevated temperatures: Development of a novel high-resolution, high-frequency, low-amplitude test method for sealing materials","authors":"Martin Tockner , Tanja Stiller , Paul Staudinger , Michael Fasching , Kartik Pondicherry , Andreas Hausberger , Florian Grün , Thomas Schwarz","doi":"10.1016/j.wear.2025.206442","DOIUrl":"10.1016/j.wear.2025.206442","url":null,"abstract":"<div><div>Fretting wear is a critical failure mechanism in elastomer seals used in dynamic systems, particularly under low-amplitude, high-frequency loading. In such conditions, localized surface damage progresses rapidly, with temperature exerting a significant influence on both mechanical behavior and wear processes. Low temperatures, especially during machine start-up, can dramatically affect the performance and longevity of sealing components. Despite this, experimental studies under sub-ambient conditions remain scarce, largely due to the technical complexity of cooling test setups.</div><div>To address this gap, we present a novel fretting test setup and method for elastomeric materials that enables controlled sub-ambient measurements. The novel measurement system for a modular compact rheometer (MCR) is based on a rotational Ball-on-Plate (BoP) configuration, where a steel ball serves as a counterpart against an elastomeric plate. The setup is especially designed for elastomeric materials, replicating realistic conditions in automotive, energy, or aerospace applications. Thermoplastic polyurethane (TPU) was investigated as a representative elastomer. A parameter study revealed that temperature is the dominant factor affecting fretting behavior. Between 10 °C and 80 °C, dissipated energy decreased by 75 %, and the hysteresis (Force-Displacement-diagram) angle was halved. These trends correlate well with DMA-derived viscoelastic properties and emphasize the high temperature sensitivity of TPU. At lower temperatures, stiffer material behavior promoted the formation of wear pits in shear-dominated zones of the contact area, particularly in the partial-slip regions. Higher normal forces increased energy dissipation and surface damage, while load duration had a negligible effect on hysteresis shape but contributed to progressive surface damage and wear.</div><div>The developed test setup enhances the investigation capabilities of fretting wear of elastomeric materials considering realistic conditions and offers a deeper understanding of temperature-dependent behavior and fretting wear mechanisms. These findings provide a basis for optimizing materials of sealing systems and improving durability, while also enhancing the understanding of the temperature-dependent fretting behavior of TPU.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"586 ","pages":"Article 206442"},"PeriodicalIF":6.1,"publicationDate":"2025-12-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145748876","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 : 2025-12-02DOI: 10.1016/j.wear.2025.206445
Eva Ransmark , Andreas Håkansson
High-pressure homogenizers (HPHs) are used extensively in food-, pharma-, and biotech processing. Erosion wear is a serious concern leading to high maintenance costs and downtime. Despite this, very little is known about how operating conditions and HPH design influence wear. Guidelines for optimizing design and operation are in great need. This contribution develops a relatively simple CFD-based approach to predict erosion wear in HPHs, with the long-term ambition of enabling model-based design and optimization. Comparison to previously published experimental data show that the model captures initial forcer wear. Moreover, the model is used to conclude on the effect of HPH seat inlet angle, particle properties, and operating conditions. The results suggest that erosion wear is reduced by using a lower seat inlet angle. Erosion wear also increases in proportion to the homogenizing pressure, which implies that care should be taken to design HPHs to reduce the utilized homogenizing pressure. The effects of (spherical) particle diameter and density on erosion are described in terms of a Stokes number; erosion wear is negligible if St < 1. Implications for the optimal design and operation of HPHs are discussed. As the first systematic investigation on erosion wear in HPH valves, the present numerical approach opens for improved design and operation of a unit operation with wide industrial application.
{"title":"Particle erosion wear in a high-pressure homogenizer – insights from DPM-CFD-erosion modelling","authors":"Eva Ransmark , Andreas Håkansson","doi":"10.1016/j.wear.2025.206445","DOIUrl":"10.1016/j.wear.2025.206445","url":null,"abstract":"<div><div>High-pressure homogenizers (HPHs) are used extensively in food-, pharma-, and biotech processing. Erosion wear is a serious concern leading to high maintenance costs and downtime. Despite this, very little is known about how operating conditions and HPH design influence wear. Guidelines for optimizing design and operation are in great need. This contribution develops a relatively simple CFD-based approach to predict erosion wear in HPHs, with the long-term ambition of enabling model-based design and optimization. Comparison to previously published experimental data show that the model captures initial forcer wear. Moreover, the model is used to conclude on the effect of HPH seat inlet angle, particle properties, and operating conditions. The results suggest that erosion wear is reduced by using a lower seat inlet angle. Erosion wear also increases in proportion to the homogenizing pressure, which implies that care should be taken to design HPHs to reduce the utilized homogenizing pressure. The effects of (spherical) particle diameter and density on erosion are described in terms of a Stokes number; erosion wear is negligible if <em>St</em> < 1. Implications for the optimal design and operation of HPHs are discussed. As the first systematic investigation on erosion wear in HPH valves, the present numerical approach opens for improved design and operation of a unit operation with wide industrial application.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"586 ","pages":"Article 206445"},"PeriodicalIF":6.1,"publicationDate":"2025-12-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145658772","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}
The article discusses the application of information entropy to the quantitative assessment of abrasive particle distribution in the friction zone. Using discrete element modelling (DEM) and in-situ experiments, the interaction modes between sand particles moving between the surface of a rubber roller and a flat steel surface inclined at different angles were investigated. Shannon entropy was calculated based on visual analysis of the distribution of active particles in the friction zone and compared with the amount of abrasive wear. A stable correlation was found between the uniformity of distribution and the wear rate. It was demonstrated that as entropy increases, the system tends towards a steady state with a limit entropy value of H∞ ≈ 3.4. The method showed high sensitivity and suitability for assessing and predicting wear in tribological systems.
{"title":"The use of entropy to estimate the course of abrasive wear","authors":"Vrublevskyi Oleksandr, Ligier Krzysztof, Lemecha Magdalena","doi":"10.1016/j.wear.2025.206444","DOIUrl":"10.1016/j.wear.2025.206444","url":null,"abstract":"<div><div>The article discusses the application of information entropy to the quantitative assessment of abrasive particle distribution in the friction zone. Using discrete element modelling (DEM) and in-situ experiments, the interaction modes between sand particles moving between the surface of a rubber roller and a flat steel surface inclined at different angles were investigated. Shannon entropy was calculated based on visual analysis of the distribution of active particles in the friction zone and compared with the amount of abrasive wear. A stable correlation was found between the uniformity of distribution and the wear rate. It was demonstrated that as entropy increases, the system tends towards a steady state with a limit entropy value of <em>H</em><sub><em>∞</em></sub> ≈ 3.4. The method showed high sensitivity and suitability for assessing and predicting wear in tribological systems.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"586 ","pages":"Article 206444"},"PeriodicalIF":6.1,"publicationDate":"2025-12-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145693393","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 : 2025-12-02DOI: 10.1016/j.wear.2025.206446
Zhong Xiao , Zhe Chang , Jun Liu , Zhiyuan Zhao , Zixuan Liu , Rong Kang , Feng Bian
Particle-induced material erosion compromises the reliability of structures. Damage to wind turbine blades in desert environments and to pipelines used for oil and gas transportation, caused by sand or other solid particles, demonstrates compelling examples of this threat. Therefore, accurate erosion prediction is crucial for optimizing structural designs and their maintenance schedules. This study developed an improved backpropagation (BP) artificial neural network model to predict particle impact erosion, achieving improvements through three key optimizations: the application of the Adam optimization algorithm, the identification of an appropriate activation function specifically for material erosion prediction, and the refinement of the weight initialization method, and optimization of the weight initialization method. The optimal BP neural network was trained on 616 sets of experimental data, covering diverse particle types and target materials to enhance model robustness across engineering scenarios. The model's predictions were benchmarked against existing formulas, demonstrating that it not only predicts erosion values faster (averaging 87 s per case on a 2.30 GHz CPU with 16 GB RAM) but also achieves higher accuracy than conventional approaches. Finally, parametric studies examined erosion behaviors of brittle (glass) and ductile (carbon steel) materials across varying particle parameters. Results demonstrate that repeated deformation at large impact angles predominantly governs brittle material erosion, whereas cutting effects at small angles dominate in ductile materials. Moreover, the erosion of both brittle and ductile targets increases with particle impact angle and velocity. Furthermore, target erosion initially increases with particle diameter, but this growth rate substantially decreases beyond critical diameters due to equilibrium between rising kinetic energy and declining contact stress. This study establishes an efficient, accurate, broadly applicable prediction model for solid-particle erosion using an improved BP neural network.
{"title":"An efficient prediction model for material erosion caused by solid particle impact using an improved backpropagation artificial neural network","authors":"Zhong Xiao , Zhe Chang , Jun Liu , Zhiyuan Zhao , Zixuan Liu , Rong Kang , Feng Bian","doi":"10.1016/j.wear.2025.206446","DOIUrl":"10.1016/j.wear.2025.206446","url":null,"abstract":"<div><div>Particle-induced material erosion compromises the reliability of structures. Damage to wind turbine blades in desert environments and to pipelines used for oil and gas transportation, caused by sand or other solid particles, demonstrates compelling examples of this threat. Therefore, accurate erosion prediction is crucial for optimizing structural designs and their maintenance schedules. This study developed an improved backpropagation (BP) artificial neural network model to predict particle impact erosion, achieving improvements through three key optimizations: the application of the Adam optimization algorithm, the identification of an appropriate activation function specifically for material erosion prediction, and the refinement of the weight initialization method, and optimization of the weight initialization method. The optimal BP neural network was trained on 616 sets of experimental data, covering diverse particle types and target materials to enhance model robustness across engineering scenarios. The model's predictions were benchmarked against existing formulas, demonstrating that it not only predicts erosion values faster (averaging 87 s per case on a 2.30 GHz CPU with 16 GB RAM) but also achieves higher accuracy than conventional approaches. Finally, parametric studies examined erosion behaviors of brittle (glass) and ductile (carbon steel) materials across varying particle parameters. Results demonstrate that repeated deformation at large impact angles predominantly governs brittle material erosion, whereas cutting effects at small angles dominate in ductile materials. Moreover, the erosion of both brittle and ductile targets increases with particle impact angle and velocity. Furthermore, target erosion initially increases with particle diameter, but this growth rate substantially decreases beyond critical diameters due to equilibrium between rising kinetic energy and declining contact stress. This study establishes an efficient, accurate, broadly applicable prediction model for solid-particle erosion using an improved BP neural network.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"586 ","pages":"Article 206446"},"PeriodicalIF":6.1,"publicationDate":"2025-12-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145693392","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 : 2025-12-01DOI: 10.1016/j.wear.2025.206443
Yandi Zhang, Bing Hui, Ziye Ma, Hainian Wang
The material bearing ratio (Smr), derived from the Abbott–Firestone curve, is the essential basis for calculating four key functional volume parameters (Vmp, Vmc, Vvc, Vvv), which directly quantify load-bearing capacity, skid resistance, and drainage performance of asphalt surfaces. Accurate determination of Smr1 and Smr2, representing the peak-core and core-valley boundaries, is therefore critical for evaluating the functional evolution of pavement materials under wear.However, conventional approaches that use fixed thresholds (e.g., Smr1 = 10 %, Smr2 = 80 %) ignore the intrinsic link between segmentation boundaries, bearing curve morphology, and wear progression, often resulting in biased parameter calculations and inaccurate performance assessment.This study proposes a dynamic segmentation framework based on Response Surface Methodology (RSM). Smr1 and Smr2 were treated as factor variables, while the four functional volume parameters served as responses. Sensitivity analysis guided the ranking of optimization objectives, and a desirability function was applied to integrate multi-objective optimization and identify optimal Smr combinations at different wear stages.Results show that Smr1 increases from 10 % to approximately 20 % and Smr2 decreases from 95 % to around 85 % as wear progresses, indicating a contraction of the functional bearing region. The corresponding core region height (Hc) shows a continuous downward trend, capturing compaction and surface smoothing more accurately. This dynamic approach establishes a statistically grounded and wear-responsive framework that improves functional parameter calculation, enhances degradation assessment, and supports early-stage pavement performance evaluation.
{"title":"Dynamic optimization of texture segmentation and evolution of core bearing height in asphalt mixtures under wear","authors":"Yandi Zhang, Bing Hui, Ziye Ma, Hainian Wang","doi":"10.1016/j.wear.2025.206443","DOIUrl":"10.1016/j.wear.2025.206443","url":null,"abstract":"<div><div>The material bearing ratio (Smr), derived from the Abbott–Firestone curve, is the essential basis for calculating four key functional volume parameters (Vmp, Vmc, Vvc, Vvv), which directly quantify load-bearing capacity, skid resistance, and drainage performance of asphalt surfaces. Accurate determination of Smr1 and Smr2, representing the peak-core and core-valley boundaries, is therefore critical for evaluating the functional evolution of pavement materials under wear.However, conventional approaches that use fixed thresholds (e.g., Smr1 = 10 %, Smr2 = 80 %) ignore the intrinsic link between segmentation boundaries, bearing curve morphology, and wear progression, often resulting in biased parameter calculations and inaccurate performance assessment.This study proposes a dynamic segmentation framework based on Response Surface Methodology (RSM). Smr1 and Smr2 were treated as factor variables, while the four functional volume parameters served as responses. Sensitivity analysis guided the ranking of optimization objectives, and a desirability function was applied to integrate multi-objective optimization and identify optimal Smr combinations at different wear stages.Results show that Smr1 increases from 10 % to approximately 20 % and Smr2 decreases from 95 % to around 85 % as wear progresses, indicating a contraction of the functional bearing region. The corresponding core region height (Hc) shows a continuous downward trend, capturing compaction and surface smoothing more accurately. This dynamic approach establishes a statistically grounded and wear-responsive framework that improves functional parameter calculation, enhances degradation assessment, and supports early-stage pavement performance evaluation.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"586 ","pages":"Article 206443"},"PeriodicalIF":6.1,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145693391","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 : 2025-11-29DOI: 10.1016/j.wear.2025.206440
Saman Nikpour , René Daniel Pütz , Ayush Khurana , Sina Matin , Anna Neus Igual Munoz , Stefano Mischler , Yolanda S. Hedberg
Laser powder bed fusion (LPBF) and wrought Ti6Al4V were compared from a tribocorrosion perspective in 0.9 % NaCl, distinguishing between mechanical and chemical (oxidative) wear through potential-controlled measurements. The aim was to elucidate the manufacturing- and potential-dependent tribocorrosion mechanisms in a saline environment. While both manufacturing methods resulted in excellent corrosion resistance, the LPBF titanium alloy exhibited a finer, distinct microstructure, higher microhardness, and greater tribocorrosion resistance under applied cathodic and anodic potentials in saline than the wrought alloy. More available slip systems, lower grain boundary density, easier crack formation and propagation at the oxide-subsurface interface, and more oxidized third-body particles were responsible for the higher mechanical and chemical volume loss of wrought samples. These features were related to the microstructural differences; the wrought titanium alloy consisted of a β phase, along with α phase, and a lower grain boundary density, whereas the LPBF alloy possessed α/α′ phases and a higher grain boundary density.
{"title":"Tribocorrosion of additively manufactured and wrought Ti6Al4V in a saline environment","authors":"Saman Nikpour , René Daniel Pütz , Ayush Khurana , Sina Matin , Anna Neus Igual Munoz , Stefano Mischler , Yolanda S. Hedberg","doi":"10.1016/j.wear.2025.206440","DOIUrl":"10.1016/j.wear.2025.206440","url":null,"abstract":"<div><div>Laser powder bed fusion (LPBF) and wrought Ti6Al4V were compared from a tribocorrosion perspective in 0.9 % NaCl, distinguishing between mechanical and chemical (oxidative) wear through potential-controlled measurements. The aim was to elucidate the manufacturing- and potential-dependent tribocorrosion mechanisms in a saline environment. While both manufacturing methods resulted in excellent corrosion resistance, the LPBF titanium alloy exhibited a finer, distinct microstructure, higher microhardness, and greater tribocorrosion resistance under applied cathodic and anodic potentials in saline than the wrought alloy. More available slip systems, lower grain boundary density, easier crack formation and propagation at the oxide-subsurface interface, and more oxidized third-body particles were responsible for the higher mechanical and chemical volume loss of wrought samples. These features were related to the microstructural differences; the wrought titanium alloy consisted of a β phase, along with α phase, and a lower grain boundary density, whereas the LPBF alloy possessed α/α′ phases and a higher grain boundary density.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"586 ","pages":"Article 206440"},"PeriodicalIF":6.1,"publicationDate":"2025-11-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145658704","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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