Research

18 pages, 8451 KiB

Open AccessArticle

Surface Preparation for Coating and Erosion MRR of SS 304 Using Silicon Carbide Abrasive Jet

by Deb Kumar Adak, Vivekananda Pal, Santanu Das, Tina Ghara, Hillol Joardar, Nashmi Alrasheedi and Barun Haldar

Lubricants 2023, 11(1), 10; https://doi.org/10.3390/lubricants11010010 - 28 Dec 2022

Cited by 2 | Viewed by 2593

Abstract

The surface preparation of shiny stainless steels is a must for applying esthetic paints, effective functional plasma spray coating, laser cladding, welding, etc., applications. The current work aims for effective surface roughening and erosion MRR of SS 304 work surface using SiC abrasive [...] Read more.

The surface preparation of shiny stainless steels is a must for applying esthetic paints, effective functional plasma spray coating, laser cladding, welding, etc., applications. The current work aims for effective surface roughening and erosion MRR of SS 304 work surface using SiC abrasive jet erosion and optimization of the process parameters. The response surface approach is used to design and conduct the studies using the Box–Behnken design method. The surface topography of the eroded surfaces is examined by a 2D profilometer, 3D profilometer, and scanning electron microscope (SEM). The abrasive grit size and working gas pressure greatly affect the surface roughness of SS 304 samples. The influence of the process parameters on the variation of these topographical features is analyzed and confirmed. The working jet pressure is seen to significantly impact erosion MRR. The lower working gas pressure shows a typical influence on R_a (surface preparation) and as pressure increases, erosion MRR rises, and the surface preparation mode shifts to the erosion metal removal/cutting zone. The quality of SS 304 surface prepared from SiC abrasive jet impact is characterized by 3D profilometry. Full article

(This article belongs to the Special Issue Assessment of Abrasive Wear)

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14 pages, 10917 KiB

Open AccessArticle

Three-Body Abrasive Wear Performance of High Chromium White Cast Iron with Different Ti and C Content

by Mohammad Jobayer Huq, Kazumichi Shimizu, Kenta Kusumoto and Riki Hendra Purba

Lubricants 2022, 10(12), 348; https://doi.org/10.3390/lubricants10120348 - 04 Dec 2022

Cited by 5 | Viewed by 1512

Abstract

The need for better wear-resistant materials to reduce cost and save the environment is noteworthy. The striking wear resistance of high chromium white cast iron (HCCI) has made it industry’s predominant choice. The three-body abrasive wear resistance performance of HCCI was investigated based [...] Read more.

The need for better wear-resistant materials to reduce cost and save the environment is noteworthy. The striking wear resistance of high chromium white cast iron (HCCI) has made it industry’s predominant choice. The three-body abrasive wear resistance performance of HCCI was investigated based on combined Ti and C. The Ti and C content varied in different percentages. The addition of Ti resulted in refined M₇C₃ carbides and TiC crystallization. The hardness was significantly affected by the addition of Ti. The increment in Ti content resulted in a decrease in the hardness, leading to a higher wear rate. However, the individual contribution of C led to higher hardness and, hence, better wear resistance, which is contrary to Ti. Out of the three specimens with 3, 3.5, and 4 wt.% C content, the 4 wt.% C series showed the highest hardness but the lowest wear rate and depth. This study found that the combination of a lower percentage of Ti with a higher percentage of C in HCCI can have a worthwhile result in abrasive wear. Full article

(This article belongs to the Special Issue Assessment of Abrasive Wear)

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13 pages, 3639 KiB

Open AccessArticle

Reduction in the Volumetric Wear of a Ball Polishing Tool Using Ultrasonic-Vibration-Assisted Polishing Process

by Fang-Jung Shiou, Zhao-Li Ding and Sun-Peng Lin

Lubricants 2022, 10(12), 339; https://doi.org/10.3390/lubricants10120339 - 30 Nov 2022

Cited by 2 | Viewed by 1372

Abstract

Ultraprecision freeform polishing using a bonnet or a felt ball mounted on a polishing head plays an important role in the mold and lens production industries. The volumetric wear of a bonnet or a felt polishing ball is still a problem to be [...] Read more.

Ultraprecision freeform polishing using a bonnet or a felt ball mounted on a polishing head plays an important role in the mold and lens production industries. The volumetric wear of a bonnet or a felt polishing ball is still a problem to be solved. The objective of this study was to develop an ultrasonic-vibration-assisted ball polishing process on a CNC machining center to improve the surface roughness of a STAVAX mold steel and to reduce the volumetric wear of the polishing ball. The optimal combination of the ultrasonic-vibration-assisted ball polishing parameters for a plane surface was determined by conducting the Taguchi L18 matrix experiments, ANOVA analysis, and verification experiments. The surface roughness of the polished specimens was improved from the burnished surface roughness of Ra 0.122 μm to Ra 0.022 μm. In applying the optimal plane surface ball burnishing and vibration-assisted spherical polishing parameters sequentially to a fine-milled and burnished aspherical lens surface carrier on a five-axis machining center, the surface roughness of Ra 0.014 μm was obtainable. The improvement in the volumetric wear of the polishing ball was about 62% using the vibration-assisted polishing process compared with the nonvibrated polishing process. Full article

(This article belongs to the Special Issue Assessment of Abrasive Wear)

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11 pages, 1952 KiB

Open AccessArticle

A Study on the Skin Adhesion Test of Fine Particles by Brake Pad Friction

by Jae Sang Yoo and Young Ze Lee

Lubricants 2022, 10(12), 338; https://doi.org/10.3390/lubricants10120338 - 29 Nov 2022

Viewed by 1388

Abstract

Though fine dust on the side of the road has decreased substantially due to environmental regulations, the adverse effects on the human due to air pollution still cannot be ignored. In this study, we aim to determine the effect of the vehicle’s brake [...] Read more.

Though fine dust on the side of the road has decreased substantially due to environmental regulations, the adverse effects on the human due to air pollution still cannot be ignored. In this study, we aim to determine the effect of the vehicle’s brake usage on air pollution and the human skin according to the brake pad conditions. A friction experiment device simulating the mechanical friction of a vehicle brake pad was designed to conduct a fine particle generation experiment. Different loads and rpms were set under the friction and the fine particles generated through this were analyzed using an ELPI+ (Electrical Low Pressure Impactor) apparatus. At the same time as the friction experiment was conducted, a human skin sample was installed around it, and after the experiment, the deposited fine dust was observed under a microscope for each certain area. The experiment found that there was a change in micrometer-sized microparticles affecting PM (Particulate Matter) depending on the brake pad conditions. In addition, a result graph of the adhesion of fine particles according to skin surface conditions and brake pad conditions was derived. A discussion was performed on how the fine particles affect the human skin through the characteristics of the fine particles according to the friction conditions. Full article

(This article belongs to the Special Issue Assessment of Abrasive Wear)

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14 pages, 24131 KiB

Open AccessArticle

The Preparation and Performance Analysis of a Cr₂O₃ Gel Abrasive Tool for Sapphire Substrate Polishing

by Liang Zhao, Kaiping Feng, Tianchen Zhao, Zhaozhong Zhou and Junkai Ding

Lubricants 2022, 10(12), 324; https://doi.org/10.3390/lubricants10120324 - 22 Nov 2022

Cited by 2 | Viewed by 1128

Abstract

In order to solve the problem of the agglomeration of abrasives in traditional hot-pressing abrasive tools, this paper proposes a chromium oxide (Cr₂O₃) gel abrasive tool with a polyacrylamide gel and a polyimide resin as the bonding agent. The [...] Read more.

In order to solve the problem of the agglomeration of abrasives in traditional hot-pressing abrasive tools, this paper proposes a chromium oxide (Cr₂O₃) gel abrasive tool with a polyacrylamide gel and a polyimide resin as the bonding agent. The effects of the dispersant and slurry pH on slurry viscosity and the effects of different sintering temperatures on the properties of the abrasives tool were explored. The influence of abrasive tools on the friction coefficient at different sintering temperatures was compared through friction and wear experiments. A comparison experiment of sapphire substrate polishing was carried out to compare the processing effect of the hot-pressing abrasive tool and the gel abrasive tool on the workpiece. The experimental results show that, when the pH value of the slurry is between 8–9 and the mass fraction of the dispersant is 1.5 wt%, the viscosity of the slurry is the lowest. When the sintering temperature is 350 °C, the tensile and flexural strengths of the abrasive tool reach 96 MPa and 42 MPa, and the hardness reaches 72 HRF. In the friction wear test, the friction coefficient is the most stable, and the wear rate of the abrasive tool is the lowest. In the polishing experiment, the gel abrasive tool performs better than the hot-pressing abrasive tool. After processing using the gel abrasive tool, the average surface roughness R_a reaches 2.69 nm, and the flatness PV reaches 0.65 μm; after CMP, the surface roughness R_a reaches 0.67 nm and no scratches appear on the surface of the sapphire. Full article

(This article belongs to the Special Issue Assessment of Abrasive Wear)

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17 pages, 5462 KiB

Open AccessArticle

Investigating the Effect of Operating Parameters on the Wear of Abrasive Tools in the Polishing Stage of Granitic Building Stones

by Ali Farhadian, Ebrahim Ghasemi, Seyed Hadi Hoseinie and Raheb Bagherpour

Lubricants 2022, 10(11), 321; https://doi.org/10.3390/lubricants10110321 - 21 Nov 2022

Viewed by 1678

Abstract

Operating parameters affect the wear of abrasive tools during the polishing stage in building stone processing plants. This study investigates the effects of essential operating parameters including polishing head pressure, head rotation speed and water flow rate on the wear of the abrasive [...] Read more.

Operating parameters affect the wear of abrasive tools during the polishing stage in building stone processing plants. This study investigates the effects of essential operating parameters including polishing head pressure, head rotation speed and water flow rate on the wear of the abrasive tools. For this purpose, a building stone abrasivity test was used to determine the weight loss of the abrasive tools during laboratory polishing of fifteen different types of Iranian granitic building stones. The standard operating parameters of the test were a polishing head pressure of 5 bar, a head rotation speed of 300 revolutions per minute (rpm), and a water flow rate of 4 L/min. The values of the operating parameters were changed to values within the range from ±25% and ±50% of the standard conditions in order to investigate the effect of variations in these parameters on the wear of the abrasive tools during the polishing stage. The results of different tests showed that the wear of the abrasive tools was directly proportional to the pressure up until a critical value of around 6.25 bar, after which it gradually decreased. This nonlinear wear behavior does not conform to Archard’s well-known classical wear law. The FESEM images of the worn surfaces showed that due to excessive load, debonded abrasive particles could not be pulled out from the pin surface and led to an interlocking phenomenon between the pin and stone surface. It was also found that the wear of the abrasive tools increased with increasing head rotation speed, while it decreased with the water flow rate. Moreover, the main wear mechanism of tests was abrasive wear and in some cases with a mixture mode of adhesion and delamination. Full article

(This article belongs to the Special Issue Assessment of Abrasive Wear)

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16 pages, 6664 KiB

Open AccessArticle

Antibacterial TaC-(Fe,Cr,Mo,Ni)-(Ag/Cu) Composite Coatings with High Wear and Corrosion Resistance in Artificial Seawater

by Mariya N. Antonyuk, Konstantin A. Kuptsov, Alexander N. Sheveyko and Dmitry V. Shtansky

Lubricants 2022, 10(11), 320; https://doi.org/10.3390/lubricants10110320 - 20 Nov 2022

Cited by 2 | Viewed by 1586

Abstract

The synergistic effect of simultaneous mechanical wear, chemical/electrochemical corrosion (tribocorrosion) and microbial attack poses a serious threat to marine and coastal infrastructure. To address this important problem, we have developed composite coatings consisting of TaC (25–35 at.%) and a corrosion-resistant α-Fe(Cr,Ni,Mo)-based metal matrix, [...] Read more.

The synergistic effect of simultaneous mechanical wear, chemical/electrochemical corrosion (tribocorrosion) and microbial attack poses a serious threat to marine and coastal infrastructure. To address this important problem, we have developed composite coatings consisting of TaC (25–35 at.%) and a corrosion-resistant α-Fe(Cr,Ni,Mo)-based metal matrix, as well as bactericidal elements (Cu, Ag). Coatings 50–75 μm thick were obtained by electrospark deposition in vacuum. The coatings possess high hardness (up to 10 GPa) and resistance to cyclic dynamic loads compared with the stainless steel (SS) substrate. Tribocorrosion experiments showed that the decrease in the corrosion potential associated with the removal of a passivating film from the surface during friction was 2–2.5 times smaller for the Ag-containing coating than for the other tested materials. The material passivation rates were also different: almost instantaneous passivation of the Ag- and Cu-doped coatings, and slow passivation for several minutes of the Ag/Cu-free coating and SS. The Ag-containing coating shows the lowest friction coefficient (0.2–0.25) and a minimal wear rate (1.6 × 10⁻⁶ mm³/Nm) in artificial seawater. The Ag-doped coating also exhibits the most positive value of corrosion potential and the lowest current density. After exposure in seawater for 20 days, only the Ag-doped coating showed no signs of pitting corrosion. All the studied materials have a pronounced bactericidal effect against Bacillus cereus Arc30 bacteria. The resulting coatings can be used to protect steel products from tribocorrosion and fouling in seawater. Full article

(This article belongs to the Special Issue Assessment of Abrasive Wear)

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17 pages, 11964 KiB

Open AccessArticle

Analysis of Tool Wear and Counter Surface Roughness in the Flexible Abrasive Tool Finishing

by Mayank Kumar, Ajay Sidpara and Vikranth Racherla

Lubricants 2022, 10(11), 318; https://doi.org/10.3390/lubricants10110318 - 18 Nov 2022

Cited by 3 | Viewed by 1684

Abstract

This work uses the solvent casting method to fabricate an elastomeric tool with polyurethane as the base material and silicon carbide (SiC) as embedded abrasive particles. The distribution of abrasive particles and the pore structure in the fabricated tools are analyzed. The fabricated [...] Read more.

This work uses the solvent casting method to fabricate an elastomeric tool with polyurethane as the base material and silicon carbide (SiC) as embedded abrasive particles. The distribution of abrasive particles and the pore structure in the fabricated tools are analyzed. The fabricated tools are porous in nature and have self-replenishing as well as self-lubrication properties. Aluminum 6061 alloy and electroless nickel-phosphorus plating having different initial roughness are selected as workpieces to study the wear mechanisms and loading of the flexible abrasive tool. The rotational speed of the tool, tool compression, and feed rate are fixed input process parameters. Total finishing time, sliding distance, and roughness are varied to obtain output responses. The workpiece material is also taken into account as a variable parameter in this study. These materials are classified as different counter surfaces as their surface roughness and mechanical properties vary. The finishing time and sliding distance for these counter surfaces differ in order to relate their effects on tool wear and loading. The nickel-plated surface shows a higher percentage reduction in surface roughness of 92% as compared to the aluminum surface, with a 62% reduction in surface roughness. The coefficient of friction, wear, and tool condition are analyzed to understand the mechanism of tool wear and tool loading. In this process, both two-body and three-body abrasions occur simultaneously and continuously. Full article

(This article belongs to the Special Issue Assessment of Abrasive Wear)

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18 pages, 5773 KiB

Open AccessArticle

Finite Element Modelling of Wear Behaviors of Composite Laminated Structure

by Mohammed Y. Abdellah, Mohamed K. Hassan, Abdel-Aziz AlMalki, Ahmed F. Mohamed and Ahmed H. Backar

Lubricants 2022, 10(11), 317; https://doi.org/10.3390/lubricants10110317 - 18 Nov 2022

Cited by 2 | Viewed by 1843

Abstract

Three different laminated composites are used in this study: carbon fiber, woven glass fiber, and glass-fiber-reinforced epoxy. The composite laminate structures were fabricated using the hand lay-up technique at room temperature. The laminates were reinforced with epoxy resin, carbon fibers (CFRP), woven glass [...] Read more.

Three different laminated composites are used in this study: carbon fiber, woven glass fiber, and glass-fiber-reinforced epoxy. The composite laminate structures were fabricated using the hand lay-up technique at room temperature. The laminates were reinforced with epoxy resin, carbon fibers (CFRP), woven glass fibers (GFRP-W), and random-orientation glass fibers (GFRP-R) to obtain laminates with eight layers. The wear test was performed using a pin-on-disc tribometer with five different loads of 10, 20, 30, 40, and 50 N at room temperature and a constant speed of 3 m/s. In addition, three different surfaces were lubricated: dry, with grease, and with oil. The effect of lubrication on the weight loss of the laminates was measured. The linear elastic finite element model FEM was derived to simulate the pin on the disc and the failure mode in shear mode for the case of dry lubrication. In addition, the FEM allows the friction force to be measured to determine the friction coefficient numerically. For validation, a simple analytical model based on the shear stress induced by the laminates at the interfaces was extracted to measure the friction coefficients. Tensile strength is a characteristic property that is very important for the purpose of material description from FEM and the analytical model. Therefore, it was determined experimentally with a simple tensile test. The results show that the wear rate is better with GFRP-R composites. Moreover, the wear rate with grease is lower than with oil or dry. The FEM showed that the coefficient of friction decreases with normal force to a minimum value of 0.02 for the case of 50 N normal force and for GFRP-R, while the maximum value of the coefficient of friction was 0.55 for CFRP at 10 N normal load and the FEM results were in good agreement with the analytically determined data. Full article

(This article belongs to the Special Issue Assessment of Abrasive Wear)

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19 pages, 8378 KiB

Open AccessArticle

Surface Damage Analysis on the Application of Abrasion and Slurry Erosion in Targeted Steels Using an Erosion Test Rig

by Ádám Kalácska, Rajini Nagarajan, Levente Ferenc Tóth, Patrick De Baets, Karthikeyan Subramanian, Suchart Siengchin and Gábor Kalácska

Lubricants 2022, 10(11), 316; https://doi.org/10.3390/lubricants10110316 - 18 Nov 2022

Cited by 1 | Viewed by 1372

Abstract

The research focuses on slurry abrasion and erosion of martensitic steels used in the mining and agricultural industries. A traditionally constructed slurry pot tester with corundum abrasives in slurry form was used for wear characterisation. Wear testing was performed on each specimen for [...] Read more.

The research focuses on slurry abrasion and erosion of martensitic steels used in the mining and agricultural industries. A traditionally constructed slurry pot tester with corundum abrasives in slurry form was used for wear characterisation. Wear testing was performed on each specimen for 180 h. Every 20 h, pauses were taken to characterise the specimen size, weight, hardness, and surface roughness. The worn zone’s damage progression was studied using optical microscopy. As the test period rose, the mass loss due to the wear, which was governed by the impact angle of the slurry flow, followed a linear pattern. The impact of specimen orientation on the wear rate was more pronounced than that of abrasive flow velocity. High-speed video recordings highlighted the varied contact conditions that caused the wear mechanism to shift from abrasion to slurry erosion. Slurry abrasion was seen at the bottom of the specimen as a result of pure sliding conditions, while pitting was observed at the top of the specimen as a result of fatigue from particle impact. Studies of 3D surfaces demonstrated a decrease in wear rate while transitioning from the abraded zone, which witnessed polishing and minor hardness, to the pitting zone. The wear performance of the materials was rated, with tempered martensitic steel coming out on top. Full article

(This article belongs to the Special Issue Assessment of Abrasive Wear)

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17 pages, 11046 KiB

Open AccessArticle

Nanocrystallized Surface Effect on the Tribocorrosion Behavior of AISI 420

by Fatma Ben Saada, Mariem Ben Saada, Khaled Elleuch and Pierre Ponthiaux

Lubricants 2022, 10(11), 304; https://doi.org/10.3390/lubricants10110304 - 12 Nov 2022

Cited by 3 | Viewed by 1235

Abstract

Nanopeening treatment was applied to the AISI 420 steel to decrease its sensitivity to tribocorrosion damage. The microstructural investigation highlighted that the nanopeening treatment led to high plastic deformation and a nanostructured surface layer with a 110 µm depth. In order to study [...] Read more.

Nanopeening treatment was applied to the AISI 420 steel to decrease its sensitivity to tribocorrosion damage. The microstructural investigation highlighted that the nanopeening treatment led to high plastic deformation and a nanostructured surface layer with a 110 µm depth. In order to study the combined effect of corrosion and mechanical wear, tribocorrosion tests were performed on non-treated and nanopeened samples in boric acid and lithium hydroxide solutions, considering both continuous and intermittent sliding. It was found that the AISI 420 steel is sensitive to the synergy between mechanical friction and electrochemical corrosion with the dominance of abrasive wear. Adhesive wear was also detected in the wear track. Indeed, the mechanical wear was pronounced under intermittent sliding because of hard wear debris generation from the repassivated layer during rotating time. The nanopeening treatment led to enhanced mechanical performance and corrosion properties. Such improvement could be explained by the high plastic deformation resulting in the nano-structuration of grains and the increasing hardness of AISI 420 steel. Full article

(This article belongs to the Special Issue Assessment of Abrasive Wear)

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17 pages, 11456 KiB

Open AccessArticle

The Combined Effects of Sliding Velocity and Martensite Volume Fraction on Tribological Behavior of a Dual-Phase Steel

by Yunbo Zhang and Abdeljalil Jourani

Lubricants 2022, 10(11), 303; https://doi.org/10.3390/lubricants10110303 - 11 Nov 2022

Viewed by 1096

Abstract

The focus of this study was the combined effects of sliding velocity (SV) and martensite volume fraction (MVF) on the tribological behavior of dual-phase (DP) steel. Dry frictional tests were realized on a ball-on-disk tribometer by unidirectional sliding at 0.1 m/s, 0.6 m/s, [...] Read more.

The focus of this study was the combined effects of sliding velocity (SV) and martensite volume fraction (MVF) on the tribological behavior of dual-phase (DP) steel. Dry frictional tests were realized on a ball-on-disk tribometer by unidirectional sliding at 0.1 m/s, 0.6 m/s, and 1 m/s. Considering the increase in SV, both the friction coefficient (COF) and wear rate decrease due to the increase in oxidative wear. At 0.1 m/s, the major wear mechanism is abrasive wear, accompanied by partial material flaking and less oxidation wear; at 0.6 m/s, the wear mechanism is in the transition between abrasive wear and oxidation wear; at 1 m/s, oxidation wear becomes the dominant wear mechanism. For the same SV, specimens with lower MVF exhibited lower wear compared to specimens with higher MVF; this phenomenon is especially evident at low SV. As the SV increases, the effect of MVF on the wear decreases, and the velocity becomes the dominant factor. Full article

(This article belongs to the Special Issue Assessment of Abrasive Wear)

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19 pages, 5914 KiB

Open AccessArticle

A Novel Polishing Method for Extending the Service Life of Magnetic Compound Fluid

by Youliang Wang, Xichun Gao, Jibo Gao, Xiujuan Chen, Wenjuan Zhang and Ming Feng

Lubricants 2022, 10(11), 299; https://doi.org/10.3390/lubricants10110299 - 06 Nov 2022

Viewed by 1300

Abstract

Magnetic field-assisted magnetic compound fluid (MCF) ultra-precision machining technology is regarded as an effective method to obtain a smooth surface. However, due to the evaporation and splashing of water in the polishing fluid during processing, the service life of the MCF slurry is [...] Read more.

Magnetic field-assisted magnetic compound fluid (MCF) ultra-precision machining technology is regarded as an effective method to obtain a smooth surface. However, due to the evaporation and splashing of water in the polishing fluid during processing, the service life of the MCF slurry is reduced. This paper presents a material removal model for MCF polishing, and a novel experimental apparatus is proposed to extend the service life by supplying MCF components into the MCF slurry. Firstly, in order to obtain the ideal polishing tool, the appearance morphologies and the formation process of the MCF slurry were observed by an industrial camera. On this basis, the optimum parameters were determined by multi-factor and multi-level orthogonal experiments. Finally, the investigation of the MCF service life was carried out under the optimal processing parameters. The main findings are summarized as follows. (1) Excellent MCF polishing tools are obtained when the eccentric distance r is 4 mm and the MCF slurry supply V is 1 mL. (2) When the eccentric distance increases from 2 mm to 4 mm, the forming time of the MCF tool decreases sharply, but when the eccentricity exceeds 4 mm, the decreasing trend becomes slow. The molding time grows steadily as the supply is increased. (3) When the machining gap Δ, the MCF carrier speed n_c, the eccentricity r, and the revolution speed of magnetic n_m are 1 mm, 500 rpm, 4 mm, and 600 rpm, respectively, the ideal machining effect can be obtained. (4) It could be proven that the polishing device is feasible to extend the service time of the MCF slurry by adding MCF components. Full article

(This article belongs to the Special Issue Assessment of Abrasive Wear)

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18 pages, 17870 KiB

Open AccessArticle

Effect of Temperature and Sliding Velocity on the Dry Sliding Wear Mechanisms of Boron Modified Ti-6Al-4V Alloys

by Tulika Dixit and K. Eswar Prasad

Lubricants 2022, 10(11), 296; https://doi.org/10.3390/lubricants10110296 - 04 Nov 2022

Cited by 5 | Viewed by 1237

Abstract

The dry sliding wear behavior of as-cast pristine and boron-modified Ti-6Al-4V (Ti64) alloys (having 0.3 and 0.55 wt% B) is investigated using pin-on-disc experiments with the pin being Ti64 alloy and the EN31 steel disc. Experiments are performed at sliding speeds (s [...] Read more.

The dry sliding wear behavior of as-cast pristine and boron-modified Ti-6Al-4V (Ti64) alloys (having 0.3 and 0.55 wt% B) is investigated using pin-on-disc experiments with the pin being Ti64 alloy and the EN31 steel disc. Experiments are performed at sliding speeds (s) of 1, 2, and 4 m/s and temperatures 300 and 573 K. A mixed response in wear behavior is observed. At the lowest sliding speed, all three alloys (except 0.55B alloy at 300 K) exhibit similar wear rates, with abrasive wear being the dominant wear mechanism. At 2 m/s, temperature and s increase, and adhesive wear takes over along with delamination wear. Here, the 0.55B sample shows the highest wear rate due to the debonding of more TiB particles, which increases three body abrasion wear. With further increase in s to 4 m/s, delamination and oxidation wear are observed for all the samples. XRD evaluation shows traces of TiO₂ and Fe₂O₃, which imply the formation of MML in samples tested at s = 4 m/s, which is also validated through subsurface microstructure analysis. It is found that MML having more TiB particles has more stability, because of which 0.3B samples show higher wear rate. Full article

(This article belongs to the Special Issue Assessment of Abrasive Wear)

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11 pages, 8801 KiB

Open AccessArticle

Microstructure and Wear Resistance of FeCuNiTiAl High-Entropy Alloy Coating on Ti6Al4V Substrate Fabricated by Laser Metal Deposition

by Dongqi Zhang, Dong Du, Guan Liu, Ze Pu, Shuai Xue and Baohua Chang

Lubricants 2022, 10(10), 263; https://doi.org/10.3390/lubricants10100263 - 18 Oct 2022

Cited by 5 | Viewed by 1114

Abstract

In order to improve the hardness and wear resistance of titanium alloys, an equimolar ratio high-entropy alloy (HEA) FeCuNiTiAl coating was fabricated on the surface of titanium alloy Ti6Al4V by means of laser metal deposition for the first time. The microstructure and composition [...] Read more.

In order to improve the hardness and wear resistance of titanium alloys, an equimolar ratio high-entropy alloy (HEA) FeCuNiTiAl coating was fabricated on the surface of titanium alloy Ti6Al4V by means of laser metal deposition for the first time. The microstructure and composition of the HEA coating and the transition zone were observed by scanning electron microscopy (SEM) and energy dispersive spectrometer (EDS). The results show that HEA coating and Ti6Al4V have suitable metallurgical bonding, and no defects, such as cracks, are found at the interface. The hardness of the HEA coating is between 450 and 500 HV_0.5, which is about 1.5 times that of the Ti6Al4V substrate. Wear tests show that the wear rate of HEA coating is 0.89 × 10⁻⁵ mm³/(N·m), while that of Ti6Al4V reaches 53.97 × 10⁻⁵ mm³/(N·m), and the wear resistance of substrate is increased 60 times by the HEA coating. The wear mechanism of the Ti6Al4V substrate is mainly abrasive wear, and the wear mechanism of FeCuNiTiAl HEA coating is mainly adhesive wear, accompanied by slight oxidation wear and abrasive wear. Full article

(This article belongs to the Special Issue Assessment of Abrasive Wear)

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11 pages, 3536 KiB

Open AccessArticle

Whole Elliptical Surface Polishing Using a Doughnut-Shaped MCF Polishing Tool with Variable Tilt Angle

by Ming Feng, Yang Lei, Zhixiang Chen, Xianglei Zhang, Xizhang Chen and Youliang Wang

Lubricants 2022, 10(10), 232; https://doi.org/10.3390/lubricants10100232 - 23 Sep 2022

Cited by 2 | Viewed by 1424

Abstract

Elliptical elements are essential optical surfaces for modifying optical systems. For polishing the whole elliptical surface using doughnut-shaped MCF polishing tool with variable tilt angle, an experimental investigation was conducted in this work. Firstly, a flat workpiece was polished to determine the polishing [...] Read more.

Elliptical elements are essential optical surfaces for modifying optical systems. For polishing the whole elliptical surface using doughnut-shaped MCF polishing tool with variable tilt angle, an experimental investigation was conducted in this work. Firstly, a flat workpiece was polished to determine the polishing feasibility. It was found that the middle portion of the polishing tool had optimal ability to remove materials, and the surface roughness S_a at the material removal peak was changed from 134 nm to 17.5 nm within 50 min of polishing. A smoother surface could be obtained using MCF2 slurry and MCF3 slurry, but the use of MCF1 slurry resulted in a rough surface. Then, the effects of working gap h, revolution speed of MCF polishing tool and polishing time on the polishing results were tested to study the polishing characteristics. S_a 9.6 nm and glossiness 278 Gu were obtained, and form error improved from 2.3 μm to 1.3 μm. Finally, the MCF polishing tool was dried to observe the microstructure of the MCF polishing tool after polishing. Abrasive particles were distributed evenly after polishing. It was seen that the abrasive particles were grabbed by the ferric clusters, and the α-celluloses were interleaved between the clusters. Full article

(This article belongs to the Special Issue Assessment of Abrasive Wear)

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10 pages, 3248 KiB

Open AccessArticle

Experimental Study of Both-Sides Cylindrical Roller Machining Based on Ceramic Plate

by Tianchen Zhao, Junkai Ding, Kaiping Feng, Julong Yuan, Binghai Lyu, Xun Lv and Xingling He

Lubricants 2022, 10(10), 227; https://doi.org/10.3390/lubricants10100227 - 20 Sep 2022

Viewed by 1416

Abstract

In order to improve the accuracy and batch consistency of cylindrical roller machining, in this paper, a both-sides cylindrical roller machining method based on hard ceramic plate is proposed. Traditional cast iron and stainless-steel polishing plate were replaced by ceramic materials with high [...] Read more.

In order to improve the accuracy and batch consistency of cylindrical roller machining, in this paper, a both-sides cylindrical roller machining method based on hard ceramic plate is proposed. Traditional cast iron and stainless-steel polishing plate were replaced by ceramic materials with high hardness and good wear resistance. After processing by centerless grinding, the cylindrical roller is processed by both-sides lapping and polishing using Al₂O₃ ceramic plates. The roundness, diameter and surface quality of the roller and the wear of the ceramic plate before and after machining were compared and analyzed in order to evaluate the feasibility and effectiveness of this method. After grinding for 1 h and polishing for 8 h, the average roundness of the cylindrical rollers decreased from the initial 2.3 μm to 0.32 μm, while the roundness of each roller tended to be the same. At the same time, the batch diameter deviation of cylindrical rollers was reduced from 3 μm to 1 μm, and the batch consistency was satisfactory. The machining marks produced by centerless grinding on the roller surface were completely removed, and the surface quality was significantly improved. The surface roughness after polishing reached Ra 16 nm. The upper and lower ceramic plate had certain wear, but the amount was small, having little impact on the machining results. The shape accuracy and batch consistency of the rollers after machining were satisfactory. The ceramic plate had high hardness, good wear resistance and small wear in the machining process. Additionally, it could maintain extremely high flatness for a long time. Using hard ceramic plates to process cylindrical rollers, high precision and high consistency cylindrical rollers can be obtained after machining. Full article

(This article belongs to the Special Issue Assessment of Abrasive Wear)

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15 pages, 6715 KiB

Open AccessArticle

Near-Net Forging of Titanium and Titanium Alloys with Low Friction and Low Work Hardening by Using Carbon-Supersaturated SKD11 Dies

by Tatsuhiko Aizawa, Tatsuya Funazuka and Tomomi Shiratori

Lubricants 2022, 10(9), 203; https://doi.org/10.3390/lubricants10090203 - 28 Aug 2022

Cited by 3 | Viewed by 1682

Abstract

A new near-net forging procedure of titanium and titanium alloys was proposed by using a carbon-supersaturated punch and die. Due to the in situ formation of carbon-based tribofilm on the contact interface between the dies and work materials, a low frictional state was [...] Read more.

A new near-net forging procedure of titanium and titanium alloys was proposed by using a carbon-supersaturated punch and die. Due to the in situ formation of carbon-based tribofilm on the contact interface between the dies and work materials, a low frictional state was sustained through the forging process even in a high reduction in thickness. The work hardening was suppressed during forging; an additional annealing process was unnecessary through the whole process of near-net forging. Pure titanium and β-phase titanium alloy wires were utilized to describe their galling-free forging behavior when increasing the reduction in thickness. Wires with a diameter of 3 mm were upset in a single-shot forging. The reduction in thickness reached 58% when upsetting the pure titanium wire and 45% when upsetting the β-phase titanium alloys, without lubricating materials or oils at room temperature. The friction coefficient on the contact interface was estimated to be 0.05 by inverse analysis. The work-hardening behavior was described by the hardness mapping on the work cross section. The formation of carbon tribofilms was explained by microstructural analysis, element mapping, and Raman spectroscopy. This tribofilm was formed from the isolated carbon solute from the carbon-supersaturated punch and die to sustain the in situ solid lubrication on the contact interface. Full article

(This article belongs to the Special Issue Assessment of Abrasive Wear)

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20 pages, 20777 KiB

Open AccessArticle

A Comparative Study of Hardfacing Deposits Using a Modified Tribological Testing Strategy

by Ján Slota, Andrzej Kubit, Ivan Gajdoš, Tomasz Trzepieciński and Ľuboš Kaščák

Lubricants 2022, 10(8), 187; https://doi.org/10.3390/lubricants10080187 - 18 Aug 2022

Cited by 4 | Viewed by 1626

Abstract

In this study, hardfacing deposits using materials of different surface hardness are investigated using an innovative strategy for tribological testing. The abrasive wear behaviour of AISI 316L stainless steel is compared to the Cr–Ni–Mn alloy (OK Autrod 16.95) and the Cr-Mo alloy (Fluxofil [...] Read more.

In this study, hardfacing deposits using materials of different surface hardness are investigated using an innovative strategy for tribological testing. The abrasive wear behaviour of AISI 316L stainless steel is compared to the Cr–Ni–Mn alloy (OK Autrod 16.95) and the Cr-Mo alloy (Fluxofil 58), deposited on a substrate of S355JR steel. A modified three-body abrasion test and a modified scratch test were used to evaluate the tribological behaviour and wear mechanisms of these materials. The modified double-pass scratch test on the abraded surfaces is analysed using the geometrical parameters of grooves to aid in predicting the lifetime of machinery parts in abrasive working conditions. This leads to a shortening of the resistance to abrasion wear time of the evaluation of the abrasion wear resistance of materials. The validation of the results obtained in the double-pass scratch tests was carried out using three-body abrasion tests, according to the ASTM G65 standard. Wear mechanism investigations were carried out by scanning electron microscopy and three-dimensional surface topography and was analysed using an optical microscope. The results obtained from experimental research show that double-pass scratch tests demonstrated that it is possible to shorten the time needed to predict the abrasive behaviour of materials using this method. Full article

(This article belongs to the Special Issue Assessment of Abrasive Wear)

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