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Advances in Friction, Lubrication, Wear and Oxidation in Metals Manufacturing

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A special issue of Metals (ISSN 2075-4701).

Deadline for manuscript submissions: closed (31 December 2021) | Viewed by 26661

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Special Issue Editors

Dr. Guanyu Deng

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Guest Editor

School of Mechanical, Materials, Mechatronic and Biomedical Engineering, University of Wollongong, Wollongong, Australia
Interests: high entropy alloys; titanium alloys; advanced manufacturing; severe plastic deformation; computational modelling; contact mechanics; oxidation and tribology; texture and residual stress
Special Issues, Collections and Topics in MDPI journals

Dr. Hongtao Zhu

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Guest Editor

School of Mechanical, Materials, Mechatronic and Biomedical Engineering, University of Wollongong, Australia
Interests: metal forming; tribology and lubrication; contact mechanics; rolling contact fatigue; fracture control; oxidation mechanics; quantum and molecular dynamic simulation

Prof. Dr. Anh Kiet Tieu

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Guest Editor

School of Mechanical, Materials, Mechatronic and Biomedical Engineering, University of Wollongong, Wollongong, Australia
Interests: metal and alloys; rolling technology; mechanics of materials; computational materials science; multiscale modelling; severe plastic deformation; tribology in manufacturing process; friction and wear analysis; novel lubricants; oxidation and corrosion of materials
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

In recent years, metals manufacturing has been undergoing significant transformation through optimizations of conventional manufacturing methods and systems (rolling, forging, welding, etc.) and through the promotion of new manufacturing processes and techniques (e.g., additive manufacturing and nanomanufacturing), due to the emergence of new materials such as high-entropy alloys and the growing requirement of manufacturing efficiency and product quality. Simultaneously, tribology, which plays an important role in metals manufacturing, has attracted increasing attention and interest in both the industrial and academic communities. With the development of both experimental techniques and computer simulation methods, the origin of friction, principles of lubrication, the performance of lubricants, mechanisms of wear, and the oxidation of metals and alloys during the manufacturing processes have become assessable at different length and time scales.

We would like to invite researchers to submit original research papers, short communications, and review articles to this Special Issue on “Advances in Friction, Lubrication, Wear and Oxidation in Metals Manufacturing”. This Special Issue is dedicated to disseminating the latest research and understandings based on advanced experimental studies and computational modellings related to the development of novel lubricants for the manufacturing and characterization of tribological properties and oxidation behavior of metals. The potential scope of interest includes (but is not limited to):

Advanced manufacturing;
Metal forming;
Metals and alloys;
Development and application of novel lubricants;
Tribology testing;
Characterization of friction and wear;
Oxidation in manufacturing;
Contact mechanics, computational simulation, and multiscale modeling.

Dr. Guanyu Deng
Dr. Hongtao Zhu
Prof. Anh Kiet Tieu
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Metals is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

Manufacturing
Metal forming
Metals and alloys
Tribology
Lubricants and lubrication
Friction and wear
Oxidation
Simulation and modeling

Published Papers (12 papers)

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Editorial

Jump to: Research

5 pages, 190 KiB

Open AccessEditorial

Advances in Friction, Lubrication, Wear and Oxidation in Metals Manufacturing

by Guanyu Deng, Hongtao Zhu and Anh Kiet Tieu

Metals 2023, 13(3), 505; https://doi.org/10.3390/met13030505 - 02 Mar 2023

Viewed by 975

Abstract

When quickly reviewing the developments of new materials design and fabrication, and engineering and industrial manufacturing, it was found that tribology is a very complicated and highly challenging field that cannot be avoided to improve the manufacturing cost and increase the material service [...] Read more.

(This article belongs to the Special Issue Advances in Friction, Lubrication, Wear and Oxidation in Metals Manufacturing)

Research

Jump to: Editorial

14 pages, 10833 KiB

Open AccessArticle

Tribological Properties of Different-Sized Black Phosphorus Nanosheets as Water-Based Lubrication Additives for Steel/Titanium Alloy Wear Contact

by Shaowen Dong, Wei Wang, Yuan Gao and Guanyu Deng

Metals 2022, 12(2), 288; https://doi.org/10.3390/met12020288 - 07 Feb 2022

Cited by 8 | Viewed by 2171

Abstract

Titanium alloys are extensively used in the aerospace, chemical, and biomedical industries. However, it has always been a challenge in the manufacturing and machining of titanium alloys because they exhibit poor friction and wear characteristics, which results in serious problems and significantly restricts their further production and application. Therefore, in the present study, the wear contact between GCr15 steel and Ti6Al4V alloy is specifically studied by considering black phosphorus nanosheets (BP-NS) as water-based lubrication additives, which is expected to have a great potential application in manufacturing and machining titanium alloys. The influence of BP nanosheet size on the coefficient of friction (COF) and wear rate of Ti6Al4V alloy has been comprehensively studied, based on comparisons among adding large BP nanosheets (L-BP) (2–4 μm), medium BP nanosheets (M-BP) (300–500 nm), and black phosphorus quantum dots (BPQDs) (6–10 nm). Compared with ultrapure water, the COF and wear rate of Ti6Al4V alloy are reduced by 42.4% and 82.3%, respectively, when BPQDs are used as water-based lubrication additives. This paper also shows that a lower COF and wear rate is achieved with the addition of BPQDs than the other two BP nanosheet sizes. Derived from the friction tests and worn surface analysis of Ti6Al4V alloy, lubrication mechanisms of different-sized BP lubricants were proposed. The interlaminar shearing between BP-NS and the adsorbed films were the main mechanisms for L-BP and M-BP lubricants, while the adsorption, repair, and ball-bearing effects were mainly presented in the BPQD lubricants. The discoveries in this paper would be beneficial to developing novel lubricants for the manufacturing and machining of titanium alloys. Full article

(This article belongs to the Special Issue Advances in Friction, Lubrication, Wear and Oxidation in Metals Manufacturing)

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12 pages, 4400 KiB

Open AccessArticle

Enhanced Mechanical and Tribological Capabilities of a Silicon Aluminum Alloy with an Electroplated Ni–Co–P/Si₃N₄ Composite Coating

by Zhijie Li, Fei Ma, Dongshan Li, Shanhong Wan, Gewen Yi, Guofang Geng and Lingyan Guo

Metals 2022, 12(1), 120; https://doi.org/10.3390/met12010120 - 07 Jan 2022

Cited by 6 | Viewed by 1365

Abstract

Ni–Co–P/Si₃N₄ composite coatings were fabricated over an aluminum–silicon (Al–Si) substrate using a pulse-current electroplating process, in which the rapid deposition of an intermediate nickel–cobalt layer was used to improve coating adhesion. The microstructure, mechanical, and tribological behaviors of the electroplated Ni–Co–P/Si₃N₄ composite coating were characterized and evaluated. The results revealed that the electroplated Ni–Co–P/Si₃N₄ composite coating primarily consisted of highly crystalline Ni–Co sosoloid and P, and a volumetric concentration of 7.65% Si₃N₄. The electroplated Ni–Co–P/Si₃N₄ composite coating exhibited hardness values almost two times higher than the uncoated Al–Si substrate, which was comparable to hard chrome coatings. Under lubricated and dry sliding conditions, the electroplated Ni–Co–P/Si₃N₄ composite coating showed excellent anti-wear performance. Whether dry or lubricated with PAO and engine oil, the composite coating showed minimum abrasive wear compared to the severe adhesive wear and abrasive wear observed in the Al–Si substrate. Full article

(This article belongs to the Special Issue Advances in Friction, Lubrication, Wear and Oxidation in Metals Manufacturing)

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24 pages, 9238 KiB

Open AccessFeature PaperArticle

Split-Plot I-Optimal Design Optimisation of Combined Oil-Based and Friction Stir Rotation-Assisted Heating in SPIF of Ti-6Al-4V Titanium Alloy Sheet under Variable Oil Pressure

by Tomasz Trzepieciński, Marcin Szpunar and Robert Ostrowski

Metals 2022, 12(1), 113; https://doi.org/10.3390/met12010113 - 07 Jan 2022

Cited by 4 | Viewed by 1342

Abstract

The aim of this paper is to determine the optimal input parameters for the process in order to ensure the maximum formable wall angle is obtained in a conical frustum with a varying wall angle fabricated using Single Point Incremental Forming (SPIF). The test material was 0.8-mm-thick Ti-6Al-4V titanium alloy sheets, and the test used a tungsten carbide tool with a rounded tip with a radius of 4 mm. Complete workpieces were heated using hot oil with a temperature of about 200 °C, and in addition, the high rotation speed of the forming tool generated an amount of friction heat. The input parameters were tool rotational speed, feed rate, step size, and tool rotation direction. Various oil pressures were used to improve both the accuracy of the components formed and the friction heating process. On the basis of calculations performed by means of the response surface methodology, split-plot I-optimal design responses were obtained by means of polynomial regression models. Models were fitted using REstricted Maximum Likelihood (REML), and p-values are derived using the Kenward–Roger approximation. Observation of the fracture surface of Ti-6Al-4V drawpieces showed that the destruction is as a result of ductile fracture mode. Tool rotational speed and step size are the most significant factors that affect the axial force, followed by feed rate. It was also found that step size is the most significant factor that affects the in-plane SPIF force. Full article

(This article belongs to the Special Issue Advances in Friction, Lubrication, Wear and Oxidation in Metals Manufacturing)

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10 pages, 4077 KiB

Open AccessArticle

Wear Behaviors of Stainless Steel and Lubrication Effect on Transitions in Lubrication Regimes in Sliding Contact

by Yoon-Seok Lee, Shunnosuke Yamagishi, Masataka Tsuro, Changwook Ji, Seungchan Cho, Yangdo Kim and Moonhee Choi

Metals 2021, 11(11), 1854; https://doi.org/10.3390/met11111854 - 18 Nov 2021

Cited by 8 | Viewed by 2345

Abstract

The wear behavior of AISI304 stainless steel was investigated under dry, water-, and oil-lubricated conditions. A block-on-disk wear test was conducted in this work, since the test conditions could be controlled easily. For oil-lubricated contact, a significant amount of thin and elongated cutting chip-like debris was observed. This is attributed to the high lubricating effect of oil. Strain-induced martensitic (SIM) transformation was observed for all AISI304 blocks after the wear test, while AISI304 consisted of a single γ-austenite phase prior to the wear test. The Stribeck curve and the corresponding lubrication regimes were also considered to explain the wear behaviors and lubrication effect of AISI304. In comparison to the dry or water-lubricated conditions, which fall in the boundary lubrication regime at a low rotation speed, it is considered that the high viscosity of the oil-based lubricant causes the lubrication condition to enter the mixed lubrication regime early at a lower speed, thus reducing the specific wear rate over the 100–300 rpm range. Full article

(This article belongs to the Special Issue Advances in Friction, Lubrication, Wear and Oxidation in Metals Manufacturing)

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16 pages, 4833 KiB

Open AccessArticle

Study on Lubrication Characteristics of C4-Alkane and Nanoparticle during Boundary Friction by Molecular Dynamics Simulation

by Xuan Zheng, Lihong Su, Guanyu Deng, Jie Zhang, Hongtao Zhu and Anh Kiet Tieu

Metals 2021, 11(9), 1464; https://doi.org/10.3390/met11091464 - 15 Sep 2021

Cited by 7 | Viewed by 1735

Abstract

Lubricant has been widely applied to reduce wear and friction between the contact surfaces when they are in relative motion. In the current study, a nonequilibrium molecular dynamics (NEMD) simulation was specifically established to conduct a comprehensive investigation on the dynamic contact between two iron surfaces in a boundary friction system considering the mixed C4-alkane and nanoparticles as lubricant. The main research objective was to explore the effects of fluid and nanoparticles addition on the surface contact and friction force. It was found that nanoparticles acted like ball bearings between the contact surfaces, leading to a change of sliding friction mode to rolling friction mode. Under normal loads, plastic deformation occurred at the top surface because nanoparticles were mainly supporting the normal load. By increasing the number of C4-alkane molecules between two contact surfaces, the contact condition has been changed from partial to full lubrication. In addition, an attractive force from the solid–liquid LJ interaction between C4-alkane and surfaces was observed at the early stage of sliding, due to the large space formed by wall surfaces and nanoparticles. The findings in this paper would be beneficial for understanding the frictional behavior of a simple lubricant with or without nanoparticles addition in a small confinement. Full article

(This article belongs to the Special Issue Advances in Friction, Lubrication, Wear and Oxidation in Metals Manufacturing)

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12 pages, 4111 KiB

Open AccessArticle

Reductions of Intergranular Corrosion Resistance and Wear Resistance in a Ni-Cr-Mo-Based Superalloy by Aging-Treatment-Induced Precipitation

by Pengyan Zhang, Chi Zhang, Xiaoguang Zhou and Zhenyi Huang

Metals 2021, 11(8), 1329; https://doi.org/10.3390/met11081329 - 23 Aug 2021

Cited by 1 | Viewed by 1844

Abstract

Ni-Cr-Mo-based superalloy is widely used as a key component in many critical environments. To ensure that the manufacturing process does not impact the long-term service performance of these components, the aging precipitation behavior at different temperatures and its effect on intergranular corrosion (IGC) resistance and wear resistance of a Ni-Cr-Mo-based C276 superalloy were investigated. The equilibrium phase diagram was calculated first using thermodynamic software to confirm the potential phases. Carbides of M₆C were found to be formed at grain boundaries after aging at 800–850 °C for short-term treatment. The other two phases (μ phase and P phase) indicated in the phase diagram were not observed for the samples after aging treatment up to 15 h. Furthermore, double loop electrochemical potentiokinetic reactivation (DL-EPR) tests were conducted to examine the IGC resistance. The degree of sensitization increased with the aging time and severe corrosion was found to occur at grain boundaries. For the first time, the influence of aging treatment on the wear behavior of this superalloy has been specifically studied. Concerning the hot processing of Ni-Cr-Mo-based C276 superalloy, these results indicate the importance of avoiding high-temperature heat treatment for long periods. Full article

(This article belongs to the Special Issue Advances in Friction, Lubrication, Wear and Oxidation in Metals Manufacturing)

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11 pages, 1825 KiB

Open AccessFeature PaperArticle

Formulation of Sustainable Water-Based Cutting Fluids with Polyol Esters for Machining Titanium Alloys

by Elisabet Benedicto, Eva María Rubio, Laurent Aubouy and María Ana Sáenz-Nuño

Metals 2021, 11(5), 773; https://doi.org/10.3390/met11050773 - 08 May 2021

Cited by 14 | Viewed by 3002

Abstract

The machinability of titanium alloys still represents a demanding challenge and the development of new clean technologies to lubricate and cool is greatly needed. As a sustainable alternative to mineral oil, esters have shown excellent performance during machining. Herein, the aim of this work is to investigate the influence of esters’ molecular structure in oil-in-water emulsions and their interaction with the surface to form a lubricating film, thus improving the efficiency of the cutting fluid. The lubricity performance and tool wear protection are studied through film formation analysis and the tapping process on Ti6Al4V. The results show that the lubricity performance is improved by increasing the formation of the organic film on the metal surface, which depends on the ester’s molecular structure and its ability to adsorb on the surface against other surface-active compounds. Among the cutting fluids, noteworthy results are obtained using trimethylolpropane trioleate, which increases the lubricating film formation (containing 62% ester), thus improving the lubricity by up to 12% and reducing the torque increase due to tool wear by 26.8%. This work could be very useful for fields where often use difficult-to-machine materials—such as Ti6Al4V or γ-TiAl—which require large amounts of cutting fluids, since the formulation developed will allow the processes to be more efficient and sustainable. Full article

(This article belongs to the Special Issue Advances in Friction, Lubrication, Wear and Oxidation in Metals Manufacturing)

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18 pages, 7418 KiB

Open AccessArticle

Effect of Mo Element on the Mechanical Properties and Tribological Responses of CoCrFeNiMox High-Entropy Alloys

by Ying Liu, Yongxin Xie, Shaogang Cui, Yanliang Yi, Xuewei Xing, Xiaojian Wang and Wei Li

Metals 2021, 11(3), 486; https://doi.org/10.3390/met11030486 - 15 Mar 2021

Cited by 38 | Viewed by 2957

Abstract

Certain amounts of precipitate in CoCrFeNiMox (simplified as Mox) is beneficial to the wear resistance; however, the optimal chemical content of Mo and the anti-wear mechanism behind it remains unclear. The Mox (x = 0, 0.3, 0.5, 1, 1.5 in molar ratio) high entropy alloys (HEAs) were manufactured, the evolution of their microstructure, mechanical, friction, and wear properties with Mo content was studied. The results displayed that the mechanical properties of the FCC solid solution were enhanced from Mo0 to Mo0.3, then kept unchanged till x = 1.5. The volume fraction of the precipitates increased with Mo content. The Mo1 presents the lower average friction coefficient and wear rate, attributed to the desired types, amount, size, distribution of the hard σ and μ phases in the ductile FCC solid solution. The detailed mechanism behind their tribological behaviors were discussed in the manuscript. Full article

(This article belongs to the Special Issue Advances in Friction, Lubrication, Wear and Oxidation in Metals Manufacturing)

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10 pages, 5520 KiB

Open AccessArticle

The Oxidation Behaviors of Indefinite Chill Roll and High Speed Steel Materials

by Liang Hao, Tuanjie Li, Zhongliang Xie, Qingjuan Duan and Guoyuan Zhang

Metals 2020, 10(8), 1095; https://doi.org/10.3390/met10081095 - 13 Aug 2020

Cited by 7 | Viewed by 2352

Abstract

Indefinite chill (IC) roll and high speed steel (HSS) materials have been widely employed to manufacture work rolls as latter and former stands in hot rolling mills. The oxidation of work rolls is of importance for the surface quality of the rolled workpieces. The isothermal oxidation of the IC and HSS materials was conducted at 650 °C and 700 °C in both dry air and humid air. The isothermal oxidation curves indicate that HSS shows faster kinetics than the IC materials in dry air, whereas the opposite occurred in humid air. The oxide scales of the IC materials after the oxidation in both dry air and humid air are made up of two oxide phases. Two oxide phases were found when the HSS oxidized in the dry air and three oxide phases were found when oxidized in the humid air. Full article

(This article belongs to the Special Issue Advances in Friction, Lubrication, Wear and Oxidation in Metals Manufacturing)

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13 pages, 2593 KiB

Open AccessArticle

Research on Shape Control Characteristics of Non-oriented Silicon Steel for UCMW Cold Rolling Mill

by Hao Tao, Hongbo Li, Jian Shao, Jie Zhang, Yujin Liu and Xuechang You

Metals 2020, 10(8), 1066; https://doi.org/10.3390/met10081066 - 07 Aug 2020

Cited by 3 | Viewed by 2714

Abstract

In order to analyze the flatness control characteristics for a certain UCMW (Universal Crown Mill with Work roll shifting) cold rolling mill, combined with the actual parameters in the field, a static simulation model of the quarter roll systems of the UCMW cold rolling mill was established by the ANSYS finite element software. The bearing roll gaps under the factors of the unit width rolling force, the roll bending force and the roll shift were calculated, which reflects the shape control characteristics and has a great influence on the friction and lubrication characteristics between the roll gaps. Additionally, the shape control strategy of the process parameters in the field was put forward. The results show that, at first, the work roll shift is the most effective shape control means, while the current-used range of the intermediate roll shift cannot make full use of the roll end contour of the intermediate roll, so the intermediate roll negative shift should be considered for shape control. At second, the excessive rolling force goes against the shape control, so the rolling force of each stand should be reasonably distributed. Finally, the shape control ability of the bending force is relatively weak, so the range of the work roll bending force should be appropriately increased. Full article

(This article belongs to the Special Issue Advances in Friction, Lubrication, Wear and Oxidation in Metals Manufacturing)

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14 pages, 3677 KiB

Open AccessArticle

Concurrent Multiscale Simulations of Rough Lubricated Contact of Aluminum Single Crystal

by Jie Zhang, Lihong Su and Zhongnan Wang

Metals 2020, 10(7), 965; https://doi.org/10.3390/met10070965 - 17 Jul 2020

Cited by 2 | Viewed by 2317

Abstract

In this paper, a concurrent multiscale simulation strategy coupling atomistic and continuum models was proposed to investigate the three-dimensional contact responses of aluminum single crystal under both dry and lubricated conditions. The Hertz contact is performed by using both the multiscale and full molecular dynamics (MD) simulations for validation. From the contact area, kinetic energy and stress continuity aspects, the multiscale model shows good accuracy. It can also save at least five times the computational time compared with the full MD simulations for the same domain size. Furthermore, the results of lubricated contact show that the lubricant molecules could effectively cover the contact surfaces; thereby separating the aluminum surfaces and bearing the support loads. Moreover, the surface topography could be protected by the thin film formed by the lubricant molecules. It has been found that the contact area decreases obviously with increasing the magnitude of load under both dry and lubricated contacts. Besides, a decrease in contact area is also seen when the number of lubricant molecules increases. The present study has confirmed that the dimension of lubricated contacts could be greatly expanded during the simulation using the proposed multiscale method without sacrificing too much computational time and accuracy. Full article

(This article belongs to the Special Issue Advances in Friction, Lubrication, Wear and Oxidation in Metals Manufacturing)

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