The relationship between the abrasive wear resistance,hardness and microstructure of ferritic materials

The relationship between the abrasive wear resistance and bulk hardness of ferritic materials in the pearlitic and martensitic conditions has been investigated. For pearlitic materials the abrasive wear resistance and bulk hardness are dependent on the pearlite content and for martensitic materials the abrasive wear resistance and bulk hardness are dependent on the square root of the carbon content. Thus for each structure there is a linear relationship between abrasive wear resistance and bulk hardness, but it is suggested that the material microstructure has a greater influence on wear resistance than the bulk hardness.     

O-ring wear test machine

An abrasive wear test machine was built to study the friction and wear resistance of O-ring materials. In this test machine, two O-ring segments are held against a rotating roughened metal disc. The disc and the O-ring specimens are submerged in an abrasive fluid (drilling mud). The roughened disc surface draws the abrasive particles between the O-ring and the disc surface to produce three-body abrasive wear. Wear occurs on both the specimen and the disc. The wear of the O-ring specimen is determined by weight loss measurements. By careful design of the disc and selection of the test conditions, wear surface similarity was obtained between machine-tested O-rings and O-rings used in field-operated equipment. The testing machine is described, preliminary wear results are presented and photographs of field-worn and machine-worn specimens are shown for three materials.     

Wear by paper and ribbon

A wear apparatus developed by Roshon was used to investigate the nature of wear produced by paper and printer ribbon. The characteristics of the wear produced by these materials on hardened steel were studied and compared with the characteristics of wear produced by abrasive and adhesive wear mechanisms. The wear was also compared with a simulated abrasive situation using a mixture of Al₂O₃ powder and oil on a fabric surface. It was concluded that the wear processes of paper and ribbon are similar and primarily abrasive. Small quantities of hard micron-size and submicron-size particles in these materials were identified as the cause of this abrasive wear. In addition, the influence of such test parameters as load, speed, temperature and humidity on wear was also investigated. Recommendations regarding test conditions to establish the abrasiveness of these materials were developed.     

Abrasive erosive wear of powder steels and cermets

Composite materials produced by powder metallurgy provide solutions to many engineering applications that require materials with high abrasive wear resistance. The actual wear behaviour of a material is associated with many external factors (abrasive particle size, velocity and angularity) and intrinsic material properties of wear (hardness, toughness, Young modulus, etc.). Hardness and toughness properties of wear resistant materials are highly dependent on the content of the reinforcing phase, its size and on the mechanical properties of the constituent phase. This study is focused on the analysis of the (AEW) abrasive erosive wear (solid particle erosion) using different wear devices and abrasives. Powder materials (steels, cermets and hardmetals) were studied. Wear resistance of materials and wear mechanisms were studied and compared with those of commercial steels. Based on the results of wear studies, surface degradation mechanisms are proposed. The following parameters characterizing the materials were found necessary in materials creation and selection: hardness (preferably in scale comparable with impact), type of structure (preferably hardmetal type) and wear parameters characterizing material removal at plastic deformation.     

Wear of Chromium Carbide-Copper Composites with Continuous Phases

A tribological study has been carried out on a new type of carbide-metal composite, in which the two phases form a continuous skeleton microstructure interwoven throughout the body. The composites' resistance to two-body abrasion is evaluated in a pin-on-drum set-up with diamond and SiC abrasive papers. Also sliding wear and friction tests with steel and alumina as counter materials were undertaken. The composites show promising tribological properties, comparable to those of established wear resistant materials. Scanning electron microscopy was used to study the worn surfaces. The implications of the skeleton microstructure on the abrasive wear resistance are discussed on the basis of a wear model for multiphase materials.     

Prediction of abrasive wear rate of in situ Cu–Al2O3 nanocomposite using artificial neural networks

In this work, artificial neural networks (ANNs) technique was used in the prediction of abrasive wear rate of Cu–Al₂O₃ nanocomposite materials. The abrasive wear rates obtained from series of wear tests were used in the formation of the data sets of the ANN. The inputs to the network are load, sliding speed, and alumina volume fraction. Correlation coefficients between the experimental data and outputs from the ANN confirmed the feasibility of the ANNs for effectively model and predict the abrasive wear rate. The comparison between the ANNs and the multi-variable regression analysis results showed that using ANNs technique is more effective than multi-variable regression analysis for the prediction of abrasive wear rate of Cu–Al₂O₃ nanocomposite materials. Optimization of the training process of the ANN using genetic algorithm (GA) is performed and the results are compared with the ANN trained without GA. Sensitivity analysis is also done to find the relative influence of factors on the wear rate. It is observed that load and alumina volume fraction effectively influence the wear rate.     

Abrasive wear by soil

Properties of the soil and wearing material determine the volume wear. Volume wear increases as the stone content of a soil and its resistance to penetration by spherical probes increase. During abrasive wear the abrasive deteriorates by one of two mechanisms, plastic flow or fracture. When the abrasive flows plastically large gains in wear life by using hard materials can be obtained. When the abrasive fractures, the gains in life are much smaller. In soils, the type of abrasive or stone and the strength of the soil affect the way the abrasive deteriorates. Abrasive wear resistance in soils depends in a complex way on the stress—strain properties of the material and the amount of plastic deformation caused by the wear process.     

Prediction of lining wear life of bins and chutes in bulk solids handling operations

This paper is concerned with the prediction of lining wear life of bins and chutes in bulk solids handling plant. It focuses on abrasive wear and outlines the basic principles to be embodied in the development of a laboratory wear tester. Emphasis is given to a linear action wear tester developed jointly by the University of Twente, The Netherlands, and the University of Newcastle, Australia. The characteristics of abrasive wear in bins, hoppers and chutes are described and the application of test results to the prediction of wear life of lining materials is illustrated.     

A study on the formation of wear debris during abrasion

A set of five material specimens have been tested on five abrasives, some of which are harder, some softer than the materials, using the dynamic abrasive wear tester. Characteristics of selected wear debris have been observed by sem and wear debris of 9Cr2Mo steel analysed by Mossbauer spectroscopy. The test results show three wear mechanisms operating during abrasion: microcutting, plougging deformation and brittle fragmentation. Different abrasives formed different constituents of wear debris due to dissimilar wear conditions. Softer abrasive tended to form more ploughing debris, although some typical microcutting chips were produced. Crushing strength of abrasive may be an important factor in addition to hardness of abrasive. The microstructure of 9Cr2Mo steel wear debris has been changed by abrasion heat; this temperature could be estimated by Mossbauer spectroscopy.     

A preliminary investigation of frictional heating during abrasive wear

The frictional heating occurring under conditions of slow abrasive wear was estimated by measuring the thermoelectric output between abrasive particles and a wear pin. It is suggested that wearing surfaces locally reach temperatures high enough to affect properties determining the wear rate, and this is discussed with reference to specific materials.     

Wear of tools during the pregrinding of beads from mineral raw materials

We investigate wear of the abrasive disk end face during the grinding of raw stones into beads. The disk wear was measured after grinding of beads by different techniques: grinding in a vertical drum, in a disk separator, with an inclined abrasive disk, and by placing stones into a segment-like container. The factors are determined that relieve impact loads when beads are preground from brittle materials. The results of studies of pregrinding of beads from cube-shaped gems with an inclined abrasive disk are shown.     

高压磨料水射流切割工程陶瓷研究

采用高压磨料水切割和工程陶瓷,研究高压磨料水工艺参数对其切割深度的影响.从陶瓷材料力学和高压磨料水流体力学基础出发,建立冲击力和加工参数关系.实验结果表明切割深度与水的压力成正比,与喷嘴移动速度成反比.采用硬质合金和陶瓷两种材料制备了磨料喷嘴,研究了喷嘴磨损量与加工参数的关系,采用SEM分析了喷嘴磨损原因.     

Abrasive wear of embossed surfaces with convex domes

Some soil-burrowing animals and other biological organisms living in contact with abrasive materials have surfaces optimized for reducing drag and wear. In this study, bio-inspired embossed surfaces consisting of an array of convex domes are investigated to quantify their abrasive wear resistance properties. The experimental procedure proposed in this work is based on sliding seven different embossed surface specimens against an abrasive material for distances up to 3948.9 m with sliding velocities up to 3.02 m/s. The seven specimens consist of 20 mm-wide convex domes made of bakelite and calcium carbonate fixed to flat steel substrates. Quartz sand particles having three different sizes are used as abrasive material for the tests. Experimental results are analyzed and guidelines for designing embossed surfaces, which are optimized to minimize abrasive wear, are proposed.     

Wear reducing effects and temperature dependence of tribolayer formation in harsh environment

Certain materials show a tribolayer formation especially at enhanced temperatures in abrasive environment, building a wear protection layer with the abrasive on the surface. Three materials with different microstructures were tested in three-body abrasive and impact/abrasive environments at temperatures up to 700 °C to investigate tribolayer formation. Optical and electron microscopical methods were used for wear qualification. Furthermore, hot hardness tests were performed up to 700 °C to investigate the influence of hardness drop on tribolayer formation.It was shown that no significant tribolayer formation occurs on grey cast iron, whereas other materials form tribolayers. Generally, tribolayer formation increases with increasing testing temperature, especially for austenitic and ferritic materials. This entails a self-protecting effect and thus superior wear resistance in abrasive environment.     

Development of triboengineering composite materials based on thermoplastic polyurethanes

The work presents results of study of gasoabrasive wear of a wide range of thermoplastic polymers. A relationship is found between the conditions of synthesis of thermoplastic polyurethanes and their structure, physicomechanical, and triboengineering characteristics. Methods of predicting wear of polyurethane thermoplastics in a flow of abrasive particles are developed with account of varying structural parameters (concentration of rigid blocks, molecular mass), origin and type of initial components, and service characteristics (flow velocity of abrasive particles, angle of attack). Recommendations are given for enhancing abrasive resistance by synthesizing initial materials with preset properties.     

不同润滑条件下氧化铝陶瓷衬板的磨损机制

在干摩擦、水润滑、油润滑3种不同润滑条件下对氧化铝陶瓷进行摩擦磨损试验。利用SEM对磨损后的磨痕进行观察并进行显微组织结构分析,探讨不同介质下氧化铝陶瓷的磨损机制。结果表明:氧化铝陶瓷材料干摩擦条件下的磨损机制为大量的脆性剥落和大量的磨粒磨损,在水润滑条件下为较少的脆性剥落和轻微的磨粒磨损,在油润滑条件下为很少的脆性剥落和极微的磨粒磨损;液体润滑剂可使氧化铝陶瓷材料的磨损量大幅度降低,其中油润滑条件的减磨效果最为突出。     

Metal transfer and wear in fine grinding

The transfer and wear characteristics of two widely used abrasive materials (A1₂O₃ and SiC) are studied when grinding two difficult materials (AISI T15 tool steel and Ti-6Al-4V titanium alloy). A newly developed accelerated wear technique (cluster overcut flygrinding) is employed together with Auger electron spectroscopy, X-ray diffraction and scanning transmission electron microscopy. Experimental results suggest that when grinding steel the wear of SiC is primarily due to oxidation, while the wear of Al₂O₃ is primarily due to metal build-up, resulting in microchipping. When a titanium alloy is being ground, both types of abrasive result in a microchipping type of wear, the rate of which decreases when the wheel speed is reduced.     

Wear mechanisms in polymer matrix composites abraded by bulk solids

An experimental study of the wear of polymer matrix composite materials subjected to abrasion from bulk materials has been conducted. Three examples of vinyl ester resin systems were considered: (a) unreinforced, (b) reinforced with glass fibres, and (c) reinforced with particles of ultra high molecular weight polyethylene (UHWMPE). Soft and hard bulk materials used for abrasion were granular forms of coal and the mineral ignimbrite. The bulk material was presented to the wear surface on a conveyor belt in a novel wear tester. While UHWMPE reinforcement enhanced the wear resistance to both hard and soft abrasives, the situation for fibre reinforcement was more complicated. With coal as the abrasive, it was found that glass fibre reinforcement reduced the wear rate, whereas in the case of the harder ignimbrite, fibre reinforcement increased the wear rate. Microscopy indicated significant differences in the mechanism of wear in each surface/abrasive combination. Wear textures, consistent with both two and three-body wear, were observed with, respectively, soft and hard abrasive particles.     

The abrasive wear resistance of TIC and (Ti,W)C-reinforced Fe–17Mn austenitic steel matrix composites

Pin-on-disc dry sliding wear tests have been carried out to study the wear behaviour of 10 vol% TiC and (Ti,W)C-reinforced Fe–17Mn austenitic steel matrix composites. The composites have been synthesized in situ by means of conventional melting and casting route. It has been observed that the abrasive wear resistance of the composites is higher than that of their unreinforced Fe–17Mn austenitic steel. Compared with the TiC-reinforced composite, the abrasive wear resistance of the (Ti,W)C-reinforced composite is better. The abrasive wear resistance and coefficient of friction of both reinforced and unreinforced materials decrease as the load increases.     

Wear mechanisms of statically loaded hydrodynamic bearings by contaminant abrasive particles

Wear mechanisms in hydrodynamic bearings by contaminant abrasive particles in the oil were investigated. This type of wear is one of the main factors responsible for failure of hydrodynamic bearings especially when operating in dusty environments. A test bearing system was developed to study this type of wear under carefully controlled conditions. Experiments were conducted with two shaft materials and three liner materials, giving a total of six material combinations. The circumferential liner wear distribution and the relative magnitude of shaft and liner wear were found to depend mainly on the shaft-to-liner hardness ratio. A smaller hardness ratio resulted in relatively more liner wear and less shaft wear. A model is proposed to account for this behaviour whereby the action of the abrasive particle is considered to consist of both cutting and rolling motions.