Effect of load on the friction and wear characteristics of Si3N4-hBN ceramic composites sliding against steels

The tribological behaviors of Si₃N₄-hBN ceramic composites sliding against steels (austenitic stainless steel (ASS) and 45 steel) under dry friction conditions at different loads were investigated by using an MMW-1 type vertical universal friction and wear tester. The experimental results showed that the friction coefficients and wear rates first showed a decrease and then an increase with an increase in the load under dry friction conditions. The better tribological performance was exhibited by the SN10/ASS sliding pair under a load of 20 N (the friction coefficient was as low as 0.27 and the wear rates of both pin and disc had a magnitude of 10⁻⁶ mm³ N⁻¹ m⁻¹). This may be attributed to the formation of a black surface film (consisting of B₂O₃, SiO₂, and Fe₂O₃). For the same sliding pair, when the load was 10 N, the dominating wear mechanism was abrasive wear. Hence, the friction coefficient was higher (0.7). When the load increased to 30 and 50 N, the wear mechanism of the SN10/ASS sliding pair was a combination of abrasive and adhesive wears, and higher friction coefficients (0.48 and 0.72 under loads of 30 and 50 N, respectively) were obtained. On the other hand, the contents of hBN also showed a significant impact on the tribological behaviors of the Si₃N₄-hBN/ASS sliding pairs. When the hBN content was less than 10%, the friction coefficients of the Si₃N₄-hBN/ASS sliding pairs decreased with an increase in the hBN content. On the other hand, at hBN contents of 10% or more, the friction coefficients of the sliding pairs increased with an increase in the hBN content. Under the same experimental conditions, the Si₃N₄-hBN/45 steel pairs showed poor tribological properties as compared with the Si₃N₄-hBN/ASS pairs.     

Fast preparation of ZTA-TiC-FeCrNi cermets by high-gravity combustion synthesis

ZTA-TiC-FeCrNi cermets are prepared by a fast and furnace-free way called high-gravity combustion synthesis. The synthesized cermet samples show the maximum relative density of 97.6% and a hierarchical microstructure with grain sizes from submicron to >50 µm. The content of TiC has a strong influence on the microstructure and mechanical properties of the cermet samples. A higher TiC content results in refined microstructure, improved hardness, and reduced coefficient of friction. With increasing TiC content, the strength and toughness of the samples first increase and then drops, and reach the maximum of 469±26 MPa and 11.3±0.2 MPa m^1/2 at 20% TiC. Compared with commercial polycrystalline Al₂O₃ ceramics, the ZTA-TiC-FeCrNi cermets exhibit better wear resistance, and the volume loss is lower by one magnitude than Al₂O₃ under the same condition.     

Friction and wear property of a-CNx coatings sliding against ceramic and steel balls in water

The amorphous carbon nitride coatings (a-CN_x) were deposited on Si₃N₄ disks using ion beam assisted deposition (IBAD), and their composition and chemical bonding were determined by X-ray photoelectron spectroscopy (XPS). The a-CN_x coatings' hardness was measured by nano-indentation and the friction and wear property of the a-CN_x coatings sliding against Si₃N₄, SiC, Al₂O_3, SUS440C and SUJ2 balls in water were investigated by using ball-on-disk tribo-meter. The worn surfaces were observed using optical microscopy and analyzed by XPS. The results of XPS analysis showed that the a-CN_x coatings contained 12 at.% nitrogen and the major chemical bonding was sp² C = N and sp³C–N. The nano-hardness of the a-CN_x coatings was 29 GPa, higher than those of balls. Among five kinds of tribo-systems, the lowest friction coefficient was obtained in the range of 0.01 to 0.02 for the tribo-systems with SiC and Si₃N₄ balls, the largest wear rate of the a-CN_x coating of 1.77 × 10^− 7 mm³/Nm was obtained as sliding against Al₂O₃ ball, while the smallest wear rate of a-CN_x coating of 1.44 × 10^− 8 mm³/Nm was gotten as sliding against Si₃N₄ ball. However, SUJ2 ball showed the highest wear rate of 7.0 × 10^− 7 mm³/Nm, whereas Al₂O₃ ball exhibited the lowest wear rate of ball of 3.55 × 10^− 9 mm³/Nm. The XPS analysis on the worn surface for the a-CN_x coatings displayed that the nitrogen concentration decreased and the sp²-bonding-rich structure was formed after sliding tests in water.     

Effect of CuO on self-lubricating properties of ZrO2(Y2O3)–Mo composites at high temperatures

In this paper, ZrO₂ matrix high-temperature self-lubricating composites with addition of CuO as lubricant were prepared using a hot-pressing method by tailoring the content of CuO. The wear and friction behaviour of the composites were investigated from 700 °C to 1000 °C. The composites sliding against an Al₂O₃ ceramic ball exhibited excellent self-lubricating and anti-wear properties at high temperatures. The low friction and wear mechanisms were investigated in detail.     

Tribological behavior of Ti3SiC2 and Ti3SiC2/Pb composites sliding against Ni-based alloys at elevated temperatures

The Ti₃SiC₂ and Ti₃SiC₂/Pb composites were tested under dry sliding conditions against Ni-based alloys (Inconel 718) at elevated temperatures up to 800 °C using a pin-on-disk tribometer. Detailed tribo-chemical changes of Pb on sliding surface were discussed. It was found that the tribological behavior were insensitive to the temperature from 25 °C (RT) to 600 °C (friction coefficient ≈0.61–0.72, wear rate ≈10⁻³ mm³ N m⁻¹). An amount of Pb in the composites played a key role in lubricating with the temperature below 800 °C. The friction coefficient (≈0.22) and wear rate (≈10⁻⁷ mm³ N m⁻¹) at elevated temperatures were both decreased by the added PbO. The wear mechanisms of Ti₃SiC₂/Pb-Inconel 718 tribo-pair at elevated temperatures were believed to be the combined effect of abrasive wear and tribo-oxidation wear. During the sliding, two oxidization reactions proceed, 2Pb+O₂=2PbO (below 600 °C) and 6PbO+O₂=2Pb₃O₄ (800 °C). The friction coefficient and wear rate of the composites were reduced due to the self-lubricating effect of the tribo-oxidation products.     

Comparative study on wear behavior of plasma sprayed Al2O3 coatings sliding against different counterparts

Although the friction and wear behavior of plasma sprayed aluminum matrix ceramic coatings have been extensively discussed in the last decades, only few researches have been carried out the wear mechanisms sliding against different pairs. The tribological behaviors of plasma sprayed Al₂O₃ coating sliding against ZrO₂, Si₃N₄, Al₂O₃ and stainless steel balls in air were comparatively investigated in this study. It was showed that Al₂O₃ coating sliding against different counterparts exhibited diverse tribological behaviors, which could be mainly ascribed to the different mechanical properties of counterparts. Meanwhile, the tribochemical reactions influenced the friction performances significantly. Moreover, the transform of γ-Al₂O₃ to α-Al₂O₃ occurred during the friction, which was closely related to the coefficient of friction and thermal conductivities of counterparts. The main wear of Al₂O₃ coating sliding against ceramic materials resulted from the brittle fracture and abrasive wear. While it was dominated by adhesive wear when sliding against stainless steel, and accompanied with abrasive wear.     

Mechanical properties and sliding wear behaviour of Al2O3-SiC nanocomposites with 3–20 vol% SiC

Al₂O₃/SiC composites containing different volume fractions (3, 5, 10, 15, and 20 vol%) of SiC particles were produced by conventional mixing of alumina and silicon carbide powders, followed by hot pressing at 1740 °C for 1 h under the pressure of 30 MPa in the atmosphere of Ar. The influence of the volume fraction and size of SiC particles (two different powders with the mean size of SiC particles 40 and 200 nm were used), and final microstructure on mechanical properties and dry sliding wear behaviour in ball-on-disc arrangement were evaluated. The properties of the composites were related to a monolithic Al₂O₃ reference. Microstructure of the composites was significantly affected by the volume fraction of added SiC, with the mean size of alumina matrix grains decreasing with increasing content of SiC particles. The addition of SiC moderately improved the Vickers hardness. Fracture toughness was lower with respect to monolithic Al₂O₃, irrespective of the volume fraction and size of SiC particles. Al₂O₃/SiC nanocomposites conferred significant benefits in terms of wear behaviour under the conditions of mild dry sliding wear. Wear resistance of the alumina reference was poor, especially at the applied load of 50 N. The wear rates of composites markedly decreased with increasing volume fraction of SiC. Wear of the composites was also influenced by the material of counterparts, especially their hardness, with softer counterparts resulting in lower wear rates. All composites wore by a combination of grain pull-out with plastic deformation associated with grooving and small contribution of mechanical wear (micro-fracture). No influence of SiC particle size on wear rate or mechanism of wear was observed in the materials with identical volume fractions of SiC.     

Preparation and characterization of Si3N4-based composite ceramic tool materials by microwave sintering

Si₃N₄-based composite ceramic tool materials with (W,Ti)C as particle reinforced phase were fabricated by microwave sintering. The effects of the fraction of (W,Ti)C and sintering temperature on the mechanical properties, phase transformation and microstructure of Si₃N₄-based ceramics were investigated. The frictional characteristics of the microwave sintered Si₃N₄-based ceramics were also studied. The results showed that the (W,Ti)C would hinder the densification and phase transformation of Si₃N₄ ceramics, while it enhanced the aspect-ratio of β-Si₃N₄ which promoted the mechanical properties. The Si₃N₄-based composite ceramics reinforced by 15 wt% (W,Ti)C sintered at 1600 °C for 10 min by microwave sintering exhibited the optimum mechanical properties. Its relative density, Vickers hardness and fracture toughness were 95.73 ± 0.21%, 15.92 ± 0.09 GPa and 7.01 ± 0.14 MPa m^1/2, respectively. Compared to the monolithic Si₃N₄ ceramics by microwave sintering, the sintering temperature decreased 100 °C,the Vickers hardness and fracture toughness were enhanced by 6.7% and 8.9%, respectively. The friction coefficient and wear rate of the Si₃N₄/(W,Ti)C sliding against the bearing steel increased initially and then decreased with the increase of the mass fraction of (W,Ti)C., and the friction coefficient and wear rate reached the minimum value while the fraction of (W,Ti)C was 15 wt%.     

Wear damage of Si3N4-graphene nanocomposites at room and elevated temperatures

Mechanical and tribological properties of nanocomposites with silicon nitride matrix with addition of 1 and 3 wt.% of multilayered graphene (MLG) platelets were studied and compared to monolithic Si₃N₄. The wear behavior was observed by means of the ball-on-disk technique with a silicon nitride ball used as the tribological counterpart at temperatures 25 °C, 300 °C, 500 °C, and 700 °C in dry sliding. Addition of such amounts of MLG did not lower the coefficient of friction. Graphene platelets were integrated into the matrix very strongly and they did not participate in lubricating processes. The best performance at room temperature offers material with 3 wt.% graphene, which has the highest wear resistance. At medium temperatures (300 °C and 500 °C) coefficient of friction of monolithic Si₃N₄ and composite with 1%MLG reduced due to oxidation. Wear resistance at high temperatures significantly decreased, at 700 °C differences between the experimental materials disappeared and severe wear regime dominated in all cases.     

Tribological and electrical properties of ceramic matrix composites with carbon nanotubes

Tribological behaviur of carbon fibrous phases (nanofibers and nanotubes) containing composites with Si₃N₄, ZrO₂ and Al₂O₃ matrices was studied by pin-on-disk technique in conditions of dry sliding. Coefficients of friction and wear rates were measured, wear damage mechanisms were observed and identified. The resulting tribological behaviur was related to microstructure and mechanical properties of respective materials. Electrical conductivity was measured in wide range of frequencies by two-point method and effect of volume fraction and distribution of CNTs and CNFs on percolation threshold was evaluated. Both coefficient of friction and electrical resistivity decreased with increasing amount of carbon phases, in both cases the nanofibers were more efficient than the nanotubes. The wear resistance in most cases decreased but for Si₃N₄–CNT composite a certain optimum (～5 wt.% CNT) was found.     

TEM investigations of wear mechanism of Al2O3 and Si3N4 compacts with GLPs additions

Extended lifetime of ceramic cutting plates is ever more desired. One way of approaching it entails sintering precursor materials with graphene-like nanoplatelets (GLPs) acting as solid lubricants. Therefore, Al₂O₃ and Si₃N₄ ceramic powders with addition of GLPs of grade 3 (fine) or grade 4 (coarse) were Spark Plasma Sintered. It is found that the 0.15 wt% GLPs addition of both grades allows to keep hardness practically at the same level as GLPs-free compacts (~16 GPa). Only larger GLPs additions (2 wt%) caused its evident decrease (down to 14−15 GPa). The ball-on-disc test revealed that only Al₂O₃+0.15 wt% GLPs(3) shows a 50% reduction in wear rate. The post mechanical test examination by SEM confirmed that Al₂O₃ compacts with small GLPs showed smooth wear track, as opposed to those having a Si₃N₄ matrix with large meandering cavities. TEM observations revealed that the wear damage caused by the ball was restricted to ~2 µm deep sub-surface areas, while, carbon is found to transfer from the GLPs agglomerates into tribo-film. The present experiments showed, that ceramic sinters with small addition of GLPs platelets could exhibit lower wear than GLPs-free ones and therefore show a potential for application as cutting plates.     

Influence of countersurface materials on dry sliding performance of CuO/Y-TZP composite at 600 °C

Dry sliding wear tests on 5 wt.% copper oxide doped yttria stabilized zirconia polycrystals (CuO–TZP) composite have been performed against alumina, zirconia and silicon nitride countersurfaces at 600 °C. The influences of load and countersurface materials on the tribological performance of this composite have been studied. The friction and wear test results indicate a low coefficient of friction and specific wear rate for alumina and zirconia countersurfaces at F = 1 N load (maximum Hertzian pressure ～0.5 GPa). Examination of the worn surfaces using scanning electron microscope/energy dispersive spectroscopy confirmed the presence of copper rich layer at the edge of wear scar on the alumina and zirconia countersurfaces. However, Si₃N₄ countersurface sliding against CuO–TZP shows a relatively higher coefficient of friction and higher wear at 1 N load condition. These results suggest that the countersurface material significantly affect the behavior of the third body and self-lubricating ability of the composite.     

Effect of graphite nanoplatelets on the mechanical properties of alumina-based composites

Al₂O₃-based composites using exfoliated graphite nanoplatelets (xGnPs) have been developed by powder metallurgy (PM) route using both conventional as well as spark plasma sintering (SPS) processes. Al₂O₃-0.2, 0.5, 0.8, 3 and 5 vol% xGnP composites have been developed, and the effect of the addition of xGnP on the density, hardness, fracture toughness and wear behaviour of the various Al₂O₃-xGnP composites have been analyzed. Conventional sintering was done at a temperature of 1650 °C for 2, 3 and 4 h in inert atmosphere, whereas SPS was carried out at 1450 °C under 50 MPa pressure for 5 min. A uniform dispersion of the xGnP in the Al₂O₃ matrix was observed in the composites upto the addition of 3 vol% xGnP. Results indicate that a significant improvement in hardness, wear resistance and fracture toughness of the composites could be achieved by using xGnP as nanofiller. The hardness and fracture toughness of the composites developed by both conventional sintering and SPS show an increase upto the addition of 3 and 0.8 vol% xGnP respectively. The wear resistance of the composites also shows significant improvement upto the addition of 3 vol% xGnP. The composites developed by SPS have been found to possess superior mechanical properties as compared to the composites developed by conventional sintering. The improvement in the mechanical properties can be attributed to the strong interaction between the xGnP and the Al₂O₃ matrix at the interfaces and to the toughening mechanisms such as crack bridging and crack deflection.     

Tribological behaviors of hot-pressed Al2O3/TiC ceramic composites with the additions of CaF2 solid lubricants

Al₂O₃/TiC ceramic composites with the additions of CaF₂ solid lubricants were produced by hot pressing. The effect of the solid lubricant on the microstructure and mechanical properties of the ceramic composite has been studied. The friction coefficient and wear rates were measured using the ring-block method, and the tribological behaviors were discussed in relation to its mechanical properties and microstructure. Results showed that additions of CaF₂ solid lubricants to Al₂O₃/TiC matrix led to a decrease in the flexural strength, fracture toughness, and hardness compared to a conventional Al₂O₃/TiC composite. The friction coefficient of Al₂O₃/TiC/CaF₂ ceramic composites when sliding against both cemented carbide and hardened steel decreased with an increase in CaF₂ content up to 15 vol.%. The reason is that the CaF₂ released and smeared on the wear surface, and acted as solid lubricant film between the sliding couple. When the content of CaF₂ solid lubricant is less than 10 vol.%, the wear rate of Al₂O₃/TiC/CaF₂ composites decreases with an increase in CaF₂ content, with further increases in CaF₂ content, the wear rate of Al₂O₃/TiC/CaF₂ composites increases rapidly. This is due to the large degradation of mechanical properties in samples with high CaF₂ contents.     

Influence of hBN content on mechanical and tribological properties of Si3N4/BN ceramic composites

Silicon nitride materials containing 1–5 wt% of hexagonal boron nitride (micro-sized or nano-sized) were prepared by hot-isostatic pressing at 1700 °C for 3 h. Effect of hBN content on microstructure, mechanical and tribological properties has been investigated. As expected, the increase of hBN content resulted in a sharp decrease of hardness, elastic modulus and bending strength of Si₃N₄/BN composites. In addition, the fracture toughness of Si₃N₄/micro BN composites was enhanced comparing to monolithic Si₃N₄ because of toughening mechanisms in the form of crack deflection, crack branching and pullout of large BN platelets. The friction coefficient was not influenced by BN addition to Si₃N₄/BN ceramics. An improvement of wear resistance (one order of magnitude) was observed when the micro hBN powder was added to Si₃N₄ matrix. Mechanical wear (micro-failure) and humidity-driven tribochemical reaction were found as main wear mechanisms in all studied materials.     

Dry sliding wear behavior of β-Sialon ceramics at wide range temperature from 25 to 800 °C

The β-Sialons are potential candidates for high temperature application because of their excellent comprehensive performances. However, there is little research about dry sliding wear behavior of β-Sialons at wide range temperature. This study aims at revealing the mechanisms of how temperature, microstructure and mechanical properties affect the tribological properties of such composites. Four kinds of β-Sialons are prepared and their wear properties are characterized from 25 to 800 °C. Results show that β-Sialons have a preferable tribological property at 25 °C, which is ascribed to its excellent mechanical properties. Whereas, with temperature increasing, the wear rate increases two orders of magnitudes compared to 25 °C, owing to the reduced hardness and increased thermal stress of the sample. At 800 °C, the wear rate of composites decreases with z values increasing, which is attributed to the tribo-chemical reaction and generate more Al₂O₃ in β-Sialons with higher z values during sliding process.     

The interfacial and tribological properties of Ni–Cr alloy/ceramic tribo-couples under dry sliding contact

In this paper, the tribological behaviors of Ni–Cr alloy sliding against Si₃N₄ and WC–Co at 20 °C and 600 °C were investigated on a tribometer with a ball-on-disk configuration. The experimental results indicated that Ni–Cr alloy sliding against WC–Co exhibited higher wear resistance than that sliding against Si₃N₄. From the viewpoints of the interfacial interactions between metal and ceramic (chemical reaction, wetting, adhesion, transference), the wear mechanisms were elucidated. The tribological behaviors of Ni–Cr alloy/ceramic tribo-couples were well correlated with the interfacial characteristics, namely the reactive interface and the non-reactive interface. Ni–Cr alloy/Si₃N₄ tribo-couple showed severe adhesive wear as a result of the interfacial reaction between Ni and Si₃N₄, while the non-reactivity of Ni/WC interface is the most important factor corresponding to the moderate adhesive wear in Ni–Cr alloy sliding against WC–Co. Finally, the relations among the interfacial characteristics, wear behavior, and temperature were discussed. The results may provide some experimental evidences on the design and optimization of metal/ceramic tribo-couples.     

Tribo-mechanical characterization of spark plasma sintered chopped carbon fibre reinforced silicon carbide composites

Short carbon fibre (C_f) reinforced silicon carbide (SiC) composites with 7.5 wt% alumina (Al₂O₃) as sintering additive were fabricated using spark plasma sintering (SPS). Three different C_f concentrations i.e. 10, 20 and 30 wt% were used to fabricate the composites. With increasing C_f content from 0 to 20 wt%, micro-hardness of the composites decreased ~28% and fracture toughness (K_IC) increased significantly. The short C_f in the matrix facilitated enhanced fracture energy dissipation by the processes of crack deflection and bridging at C_f/SiC interface, fibre debonding and pullout. Thus, 20 wt% C_f/SiC composite showed >40% higher K_IC over monolithic SiC (K_IC≈4.51 MPa m^0.5). Tribological tests in dry condition against Al₂O₃ ball showed slight improvement in wear resistance but significantly reduced friction coefficient (COF, μ) with increasing C_f content in the composites. The composite containing 30 wt% C_f showed the lowest COF.     

Experimental and thermodynamic investigation of gradient zone formation for Ti(C,N)-based cermets sintered in nitrogen atmosphere

The influence of N₂ atmosphere on the microstructure of gradient zone in Ti(C,N)-Mo₂C-Ni cermet was systematically investigated by the coupling analysis of experimental characterization and thermodynamic calculation. Under the guidance of calculated carbon window, the composition of Ti(C,N)-Mo₂C-Ni cermet was designed, and the cermet was produced via liquid-phase sintering at 1450 °C for 2 h under N₂ pressure of 20, 200, 400 and 600 mbar. The microstructure and element distribution of cermet were analyzed by using Scanning Electron Microscopy (SEM) equipped with Energy Dispersive X-ray spectroscopy (EDX). A homogeneous microstructure was obtained for cermet sintered in 20-mbar nitrogen atmosphere, whereas the thickness of gradient layer increased with nitrogen pressure. EDX mapping demonstrate that Mo and Ti are enriched in gradient zone, while Ni is lacking and partially segregated near the surface. The diffusion of elements in cermet is caused by the different nitrogen activity between surface and interior. The carbonitride grains show typical black core and gray rim structure in the bulk of cermets, while it present light-gray core and gray rim in the surface gradient layer. In addition, the Vickers microhardness measurement was performed for the gradient zone of cermets, and the hardness increased for cermets sintered in higher nitrogen pressures, which exhibit slower grain growth phenomena.     

Frictional properties of diamond and fullerene nanoparticles sprayed by a high-velocity argon gas on stainless steel substrate

Lubricating abilities of diamond nanoparticles with size between 50 nm and 200 nm were studied in vacuum and in air to clarify the effective use of diamond fine powders for tribological purposes. Spraying of powders with a high-velocity argon gas jet was performed to form deposits on stainless steel (SUS304) substrates. For sliding in vacuum against SiC and Al₂O₃ balls under a 0.5 N applied load and 3.5 mm/s sliding speed, the deposits of microcrystalline diamond powders with a mean particle size of 50 nm and detonation nanodiamond with a mean aggregate size of around 75 nm demonstrated friction coefficients of less than 0.01 and 0.03, respectively, and ball wear rates of less than 2 · 10^− 6 mm³/(Nm). This means that diamond fine powders smaller than 100 nm can be considered as good solid lubricants in vacuum, because they demonstrate not only a low friction coefficient, but also wear rate of SiC ball lower than non-lubricated SUS304 does. A C₆₀ deposit, formed by the same method on the SUS304, was readily scratched from the substrate in vacuum; however, under open-air conditions, a friction coefficient of around 0.1 and a SiC ball wear rate of about 2 · 10^− 6 mm³/(Nm) were observed. This fact calls attention to the influence of the deposition method on C₆₀ frictional properties.