Friction and Wear Characteristics of Plasma-Sprayed Self-Lubrication Coating with Clad Powder at Elevated Temperatures up to 800 °C

NiCr/(Cr₃C₂-BaF₂·CaF₂) coating was fabricated by atmospheric plasma spray technology using clad powder. The coating shows low porosity, high microhardness and bonding strength, and it also exhibits good friction reduction and wear resistance at elevated temperatures up to 800 °C which is due to the formation of a kind of continuous BaF₂·CaF₂ eutectic lubricating film. The excellent mechanical and tribological properties of the coating are partially attributed to the protection of NiCr layer of the composite powders which can decrease oxidation, decarburization of Cr₃C₂, and ablation of BaF₂·CaF₂ eutectic during spray and deposition process.     

Effect of NiCr Clad BaF<Subscript>2</Subscript>·CaF<Subscript>2</Subscript> Addition on Wear Performance of Plasma Sprayed Chromium Carbide-Nichrome Coating

NiCr clad BaF₂·CaF₂ fluoride eutectic powders were added into chromium carbide-nichrome feedstock to improve the tribological properties of NiCr-Cr₃C₂ coating, and the structures, mechanical, and ball-on-disk sliding wear performance of the coating were characterized. The results show that NiCr cladding can effectively decrease the density and thermophysical difference between the feedstock components, while alleviate the decarburization and oxidization of the constituent phases, and form the coating with a uniform and dense microstructure. However, the addition of BaF₂·CaF₂ has a negative effect on mechanical properties of the coating. When the temperature reaches 500 °C, the BaF₂·CaF₂ eutectic is soften by the heat and smeared by the counterpart, thus the low shear stress lubricating film forms between the contact surface, that improves the tribological properties dramatically. At this temperature, the dominant wear mechanisms also change from splats spallation and abrasive wear at room temperature to plastic deformation and plawing by the counterpart. Within the temperature range from 600 to 800 °C, the friction coefficient, the wear rates of NiCr/Cr₃C₂-10% BaF₂·CaF₂ coating and its coupled Si₃N₄ ball are 20%, 40%, and 75% lower than those of the NiCr/Cr₃C₂ coating, respectively. The NiCr/Cr₃C₂-BaF₂·CaF₂ coating shows superior wear performance to the NiCr/Cr₃C₂ coating without lubricant additive.     

Preparation and wear performance of NiCr/Cr3C2-NiCr/hBN plasma sprayed composite coating

NiCr clad hexagonal BN powder (NiCr/hBN) was added to NiCr/Cr₃C₂ feedstock to improve the tribological properties of chromium carbide nichrome coating. The microstructure, flowability and apparent density of the composite powder, as well as the structure and mechanical properties of the plasma sprayed coating were characterized. The friction and wear behavior of the NiCr/Cr₃C₂-NiCr/hBN coating from ambient temperature up to 800 °C was evaluated on a ball-on-disk wear tester and compared with that of NiCr/Cr₃C₂ coating and NiCr/Cr₃C₂-NiCr/BaF₂·CaF₂ coating. The results show that NiCr cladding can reduce the decarburization of Cr₃C₂ and oxidation of hBN during the thermal spray. The main wear mechanisms of the NiCr/Cr₃C₂-NiCr/hBN composite coating are ploughing and adhesive wear. Layered hexagonal BN particle reduce the direct contact and severe adhesion between friction pairs, thus decreasing the friction coefficient. The NiCr/Cr₃C₂-NiCr/hBN composite coating shows a promising application in the high temperature environment with the request of both wear resistance and friction reduction.     

Microstructures and mechanical properties of in-situ TiB2/Al−xSi−0.3Mg composites

In-situ 2 vol.% TiB₂ particle reinforced Al?xSi?0.3Mg (x=7, 9, 12, 15 wt.%) composites were prepared by the salt–metal reaction, and the microstructures and mechanical properties were investigated. The results show that the TiB₂ particles with a diameter of 20–80 nm and the eutectic Si with a length of 1–10 μm are the main strengthening phases in the TiB₂/Al?xSi?0.3Mg composites. The TiB₂ particles promote grain refinement and modify the eutectic Si from needle-like to short-rod shape. However, the strengthening effect of TiB₂ particles is weakened as the Si content exceeds the eutectic composition, which can be attributed to the formation of large and irregular primary Si. The axial tensile test results and fractography observations indicate that these composites show more brittle fracture characteristics than the corresponding alloy matrixes.     

Sliding Wear Behavior of TiC-Reinforced Cu-4 wt.% Ni Matrix Composites

The present investigation explores the effect of TiC content on the sliding wear properties of Cu-4 wt.% Ni matrix composites. Cu-4 wt.% Ni ? x wt.% TiC (x = 0, 2, 4 and 8 wt.%) metal matrix composites were developed by powder metallurgy route. Their friction and wear was studied under dry sliding at different loads of 5, 7.5 and 10 N and constant sliding speed of 2 m/s using a pin-on-disk machine. The metallographic observations showed an almost uniform distribution of TiC particles in the matrix. Hardness of the composites increased with increasing TiC content (up to 4 wt.%). Friction and wear results of TiC-reinforced composites show better wear resistance than unreinforced matrix alloy. However, the optimum wear resistance was observed for 4 wt.% TiC-reinforced composites. Worn surfaces of specimens indicated the abrasion as the primary mechanism of wear in all the materials investigated in the study. The observed behavior has been explained on the basis of (1) the hardness which results in a decrease in real area of contact in composites containing TiC particles and (2) the formation of a transfer layer of wear debris on the surface of the composites which protects underlying substrate by inhibiting metal-metal contact.     

Effect of Ni-coated MoS2 on microstructure and tribological properties of (Cu−10Sn)-based composites

The (Cu−10Sn)−Ni−MoS₂ composites, prepared by powder metallurgy, were studied for the effects of Ni-coated MoS₂ on the microstructure, mechanical properties and lubricating properties. The mechanism of effects of Ni and MoS₂ on the properties of composites was analyzed through a comparative experiment by adding Ni and MoS₂ separately. The results show that the nickel wrapping around the MoS₂ particles decreases the reaction rate of MoS₂ with the copper matrix, and greatly improves the bonding of the matrix. The composites with 12 wt.% Ni-coated MoS₂ (C12) show the optimum performance including the mechanical properties and tribological behaviors. Under oil lubrication conditions, the friction coefficient is 0.0075 with a pressure of 8 MPa and a linear velocity of 0.25 m/s. The average dry friction coefficient, sliding against 40Cr steel disc, is measured to be 0.1769 when the linear velocity and pressure are 0.25 m/s and 4 MPa, respectively.     

Tensile,compressive and wear behaviour of self-lubricating sintered magnesium based composites

The graphite (Gr)/MoS₂ reinforced Mg self-lubricating composites were prepared through powder metallurgy. The composites were characterized for microstructure, physical, mechanical and wear properties. Gr/MoS₂ phase in the composites was identified by XRD analysis. Microstructural observation showed that the Gr/MoS₂ particles were homogeneously dispersed within the magnesium matrix. Micro-hardness was measured using an applied load of 5 g with a dwell time of 15 s at room temperature. Hardness of all the composites was measured to be in the range of VHN 29–34. The mechanical properties were studied using micro-hardness, tensile and compression tests. A fractographic analysis was performed using scanning electron microscope. The highest values of hardness, compressive strength and tensile strength were attained using Mg–10MoS₂ composite. A pin-on-disk tribometer was used to measure the friction coefficient and the wear loss of the sintered composites. In addition to that, the friction and wear mechanism of the composites were systematically studied by worn surface characterization and wear debris studies using SEM analysis. The reduced friction coefficient and wear loss were achieved in MoS₂ rather than Gr.     

车轮材料表面h-BN/CaF_2/Fe基激光熔覆涂层组织与磨损性能

激光熔覆铁基合金涂层的摩擦因数及磨损率均较高,h-BN和CaF_2作为固体添加剂已应用于激光熔覆处理,然而含h-BN和CaF_2的铁基熔覆涂层在列车车轮材料表面的磨损性能及最佳含量尚不清楚。因此,以不同比例的h-BN(0～2%)、CaF_2(2%～0)和Fe基合金(98%)粉末为熔覆材料,在列车车轮材料表面制备合金涂层,对激光熔覆车轮试样进行滚动摩擦磨损试验。结果表明:涂层微观组织主要由枝晶组织和共晶组织构成,硬度约800 HV_(0.3),表面存在残余压应力,其值为800～1 300MPa。加入h-BN粉末可将黏着系数降低至0.35～0.39,激光熔覆车轮试样表面以滚动接触疲劳损伤为主,裂纹在表面产生并在塑性变形层内扩展。随h-BN含量增加和CaF_2含量减小,微观组织尺寸、黏着系数、磨损率、滚动接触疲劳裂纹长度和深度均呈先减小后增加趋势。h-BN、CaF_2和Fe基合金质量比为1%:1%:98%时,涂层微观组织最致密、残余压应力最大、耐磨与抗疲劳性能最优。研究结果可为激光熔覆技术在列车车轮上的应用与优化提供理论与技术指导。     

Microstructure and wear resistance of <Emphasis Type="Italic">in situ</Emphasis> porous TiO/Cu composites

An in situ porous TiO/Cu composite is successfully prepared using powder metallurgy by the reaction of Ti₂CO and Cu powder. Morphological examination of the composite shows that the porosity of composites lies in the range between 10.2% and 35.2%. Dry sliding un-lubricated wear tests show that the wear resistance of the composite is higher than that of the Cu-Al alloy ingot. The coefficient of friction test shows that, as the volume fraction of the reinforced phase increases, the coefficient of friction decreases. The wear rate variation trend of the oil-lubricated wear test results is similar to that of the un-lubricated wear test results. The coefficient of friction for oil lubrication is similar for different volume fractions of the reinforced phase. The wear resistance of the composite at a sliding velocity of 200 rpm is slightly larger than that at 50 rpm. The porosity of the composites enhances the high-velocity oil-lubricated sliding wear resistance.     

High temperature tribological behaviors of aluminum matrix composites reinforced with solid lubricant particles

The AA6061−10wt.%B₄C mono composite, AA6061−10wt.%B₄C−Gr (Gr: graphite) hybrid composites containing 2.5, 5, and 7.5 wt.% Gr particles, and AA6061−10wt.%B₄C−MoS₂ hybrid composites containing 2.5, 5, and 7.5 wt.% MoS₂ particles were fabricated through stir casting. The dry sliding tribological behaviors of the mono composite and hybrid composites were studied as a function of temperature on high temperature pin-on-disc tribotester against EN 31 counterface. The wear rate and friction coefficient of the Gr-reinforced and MoS₂-reinforced hybrid composites decreased in the temperature range of 30−100 °C due to the combined lubrication offered by the wear protective layer and its solid lubricant phase. Scanning electron microscopy (SEM) observation of the worn pin surface revealed severe adhesion, delamination, and abrasion wear mechanisms at temperatures of 150, 200, and 250 °C, respectively. At 150 °C, transmission electron microscopy (TEM) observation of the hybrid composites revealed the formation of deformation bands due to severe plastic deformation and fine crystalline structure due to dynamic recrystallization.     

Tribological properties of Ti-aluminide reinforced Al-based in situ metal matrix composite

For structural application of moving components, the tribological properties (friction and wear) are considered to be one of the major factors controlling the performance. In recent years, lightweight metal matrix composites (MMC) have received wider attention for their technological application, such as automotive parts etc. This paper reports the tribological behavior of Al based composites reinforced with in situ Ti_xAl_y and Al₂O₃ particles. The wear experiments were performed on a newly designed fretting tribometer to evaluate the role of intermetallic particulates on the wear performance of in situ composites against bearing steel under the ambient conditions of temperature (22–25 °C) and humidity (50–55% RH). Based on the topographical observation of the worn surfaces the plausible wear mechanisms are discussed. An important result is that Al-based composites with 20 vol% reinforcement exhibit an extremely low coefficient of friction of 0.2 under unlubricated conditions. Also, around five times lower wear volume is measured with 20 vol% composites when compared to unreinforced Al.     

石墨/CaF2/TiC协同改善镍基合金喷涂层的摩擦磨损行为与机理（英文）

为了降低机械零件在强烈摩擦磨损条件下的摩擦因数,提高其耐磨性,制备了等离子喷涂石墨/CaF2/TiC/镍基合金复合涂层,研究其摩擦学行为及机理。结果表明,石墨/CaF2/TiC/镍基合金复合涂层的摩擦因数为0.22~0.288,较纯镍基合金涂层的降低了25.9%~53%,磨损率较之降低18.6%~70.1%。与GCr15钢球对摩时,复合涂层的磨损表面逐渐形成了由铁氧化物、石墨和CaF2组成的转移层,使GCr15钢球与复合涂层的摩擦转变为钢球与转移层的摩擦。由于转移层起到固体润滑作用,复合涂层的摩擦因数和磨损率大幅度降低。复合涂层的主要磨损机理是转移层在载荷的反复作用下而产生的层脱剥落。     

Microstructure and high-temperature friction and wear behavior of WC-(W,Cr)2C-Ni coating prepared by high velocity oxy-fuel spraying

WC-(W,Cr)₂C-Ni coating was prepared by high velocity oxy-fuel spraying (HVOF). The microstructure and phase composition of the as-sprayed coating and that after oxidation at high temperature were analyzed by means of scanning electron microscopy (SEM), field emission scanning electron microscopy (FESEM), X-ray diffraction (XRD), and transmission electron microscopy (TEM). The oxidation behavior of as-sprayed coating and starting powders was evaluated by thermogravimetry. Dry sliding friction and wear behavior of the WC-(W,Cr)₂C-Ni coating sliding against Si₃N₄ ball at different temperatures (room temperature 20 °C and elevated temperature of 700 °C and 800 °C) was evaluated using an oscillating friction and wear tester. Besides, the microhardness and fracture toughness of the coating was also measured. Results show that sintering agglomerated WC-20 wt.%Cr-7 wt.%Ni powder is an effective method to prepare agglomerated and sintered WC-(W,Cr)₂C-Ni composite powder. The excellent oxidation resistance of WC-(W,Cr)₂C-Ni coating is mainly resulted from a double-decker shell-core microstructure formed in the coating. The composition of the outer shell is (W,Cr)₂C phase and that of the inner shell is Cr₃C₂. During high-temperature friction and wear test, well remained hard WC phase in the WC-(W,Cr)₂C-Ni coating can guarantee its good mechanical properties and wear resistance, and newly generated nano NiWO₄, CrWO₄ and Cr₂WO₆ particles can further improve these properties significantly.     

High strength Ni–Zr–(Al) nanoeutectic composites with large plasticity

Micrometer-sized γ−Ni dendrite reinforced nanoeutectic matrix composites have been developed in (Ni_0.92Zr_0.08)_100–xAl_x (0 ≤ x ≤ 4) by arc melting. The eutectic matrix is composed of alternate nano-lamellae of intermetallic Ni₅Zr and fcc–Ni solid solution phases. All these composites exhibit very high strength, large compressive plasticity ∼25% and strain-hardening up to 1780 MPa. Al dissolves in γ−Ni(Zr) solid solution phase, decreases its hardness/strength, and increases the volume % of γ−Ni dendrite from 20% (x = 0) to 29% (x = 4). Whereas, refinement of the eutectic lamellae thickness from 275 nm (x = 0) to 160 nm (x = 4) increases the matrix hardness and retains the global strength of the composites. The effect of Al addition on the microstructure formation, volume fraction as well as the length scale of the constituent phases, and mechanical properties, have been discussed using an analytical model.     

Ultrafine eutectic Ti x Sn y /TiNi composites with high damping capacity

Three kinds of bulk-type ultrafine Ti _x Sn _y /TiNi (Ti _x Sn _y represents Ti₃Sn, Ti₂Sn, and Ti₅Sn₃ or Ti₆Sn₅) composites with homogeneous eutectic microstructure were prepared by arc melting. The composites exhibit high damping capacity (tanδ greater than 1 × 10^?2) and enhanced mechanical strength (the highest fracture strength is 2.15 GPa). The damping capacity originates from TiNi and Ti₃Sn, while the eutectic contributes to the mechanical strength.     

Effect of solubility on strengthening of Ag-Cu ultrafine eutectic composites

A series of binary Ag_80−xCu_20+x ultrafine eutectic composites with x = 0, 10, 20, 30 and 40 is prepared by copper mold casting in order to systematically investigate an influence of asymmetrical solubility between Ag and Cu solid solutions on the strengthening of ultrafine eutectic composites. The asymmetrical solubility of the ultrafine eutectic composites determined by the effective solubility index derived from rule of mixtures plays an important role to maintain the strength even with increasing the volume fraction of the micron-scale dendrites. Based on the results, the control of the strengthening of the ultrafine eutectic composites is governed by not only well-known volume fraction of the micron-scale dendrites but also the solubility in the micron-scale dendrites.     

Effects of solid lubricants on friction and wear behaviors of the phenolic coating under different friction conditions

The phenolic coating filled with micro-MoS₂ or micro-graphite was prepared by spraying the coating precursors. The friction and wear behaviors of the unfilled and filled phenolic composite coating sliding against the steel ring were evaluated on an MHK-500 friction and wear tester under dry friction and under water lubrication conditions. The worn surfaces of the unfilled and filled phenolic coating and the transfer films formed on the surface of the steel ring were investigated using a scanning electron microscope (SEM) and an optical microscope (OM), respectively. FTIR analysis was performed to detect the chemical changes of the composite coating under different lubrication conditions. It was found that addition of graphite was effective in enhancing the wear life of the phenolic coating. Especially, the anti-wear ability of the phenolic coating was best when the content of graphite is 10 wt.%. However, the MoS₂ as filler was harmful to the friction and wear behaviors of the phenolic coating. The character of the fillers varied with the types of the solid lubricants and the transfer films of varied features formed on the counterpart steel ring, largely accounted for the different friction and wear behaviors of the unfilled and filled phenolic composite coating. Compared with under dry sliding, the phenolic composite coating filled with 10 wt.% MoS₂ or 10 wt.% graphite had lower friction coefficients and lower wear life under water lubrication. Since water hindered the formation of transferred films, and might penetrate and corrode the filler-matrix interface, the anti-wear ability of the phenolic composite coating reinforced with MoS₂ or graphite deteriorated under water lubrication.     

重载变速冲击工况下MoDDP/CaB复合润滑油添加剂的润滑性能

为解决机械设备在恶劣工况下由润滑失效而导致的设备故障甚至安全生产事故问题,进一步提升机械设备的运行稳定性和安全性,研究纳米硼酸钙（CaB）和二烷基二硫代磷酸钼（MoDDP）单一润滑油添加剂和复合润滑油添加剂的减摩抗磨效果,并探究其润滑作用机制。研究结果表明,重载、变速、冲击工况条件下 1.5 wt.% MoDDP / 3.0 wt.% CaB 复合润滑油添加剂具有良好的减摩抗磨效果,与基础油相比,在不同转速下可最大降低 65.1%的摩擦因数和 80%的磨痕深度,施加 50 N 冲击载荷时,可分别降低66.7%的摩擦因数和76.5%的磨痕深度。MoDDP / CaB复合润滑油添加剂在润滑过程中能生成包含C-C、 Fe₂O₃、FeB 和 MoS₂的金属化合物层,添加剂中的 CaB 和 MoDDP 能够相互促进彼此反应,增加 FeB / MoS₂润滑膜的生成量, 对比单一的添加剂和基础油,复合添加剂具有更好的自修复性能和协同功效,形成具有高承载力的润滑油膜,提高了复合润滑油的抗磨减摩性能。MoDDP / CaB 复合润滑油添加剂的制备可以充分综合利用抗氧化剂与极压耐磨剂的稳定、优异润滑特性,研究结果可为复合添加剂的广泛应用提供数据支持和理论支撑。     

Microstructure and properties of intermetallic composite coatings fabricated by selective laser melting of Ti–SiC powder mixtures

Transition metal silicides and carbides are attractive advanced materials possessing unique combinations of physical and mechanical properties. However, conventional synthesis of bulk intermetallics is a challenging task because of their high melting point. In the present research, titanium carbides and silicides composites were fabricated on the titanium substrate by a selective laser melting (SLM) of Ti–(20,30,40 wt.%)SiC powder mixtures by an Ytterbium fiber laser with 1.075 μm wavelength, operating at 50 W power, with the laser scanning speed of 120 mm/s. Phase analysis of the fabricated coatings showed that the initial powders remelted and new multiphase structures containing TiC_x, Ti₅Si₃C_x, TiSi₂ and SiC phases in situ formed. Investigation of the microstructure revealed two main types of inhomogeneities in the composites, (i) SiC particles at the interlayer interfaces and, (ii) chemical segregation of the elements in the central areas of the tracks. It was suggested and experimentally proven that an increase in laser power to 80 W was an efficient way to improve the laser penetration depth and the mass transport in the liquid phase, and therefore, to fabricate more homogeneous composite. The SLM Ti–(20,30,40 wt.%)SiC composites demonstrated high hardness (11–17 GPa) and high abrasive wear resistance (3.99 × 10⁻⁷–9.51 × 10⁻⁷ g/Nm) properties, promising for the applications involving abrasive wear.