TEM studies of anti-wear films/wear particles generated under boundary conditions lubrication

Friction and wear performance of engine oil were studied in presence of Zinc-dialkyldithiophosphate (ZDDP) and ZDDP–iron fluoride (FeF₃) combination using a ball-on-ring wear testing device under boundary conditions. Friction and wear performance of engine oil improves in presence of ZDDP–FeF₃ combination. In order to understand the wear mechanisms the microstructure and the chemical composition of wear debris generated during wear process were investigated using TEM together with EDX analyzes. Novel observations on the wear debris generated at different testing loads are presented. Independent of normal loads, amorphous debris containing P, O, Fe and Zn elements and crystalline debris of Fe₂O₃ are formed. No trace of S is present in amorphous debris under low load (2.32 GPa) conditions while S is a dominating element under high loaded (3.68 GPa) conditions. On the other hand, at lower loads a few iron oxide is formed while at higher loads larger sizes of iron oxides are formed resulting in larger friction and wear.     

The friction and wear of electroless Ni–P matrix with PTFE and/or SiC particles composite

In this paper, the friction behaviour and wear mechanism of electroless Ni–P matrix with PTFE and/or SiC particles composite coating are investigated by virtue of ring-on-disk wear machine at a high load of 150 N. The worn surface, wear debris and the composition changes after wear were characterized using scanning electron microscopy (SEM) and energy-dispersive analysis of X-ray (EDAX). By comparison with Ni–P and Ni–P–SiC coatings, the results indicated that the combination of a PTFE-rich mechanical mixed layer (PRMML) formed on the worn surface and hard SiC were responsible for the good tribological properties of the hybrid Ni–P–PTFE–SiC composites at high load. After heat treatment at 400 °C for 1 h, the wear rate of Ni–P matrix composites decreased with corresponding increase in microhardness. During sliding, an obvious decrease in the temperature rise with PTFE addition was attributed to the good anti-friction of PTFE.     

The sliding wear of 316 stainless steel in air in the temperature range 20–500°C

The friction and reciprocating wear of 316 stainless steel in air has been investigated in the temperature range 20–500°C at constant load using a standard pin and flat geometry. A marked change in wear behaviour occurred above 300°C. From room temperature to 300°C the wear rate decreased slowly with increasing temperature. This was accompanied by an increasing fraction of oxide in the wear debris. At 300°C the debris consisted entirely of oxide with the α Fe₂ O₃ structure. In this temperature range wear can be explained essentially in terms of mild wear. Above 300°C the wear rate decreased by an order of magnitude and was accompanied by a severely distorted wear surface. There was a high proportion of metallic particles in the wear debris. The surface roughening occurs at an early stage of wear and stops when glazed oxide regions form. The low wear rate is explained in terms of the high hardness of the glazed load-bearing areas and re-incorporation of wear debris into the wear scar.     

Effect of transfer layer on dry sliding wear behaviour of cast Al-based composites synthesized by addition of TiO2 and MoO3

Two types of composites have been developed by solidification processing by addition of 3, 4, and 5 wt% powders of oxide—TiO₂ and MoO₃, to molten Al-5 wt% Mg alloy. The oxide particles react with the molten alloy resulting in alumina and releasing alloying elements of Ti or Mo. Dry sliding wear behaviour of pins of cast composite, fabricated by solidification of melt-particle slurry in mold, has been determined by pin-on-disc wear tests carried out conventionally and while removing wear debris by camel brush. The accumulated volume loss in composites increases linearly with increasing sliding distance and the wear rate increases more or less linearly with increasing load. Increasing particle content decreases wear rate at a given load. The accumulated volume loss is considerably higher when wear debris is removed by camel brush during dry sliding wear. The nature of the wear debris has been confirmed to be oxidative. The relatively brighter compacted oxide transfer layer could be observed in the SEM micrograph of worn pin surfaces of the composites developed by addition of MoO₃ and TiO₂ respectively. Since the accumulated volume loss in wear is relatively more when the wear debris is removed during dry sliding wear test it may be inferred that wear debris is more beneficial for wear resistance through formation of transfer layer rather than its harmful role in enhancing volume loss through three body wear. At higher loads, the oxide debris are expected to get better compacted to form transfer layer, spread over a larger area of the sliding surface and thus, their removal causes a larger wear compared to that without removal of wear debris. However, a larger cover of transfer layer at higher load does not necessarily imply reduced accumulated volume loss because the wearing process is more aggravated at higher load. Apart from adhesion, micro-cutting and abrasion, the transfer layer also flakes off during dry sliding wear as indicated by the presence of chunky sheet of oxides in wear debris.     

Influence of secondary phases on the tribological response of electro-discharge machined zirconia-based composites against WC-Co cemented carbide

Three ceramic composite grades, consisting of a ZrO₂ matrix and 40 vol.% WC, TiC_0.5N_0.5 or TiN phase, were completely self-developed by hot pressing powder mixtures of yttria-stabilised zirconia (Y-TZP) and distinctive WC, TiC_0.5N_0.5 or TiN powder sources. The friction and wear characteristics of the zirconia-based composites against WC-Co cemented carbide were investigated by performing dry reciprocating sliding experiments on a pin-on-plate tribometer under various normal contact forces. The generated wear was quantified using surface scanning topography. Post-mortem obtained wear volumes were correlated to real-time recorded wear depth. The ZrO₂-40 vol.% WC grade displayed more favorable tribological properties compared to the other grades with equal secondary phase content. The worn surfaces and the wear debris were analysed by scanning electron microscopy (SEM) and energy dispersive X-ray analysis (EDX), revealing several wear mechanisms such as polishing, abrasion and wear debris layer formation, mainly depending on the imposed contact load and the material composition.     

Studies of high temperature sliding wear of metallic dissimilar interfaces II: Incoloy MA956 versus Stellite 6

The development of wear surfaces formed during limited debris retention sliding wear of Incoloy MA956 against Stellite 6 between room temperature and 750 °C, and sliding speeds of 0.314 and 0.905 m s⁻¹ (7 N applied load, 4522 m sliding distance) were investigated. At 0.314 m s⁻¹, mild oxidational wear was observed at all temperatures, due to oxidation of Stellite 6-sourced debris and transfer to the Incoloy MA956; this debris separated the Incoloy MA956 and Stellite 6 wear surfaces. Between room temperature and 450 °C, the debris mainly took the form of loose particles with limited compaction, whilst between 510 °C and 750 °C the debris were compacted and sintered together to form a Co–Cr-based, wear protective ‘glaze’ layer. The behaviour was identical to that previously observed on sliding Nimonic 80A versus Stellite 6 at 0.314 m s⁻¹.At 0.905 m s⁻¹, mild oxidational wear was only observed at room temperature and 270 °C and dominated by Incoloy MA956-sourced debris. At 390 and 450 °C, the absence of oxide debris allowed ‘metal-to-metal’ contact and resulted in intermediate temperature severe wear; losses in the form of ejected metallic debris were almost entirely Incoloy MA956-sourced. This severe wear regime was also observed from 510 up to 630 °C, but increasingly restricted to the early stages of wear by development of a wear protective Incoloy MA956-sourced ‘glaze’ layer. This ‘glaze’ layer formed so rapidly at 690 °C and 750 °C, that severe wear was all but eliminated and wear levels were kept low.The behaviour observed for Incoloy MA956 versus Stellite 6 at 0.905 m s⁻¹ contrasts sharply with that previously observed for Nimonic 80A versus Stellite 6, in that the Incoloy MA956-sourced high Fe–Cr debris formed a protective oxide ‘glaze’, whilst the Nimonic 80A-sourced Ni and Cr oxides formed an abrasive oxide that at high sliding speeds assisted wear. The data indicates that the tendency of oxide to form a ‘glaze’ is readily influenced by the chemistry of the oxides generated.     

Friction and wear properties of lead-free aluminum alloy bearing material with molybdenum disulfide layer by a reciprocating test

Friction and wear behavior of Al–Sn–Si alloy with MoS₂ layer under lubricated condition was investigated by a reciprocating friction tester. It became clear that the Al–Sn–Si alloy with MoS₂ layer showed about 70% lower friction and about 1/10 lower wear depth compared to the Al–Sn–Si alloy. The worn surfaces of the Al–Sn–Si alloy with MoS₂ layer were observed and analyzed by a SEM, a TEM and an EDX. It indicated that the sliding surface of the counterface had larger area of Mo than the area of Al which was transferred from the Al–Sn–Si alloy with MoS₂ layer by sliding, resulting in low friction and high wear resistance.     

High-temperature sliding wear of metals

Temperature can have a considerable effect on the extent of wear damage to metallic components. During reciprocating sliding, under conditions where frictional heating has little impact on surface temperatures, there is generally a transition from severe wear to mild wear after a time of sliding that decreases with increase in ambient temperature. This is due to the generation and retention of oxide and partially-oxidized metal debris particles on the contacting load-bearing surfaces; these are compacted and agglomerated by the sliding action, giving protective layers on such surfaces. At low temperatures, from 20 to 200°C, the layers generally consist of loosely-compacted particles; at higher temperatures, there is an increase in the rates of generation and retention of particles while compaction, sintering and oxidation of the particles in the layers are facilitated, leading to development of hard, very protective oxide ‘glaze’ surfaces. This paper reviews some of the main findings of extensive research programmes into the development of such wear-protective layers, including a model that accounts closely for the observed effects of temperature on wear rates during like-on-like sliding.     

Studies of high temperature sliding wear of metallic dissimilar interfaces

The evolution of microstructures in the glaze layer formed during limited debris retention sliding wear of Nimonic 80A against Stellite 6 at 750 °C and a sliding speed of 0.314 m s⁻¹ (7 N applied load, 4522 m sliding distance) was investigated using scanning electron microscopy (SEM), energy dispersive analysis by X-ray (EDX), X-ray diffraction (XRD), scanning tunnelling microscopy (STM) and transmission electron microscopy (TEM). The collected data indicate the development of a wear resistant nano-structured glaze layer. The process of ‘fragmentation’ involving deformation, generation of dislocations, formation of sub-grains and their increasing refinement causing increasing misorientation was responsible for the formation of nano-structured grains. The rapid formation of this glaze layer from primarily cobalt–chromium debris transferred from (and also back to) the surface of the Stellite 6, kept wear of both the Nimonic 80A and Stellite 6 to very low levels.However, increasing the sliding speed to 0.905 m s⁻¹ (750 °C) suppressed glaze formation with only a patchy, unstable glaze forming on the Stellite 6 counterface and an absence of glaze development on the Nimonic 80A sample (the Nimonic 80A surface was covered with at most, a very thinly smeared layer of oxide). The high levels of oxide debris generated at 0.905 m s⁻¹ instead acted as a loose abrasive assisting wear of especially the Nimonic 80A. This behaviour was attributed to a change in oxide chemistry (due to the dominance of nickel and chromium oxides generated from the Nimonic 80A) resulting in poor oxide sintering characteristics, in combination with increased mobility and reduced residency of the oxide debris at 0.905 m s⁻¹.     

Reciprocating sliding wear of 9% Cr steel in carbon dioxide at elevated temperatures

Experiments were conducted on the initial stages of reciprocating sliding wear of a 9% chromium steel in an environment of carbon dioxide at temperatures in the range 200 to 550°C. At ambient temperatures of 290°C and above, an initial severe wear mode was followed by a transition to mild oxidational wear. At any given ambient temperature above 290°C, the distance of sliding required to reach such a transition was found to depend on load and mean sliding speed, although the dependency on speed was not simple. When a transition occurred, most of the surfaces were covered with a stable oxide film which consisted of an agglomerate layer of wear debris being mainly of oxide at the surface and mainly at the metal boundary. This film was supported by a work hardened layer extending for about 30 μm into the bulk of the metal. A surface model is proposed to explain the mechanism of formation of the supportive oxide layer; predictions of volume of material removed and final oxide coverage at the transition are in close agreement with experimental values     

Fretting wear of Ti-48Al-2Cr-2Nb

An investigation was conducted to examine the wear behavior of gamma titanium aluminide (Ti-48Al-2Cr-2Nb in atomic percent) in contact with a typical nickel-base superalloy under repeated microscopic vibratory motion in air at temperatures from 296–823 K. The surface damage observed on the interacting surfaces of both Ti-48Al-2Cr-2Nb and superalloy consisted of fracture pits, oxides, metallic debris, scratches, craters, plastic deformation, and cracks. The Ti-48Al-2Cr-2Nb transferred to the superalloy at all fretting conditions and caused scuffing or galling. The increasing rate of oxidation at elevated temperatures led to a drop in Ti-48Al-2Cr-2Nb wear at 473 K. Mild oxidative wear was observed at 473 K. However, fretting wear increased as the temperature was increased from 473–823 K. At 723 and 823 K, oxide disruption generated cracks, loose wear debris, and pits on the Ti-48Al-2Cr-2Nb wear surface. Ti-48Al-2Cr-2Nb wear generally decreased with increasing fretting frequency. Both increasing slip amplitude and increasing load tended to produce more metallic wear debris, causing severe abrasive wear in the contacting metals.     

Hot wear properties of ceramic and basalt fiber reinforced hybrid friction materials

In the present study, hybrid friction materials were manufactured using ceramic and basalt fibers. Ceramic fiber content was kept constant at 10 vol% and basalt fiber content was changed between 0 to 40 vol%. Mechanical properties and friction and wear characteristics of friction materials were determined using a pin-on-disc type apparatus against a cast iron counterface in the sliding speeds of 3.2–12.8 m/s, disc temperature of 100–350 °C and applied loads of 312.5–625 N. The worn surfaces of the specimens were examined by SEM. Experiments show that fiber content has a significant influence on the mechanical and tribological properties of the composites. The friction coefficient of the hybrid friction materials was increased with increasing additional basalt fiber content. But the specific wear rates of the composites decreased up to 30 vol% fiber content and then increased again above this value. The wear tests showed that the coefficient of friction decreases with increasing load and speed but increases with increasing disc temperature up to 300 °C. The most important factor effecting wear rate was the disc temperature followed by sliding speed. The materials showing higher specific wear rates gave relatively coarser wear particles. XRD studies showed that Fe and Fe₂O₃ were present in wear debris at severe wear conditions which is indicating the disc wear.     

Formation of Cylindrical Sliding-Wear Debris on Silicon in Humid Conditions and Elevated Temperatures

The present study investigates the mechanics of roll formation between sliding bodies at elevated temperatures and humid conditions. Silicon is used as the model material for reciprocating linear sliding tests. The evolution of tribological rolls initially involves the rapid oxidation of silicon wear debris by water, the deformation of SiO₂ particles into platelets, and then the compaction of these particles into a film deposited on the wear surface. The formation of compacted silica film requires minimum adsorption of water which enhances the adhesion between silica platelets. The stress cycle imposed on the film leads to the delamination of platelets near the sliding surface. The delaminated debris cluster into multiple aggregates that are subsequently rolled into dense cylindrical particles so as to relieve the interfacial shear stress. When the film and rolls are formed, the friction and wear rate is maintained at low steady state values.     

The effect of brush spring pressure on the wear behaviour of copper–graphite brushes with electrical current

Electrical brushes are used to conduct current between stationary part and moving part of a motor or a generator. To ensure proper current transfer and continuous contact, brushes must be loaded against the sliding contact surface with a sufficient force. High loads increase frictional losses and wear of the brushes and/or sliding surface. While relatively low contact pressure causes arcing and higher voltage drop.In this study, a novel pin-on-slip ring-type friction and wear test machine was designed and manufactured for the purpose of brush testing. Copper–graphite-based electrical brush containing 90 wt% copper and 10 wt% graphite was manufactured by powder metallurgy and the tribological behaviour and voltage drop were investigated at different brush spring pressures at 10–200 kPa with current.It was found that the specific wear curve showed three distinct wear rate regimes, such as low, mild, and severe. Severe wear was observed below 30 kPa and above 120 kPa brush spring pressures (BSP) (3 and 12 N loads, respectively). Arc erosion was the main wear mechanism below 30 kPa brush spring pressure while abrasion was dominant above 120 kPa BSP. Low and mild regimes were observed between 30–50 and 50–120 kPa BSP, respectively. SEM observations showed that a continuous surface layer was formed at the sliding surfaces of the wear samples in low and mild wear regimes. The wear debris was examined by SEM and X-ray diffractometer.     

Influence of temperature of sub-zero treatments on the wear behaviour of die steel

This study examines the influence of temperature of sub-zero treatment on the wear behaviour of AISI D2 steel. A series of dry sliding wear studies have been made under constant normal load at varying sliding velocities. Emphasis has been laid to understand the operative modes and mechanisms of wear by the estimation of specific wear rates and detailed characterizations of the worn surfaces, wear debris and subsurfaces with the help of scanning electron microscope (SEM) examinations coupled with energy dispersive X-ray (EDX) microanalyses. The obtained results unambiguously infer that lower the temperature of sub-zero treatment higher is the improvement in wear resistance. Wear resistance can increase by 1.5–125 times depending on sliding velocity while hardness increases only by 4.2% at the lowest temperature of sub-zero treatment (77 K) compared to the conventionally treated specimens. These results corroborate well with the reduction in retained austenite content associated with simultaneous increase in the amount of secondary carbide particles with lowering of sub-zero treatment temperature. The operative modes and mechanisms of wear are identified as either mild oxidative or severe delaminative, which depends on the temperature of sub-zero treatment and the sliding velocity of the wear test.     

Influence of electrical discharge machining on sliding friction and wear of WC-Ni cemented carbide

Tribological characteristics of fine-grained WC-8 wt%Ni with different surface finishing conditions corresponding to sequential wire electrical discharge machining (wire-EDM) or grinding were investigated by performing dry reciprocating sliding experiments on TE77 pin-on-plate equipment with WC-6 wt%Co as mating material. Surface finishes and wear surfaces were characterized using surface topography scanning, SEM analysis and EDX spectrometry. The decreased wear resistance due to wire-EDM could be linked to flexural strength properties as well as XRD measurements revealing tensile residual stresses on wire-EDM surfaces, in contrast with the compressive stress state on ground surfaces. Substantial improvement of wear resistance was accomplished with finer-executed EDM steps.     

Frictional behaviour of oxygen diffusion hardened titanium in dry sliding against Co–28Cr–5W–4Fe–3Ni–1Si cobalt alloy

The results of conformal pin-on-disc tribological tests of a hard layer of the solid solution of oxygen in α-titanium sliding against a Co–28Cr–5W–4Fe–3Ni–1Si cobalt alloy counterspecimen are presented. The α-Ti(O) layer was diffusely produced over 2–8 h of oxidising in the superficial zone of a technical quality titanium specimen.The friction and wear responses of the system were recorded and the wear mechanisms were studied. Investigations of the material structure and chemical constitution in micro-areas of the titanium specimen, cobalt alloy counterspecimen and wear debris formed in dry sliding were performed with a Philips XL20 microscope equipped with an EDAX analyser. Crushing of the α-Ti(O) layer, lowering of the wear rate after comminution of the hard α-Ti(O) layer, local tack spots and fine powder wear particles, mostly Ti oxides, were detected at the beginning of each test. Gradual brittle fracture and decay by pulverising of the α-Ti(O) particles embedded in both mating surfaces, which occurred during the test, led to the increase of the wear rate of the couple and domination of microcutting and tack spots spalling after their partial oxidation. Finally, after the disappearance of the α-Ti(O) loose particles, adhesive junctions, metal transfer and smearing become leading wear mechanisms.     

Abrasive wear resistance of textured steel rings

The fundamental aim of the present research is to study the effect of dimple shape and area density on abrasive wear in lubricated sliding. The other aims are to recommend a method of obtaining the local linear wear of a textured ring on the basis of profilometric measurement and to analyse the changes in the surface topography of this ring with selection of parameters that could monitor the “zero-wear” process.The experiments were conducted on a block-on ring tester. The stationary block made from cast iron of 50 HRC hardness was ground. The rotated ground ring was made from 42CrMO4 steel of 32 HRC hardness. The rings were modified by a burnishing technique in order to obtain surfaces with oil pockets. Oil pockets of spherical and of drop shape were tested. The pit-area ratios were in the range: 7.5–20%. The tested assembly was lubricated by oil L-AN 46. Because of the great hardness of the co-acting parts the wear resistance test was carried out under artificially increased dustiness conditions. The dust consists mainly of SiO₂ and Al₂O₃ particles. Measurement of local microscopic ring wear was made using a three-dimensional scanning instrument. The tendencies of ring surface topography changes during wear were analysed. Various methods of obtaining the local wear value during a low wear process were proposed and compared. We found that a spherical shape of dimples was superior to a drop shape with regard to wear resistance of steel rings.     

Failure mechanisms of a MEMS actuator in very high vacuum

The tribochemical and mechanical origins of wear of a microelectromechanical systems (MEMS) actuator (electrostatic lateral output motor) operated in very high vacuum (10⁻⁷ torr) are reported in this study. Failure mechanisms in vacuum were determined and then compared to those in dry air, which is one of the harshest environments for causing early failure. Durability in vacuum was poor, even worse than that in dry air. Poor durability in vacuum is related to the kinetics of wear and reformation of the native oxide at asperity contacts. Devices failed due to catastrophic wear in vacuum, and more wear debris was generated than in dry air. There was a fundamental difference in wear debris morphology for devices run in vacuum and dry air. In vacuum, wear debris took the form of pulled-out polysilicon grains. In dry air, wear debris was an agglomerate of smaller particles, which were largely comprised of SiO₂. An oxide layer reformed quickly enough in the air mediated wear process to provide some protection, but resulted in oxygen rich wear debris. In vacuum, the passivating native oxide layer was removed exposing reactive areas on the surface, which led to junction formation at Si–Si asperity contacts. It is proposed that interfacial bonds formed at asperity contacts were stronger than the cohesive bonds within the polysilicon, which resulted in grain pull-out in an adhesive wear process.     

High stress abrasive wear behaviour of aluminium hard particle composites: Effect of experimental parameters, particle size and volume fraction

High stress abrasive wear behaviour of aluminium alloy (ADC-12)–SiC particle reinforced composites has been studied as a function of applied load, reinforcement size and volume fraction, and has been compared with that of the matrix alloy. Two different size ranges (25–50 and 50–80 μm) of SiC particles have been used for synthesizing ADC-12–SiC composite. The volume fraction of SiC particles has been varied in the ranges from 5 to 15 wt%. It has been noted that the abrasive wear rate of the alloy reduced considerably due to addition of SiC particle and the wear rate of composite decreases linearly with increase in SiC content. It has also been noted that the wear resistance of composite varies inversely with square of the reinforcement size. The wear rate of the alloy and composite has been found to be a linear function of applied load but invariant to the abrasive size; at critical abrasive size, transition in wear behaviour is noted. This has been explained through analytically derived equations and wear–surface examination.