Correlation of microstructure with wear behaviour of deep cryogenically treated AISI D2 steel

This study aims to reveal the underlying mechanisms responsible for the enhancement of wear resistance of AISI D2 steel by deep cryogenic treatment (DCT) through in-depth microstructural analyses, and thereby attempt to correlate microstructure with wear behaviour of DCT specimens with reference to that of conventional heat treatment (CHT) and cold treatment (CT). Microstructural characterizations of the differently treated specimens have been done by image analyses of optical and SEM photographs, XRD, and EDX analyses, whereas wear behaviour has been characterized by wear rate, wear resistance, and analyses of worn surfaces, wear debris and subsurfaces. The results indicate that DCT markedly enhances the wear resistance of the selected steel compared to CHT and CT. Formation of white layer and its subsequent delamination have been identified as the operative wear mechanisms; the extent of these phenomena and the consequent wear rate is dependent on the type of treatment that determines the microstructures. The wear behaviour can be unambiguously correlated with the modifications in the precipitation behaviour of secondary carbides and reduction in the retained austenite content of the microstructure, which are the governing mechanisms for the improved of wear resistance of tool steels by DCT.     

Tribological behaviour of colloidally processed sialon ceramics sliding against steel under dry conditions

Advanced structural ceramics are presently used in several tribological applications such as precision instrument bearings, water pumps, automotive engine parts and cutting tools inserts. In the present work, the tribological behaviours of colloidally processed and pressureless sintered sialon ceramics with different phases ( and ) have been studied, aiming at increasing the industrial applications of sialon ceramics. The friction and wear behaviour of sialon ceramics against steel DIN-Ck45K were investigated using a pin-on-disk tribometer under dry conditions. Scanning electron microscopy (SEM), and energy dispersion spectroscopy (EDS) were used to analyse the worn surfaces of the sialon ceramics. Under the conditions used, sialon ceramics exhibited a typical mild wear (10^-6 mm³ N^-1 m^-1) and the dominant wear mechanisms present were adhesive and abrasion. The results confirmed that colloidal processing and pressureless sintering are effective methods to prepare wear resistant sialon ceramic components.     

Sliding wear behaviour of Zr-ion-implanted D3 tool steel

The wear and friction characteristics of zirconium-ion-implanted AISI D3 tool steel have been investigated using pin-on-disc methods. Ion implantation was carried out using a vacuum-arc-based ion implanter to form multicharged zirconium ion beams at a mean ion energy of 130 keV, and the implantation doses investigated were approximately 3.6×10¹⁶, 5×10¹⁶ and 1×10¹⁷ ions cm⁻². It was found that Zr implantation decreased both the wear and the coefficient of friction. The beneficial effects of Zr implantation in terms of associated Auger electron spectroscopy, Rutherford backscattering spectroscopy and scanning electron microscopy microprobe analyses are described.     

Effect of temperature on friction and wear of prehardened tool steel during sliding against 22MnB5 steel

Abstract

Mechanical components in tribological systems exposed to elevated temperatures are gaining increased attention since more and more systems are designed to operate under extreme conditions. In hot metal forming, the effect of temperature on friction and wear is especially important since it is directly related to process economy (tool wear) and quality of the produced parts (friction between tool and workpiece). This study is therefore focused on fundamental understanding pertaining to the tribological characteristics of prehardened hot work tool steel during sliding against 22MnB5 boron steel. The tribological tests were carried out using a high temperature reciprocating sliding friction and wear tester under a normal load of 31 N (corresponding to a contact pressure of 10 MPa), a sliding speed of 0·2 m s^?1 and temperatures ranging from 40°C to 800°C. It was found that friction coefficient and specific wear rate decreased at elevated temperature because of formation of compacted wear debris layers on the surfaces.     

The effects of cryogenic treatment on the toughness and tribological behaviors of eutectoid steel

Cryogenic treatment is a supplementary heat treatment usually applied after quenching. Its effects are permanent and this process affects the entire section. There have been many studies related to cryogenic treatment, most of which have been focused on tool steels. In the current study, a high-speed-train railway material was investigated, and different heat treatment processes were applied to the eutectoid steel. The effects of quenching and cryogenic treatment were investigated on the mechanical properties (toughness, hardness and wear). Four different structures were obtained with different heat treatment cycles: Pearlitic, tempered martensite, 12 hour cryo-treated tempered and 36 hour cryo-treated tempered. As a result of Charpy v-notch tests and hardness tests, cryogenic treatment was found to improve the toughness and hardness of quenched samples. The results of the ball-on-disc wear tests showed that the cryo-treated samples have better wear resistance than pearlitic and martensitic samples.     

High-temperature friction and wear behaviour of different tool steels during sliding against Al–Si-coated high-strength steel

The recent years have witnessed an increasing usage of high-strength steels as structural reinforcements and in energy-absorbing systems in automobile applications due to their favourable high-strength-to-weight ratios. Owing to poor formability, complex-shaped high-strength steel components are invariably produced through hot-metal forming. The high-strength steel sheets are in some instances used with an Al–Si-coating with a view to prevent scaling of components during hot-metal forming. However, friction and wear characteristics of Al–Si-coated high-strength steel during interaction with different tool steels have not yet been investigated. With this in view, friction and wear behaviours of different tool steels sliding against Al–Si-coated high-strength steel at elevated temperatures have been investigated by using a high-temperature version of the Optimol SRV reciprocating friction and wear tester at temperatures of 40, 400 and 800 °C. In these studies both temperature ramp tests with continuously increasing temperature from 40 to 800 °C and constant temperature tests at 40, 400 and 800 °C, have been conducted. The results have shown that both the friction and wear of tool steel/Al–Si-coated high-strength steel pairs are temperature dependent. Friction decreased with increasing temperature whereas wear of the tool steel increased with temperature. On the other hand, the Al–Si-coated high-strength steel showed significantly lower wear rates at 800 °C as compared to those at 40 and 400 °C. The Al–Si-coated surface undergoes some interesting morphological changes when exposed to elevated temperatures and these changes may affect the friction and wear characteristics. The mechanisms of these changes and their influence on the tribological process are unclear and further studies are necessary to fully explain these mechanisms.     

Effect of the reinforcement (carbon or glass fibres) on friction and wear behaviour of the PEEK against steel surface at long dry sliding

PEEK (poly-ether-ether-ketone) is a high performance engineering semicrystalline thermoplastic. PEEK has excellent tribological behaviour, which is optimised in the specially formulated tribological composite grade.This paper presents a comparative study of wear and friction on PEEK, PEEK-CF30 (wt%) and PEEK-GF30 (wt%) against steel, at long dry sliding. A plan of experiments was performed on a pin-on-disc machine, under the following conditions $pv=2\text{MPa}\text{m/s}$ (p = 8 MPa and $v=0.25\text{m/s}$; p = 2.68 MPa and $v=0.75\text{m}\text{/}\text{s}$) at the ambient temperature for a sliding distance of 15 km.PEEK-CF30 presented the lesser friction coefficient followed by PEEK. PEEK-GF30 presented the higher friction coefficient throughout all sliding distance. Both PEEK-CF30 and PEEK-GF30 have presented an excellent wear resistance relatively to PEEK while PEEK-CF30 presented the best tribological behaviour.     

Effect of temperature on the frictional behaviour of an aluminium alloy sliding against steel during ball-on-disc tests

Ball-on-disc tests were carried out at elevated temperatures to determine the friction behaviour of the 7475 aluminium alloy against steel, resembling the material mating during hot extrusion. Friction coefficient was found to increase markedly with rising temperature, suggesting that the commonly accepted assumption of an unvaried friction coefficient in the FE simulation of the aluminium extrusion process involving temperature evolution is incorrect. A theoretical analysis showed that the high friction values measured during high-temperature ball-on-disc tests could be partly attributed to the increased plowing friction caused by the severe deformation of the aluminium alloy. The effect of temperature on the stress and strain distributions at the ball/disc interface was revealed by means of three-dimensional finite-element (3D FE) simulation. Increased deformation in the aluminium disc around the contact point with rising temperature was confirmed. The alterations of the strain state and stress state around the contact point were considered responsible for the generation of wear debris, the oscillations of friction coefficient along the wear track and the increase of friction coefficient with rising temperature.     

Effect of rubber on tribological behaviors of polyamide 66 under dry and water lubricated sliding

The friction and wear behaviors of polyamide 66 (PA 66) and rubber-filled PA 66 (PA 66/SEBS-g-MA) composites were investigated on a block-on-wheel model friction and wear tester under dry sliding and water lubricating conditions. In order to further understand the wear mechanisms, the worn surfaces and scraps of samples were analyzed by scanning electron microscopy (SEM) and differential scanning calorimeter (DSC). The experimental results indicated that the wear mass loss and the friction coefficient of PA 66 decreased with the addition of rubber particles. The friction coefficients of PA 66 and PA 66/SEBS-g-MA composites under water lubricating condition are lower than those under dry sliding condition, but the wear mass losses are higher than those under dry sliding condition. The main wear mechanisms under dry sliding condition are the plastic deformation and mechanical microploughing. Whereas the main wear mechanisms under water lubricating condition are the mechanical microploughing and abrasive wear.     

Effect of cryogenic and QPQ compound treatment on the microstructures and performance of high speed steel

China’s High-speed steel cutting tools hold a considerable share in the global market.However,the overproduction of low-end HSS tools causes serious resource waste and low efficiency,which has become one of the major problems in the tool industry in China.So a new Surface Modification technology is developed,which can make the low-end HSS tools into the high-end ones.On the analysis of the mechanism of cryogenic and quenching-polish-quenching(QPQ),the cryogenic and QPQ compound treatment are studied by using φ8 HSS(M2) drills.The nitriding layer and the base of the drill bit are Studied and analyzed,and the mechanism of compound treatment is discussed by the technological parameters adjustment and the combination test of cryogenic,nitrogen,tempering procedures,and several analysis methods such as the optics metallographic microscope,the scanning electronic microscope (SEM),X-ray diffraction and micro hardness.The cutting test is done on the drills by cryogenic treatment,QPQ treatment and cryogenic and QPQ compound treatment separately.The results indicates that the cutting life of HSS (M2) drill can be increased dramatically by cryogenic and QPQ compound treatment.     

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.     

A study of the influence of steam treatment on the tribological behaviour of steel specimens

The influence of steam treatment (ST) on the tribological behaviour of steel was assessed by Falex, Schwingungsreibverschleiss (SRV) and Amsler tests performed either under dry conditions or using solid MoS₂, graphite, polytetrafluoroethylene (PTFE) or grease lubricants. ST produced a thin layer of magnetite containing small quantities of haematite. MoS₂ was found to be the best lubricant in Falex tests with normal test pieces. Only greaselubricated Amsler couples withstood the full testing cycle. The SRV tests were inconclusive because the endurance time was too short, only a few seconds with MoS₂ lubrication.The influence of ST varied in the Falex tests. No improvement was found with grease-lubricated journals and the load-carrying capacity of MoS₂-lubricated test pieces was decreased. However, it was beneficial for PTFE lubrication. In the Amsler tests the grease-lubricated disks were crazed and magnetite splinters were removed. The performance of the graphite lubricant was lowered by ST and the median lives of MoS₂- or PTFE-lubricated couples were increased although their reliability was impaired. In SRV tests, ST improved the performance of grease and MoS₂-lubricated test pieces. The test results do not confirm the reported improved behaviour of ST components, particularly cutting tools, in workshop practice.     

Effect of tool pin design on the microstructural evolutions and tribological characteristics of friction stir processed structural steel

In this research, friction stir processing (FSP) technique is applied for the surface modification of ST14 structural steel. Tungsten carbide tools with cylindrical, conical, square and triangular pin designs are used for surface modification at rotational speed of 400 rpm, normal force of 5 KN and traverse speed of 100 mm min⁻¹. Mechanical and tribological properties of the processed surfaces including microhardness and wear characteristics are studied in detail. Furthermore, microstructural evolutions and worn surfaces are investigated by optical and scanning electron microscopes. Based on the achievements, all designed pins were successfully applicable for low carbon steel to produce defect-free processed material. By the microstructural changes within the stirred zone, the processed specimen is obtained higher mechanical properties. This is due to the formation of fine grains as the consequence of imposing intensive plastic deformation during FSP; however, this issue is highlighted by using square pin design. In this case, minimum grain size of 5 μm and maximum hardness of 320 VHN, as well as, maximum wear resistance are all examined for the specimen modified by square pin.     

Studies on the tribological behaviour of two oil-soluble molybdenum compounds under reciprocating sliding conditions

The use of oil-soluble organo-molybdenum compounds in engine oils can help in fuel conservation by reducing engine friction and increase durability by improving wear characteristics. The tribological behaviour of molybdenum dialkyldithiophosphate (MoDDP) was studied with a SRV Optimal tester under reciprocating sliding conditions. The studies were conducted under nonconformal contact conditions on En-31 steel and conformal contact conditions on piston ring and liner materials. The results indicated that the frictional behaviour of these additives is shear sensitive. Shear sensitivity is influenced by materials, operating conditions and the interaction of MoDDP with additives present in the oil. MoDDP when used in base oil was found to increase the scuff resistance of ring and liner materials. The use of the additive reduced friction and wear (running in as well as normal) under nonconformal contact conditions, while under conformal contact conditions its effect was selective and limited.     

Effect of grain refinement and modification on the dry sliding wear behaviour of eutectic Al-Si alloys

The present study deals with an investigation of dry sliding wear behaviour of grain refined and or modified eutectic (Al-12Si) Al-Si alloy by using a Pin-On-Disc machine. The indigenously developed Al-1Ti-3B and Al-10Sr master alloys were used as grain refiner and modifier for the grain refinement of α-Al dendrites and modification of eutectic Si, respectively. Various parameters have been studied such as alloy composition, sliding speed, sliding distance and normal pressure. The cast alloys, master alloys and worn surfaces were characterized by SEM/EDX microanalysis. Results suggest that, the wear resistance of eutectic Al-Si alloys increases with the addition of grain refiner (Al-1Ti-3B) and or modifier (Al-10Sr). Further, the worn surface studies show that adhesive wear was observed in Al-12Si alloy in the absence of grain refiner and modifier. However, an abrasive and oxidative wear was observed when the grain refiner and modifier are added to the same alloy. Commercially available LM-6 (12.5%Si) alloy was used for comparison.     

Influence of the countermaterial on the dry sliding friction and wear behaviour of low temperature carburized AISI316L steel

Low temperature carburising (LTC) allows a significant hardness increase, with a consequent increase in wear resistance, without deteriorating corrosion behaviour. However, wear resistance strongly depends on contact conditions, therefore this work focuses on the dry sliding behaviour of LTC-treated AISI316L austenitic stainless steel against several countermaterials (AISI316L, LTC-treated AISI316L, hard chromium or plasma-sprayed Al₂O₃–TiO₂). LTC produced a hardened surface layer (C-supersaturated expanded austenite), which improved corrosion resistance in NaCl 3.5% and increased wear resistance, to an extent which depends on both normal load and countermaterial. The best results were obtained when at least one of the contacting bodies was LTC-treated, because this condition led to mild tribo-oxidative wear. However, LTC did not improve the behaviour in terms of friction.     

Effect of the addition of carbonaceous fibers on the tribological behavior of a phenolic resin sliding against cast iron

The tribological behavior of novolac phenolic resin matrix composites reinforced with three kinds of carbonaceous fibers was studied in sliding contact against cast iron. Slow pyrolysis was used to obtain carbonaceous fibers from Colombian plantain fiber bundles (crops residues from Urabá region). After the carbonization process the samples were heated up to either 1200 or 1400 °C ensuring that many morphological aspects of the natural fibers were retained. Then, novolac phenolic resin with HMTA as curing agent and the carbonaceous fibers were used to obtain a composite material by compression molding process. Samples with different type and volume fraction of carbonaceous fibers were prepared and tested in sliding contact against cast iron in a pin-on-disc wear testing machine. At the end of the tests, the worn surfaces and the debris were analyzed by SEM.A decrease in both friction coefficient and wear of composites was observed with the increase in fiber volume fraction, which was associated to a beneficial effect of the detachment of carbonaceous material from the worn surface. Under the tested conditions, this material remains at the interface between the composite and the cast iron and helps reduce the shear resistance of the interface. On the other hand, surface fatigue and adhesion wear was identified as the dominant wear mechanism of the phenolic resin matrix.     

Influence of heat treatment parameters on the lubricated sliding wear behaviour of a zinc-based alloy

This investigation deals with the observations made pertaining to the influence of the duration of heat treatment (ageing) on the sliding wear response of a zinc-based alloy. The heat treatment comprised of solutionizing followed by artificial ageing for different durations. Partially lubricated sliding wear tests were carried out at a fixed applied pressure, speed and distance.The heat-treated samples attained less strength and hardness but more elongation over the as-cast one. The wear rate and frictional heating initially decreased with increasing ageing duration. This was followed by the attainment of the minimum and then a reversal in the trend at longer durations of ageing. The tensile strength and hardness decreased with increasing duration of ageing and became stable beyond certain ageing period while elongation followed a reverse trend. The response of the samples has been substantiated through the fractographic features and characteristics of wear surfaces, subsurface regions and debris.     

Effect of cryogenic treatment on the matrix structure and abrasion resistance of white cast iron subjected to destabilization treatment

Effect of deep cryogenic treatment on the matrix structure and abrasion resistance of high chromium cast iron subjected to destabilization heat treatment has been investigated in this paper. The results show that, during the cryogenic treatment, the secondary carbides precipitate in austenite, which promote the transformation of retained austenite to martensite. The cryogenic treated alloys produced superior hardness and wear resistance (β) to the alloys without cryogenic treatment. When the bulk hardness and wear resistance (β) reach the maximum, there is still about 13% retained austenite in alloys. Cryogenic treatment cannot make retained austenite transform to martensite completely.     

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.