Microstructural and Tribological Properties of A356 Al–Si Alloy Reinforced with Al<Subscript>2</Subscript>O<Subscript>3</Subscript> Particles

In the present study, the effect of the Al₂O₃ particles (average size of 12 μm, 3 and 10 wt.%) reinforcement on the microstructure and tribological properties of Al–Si alloy (A356) was investigated. Composites were produced by applying compocasting process. Tribological properties of unreinforced alloy and composites were studied, using pin-on-disc tribometer, under dry sliding conditions at different specific loads and sliding speed of 1 m/s. Microhardness measurements, optical microscope and scanning electron microscope were used for microstructural characterization and investigation of worn surfaces and wear debris. During compocasting of A356 alloy, a transformation from a typical dendritic primary α phase to a non-dendritic rosette-like structure occurred. Composites exhibited better wear resistance compared with unreinforced alloy. Presence of 3 wt.% Al₂O₃ particles in the composite material affected the wear resistance only at specific loads up to 1 MPa. The wear rate of composite with 10 wt.% Al₂O₃ particles was nearly two order of the magnitude lower than the wear rate of the matrix alloy. Dominant wear mechanism for all materials was adhesion, with others mechanisms: oxidation, abrasion and delamination as minor ones.     

Manufacturing and mechanical characterization of Al<Subscript>2</Subscript>O<Subscript>3</Subscript>/β-TCP/TiO<Subscript>2</Subscript> biocomposite as a potential bone substitute

This paper focuses on the mechanical characterization of a bioceramic based on commercial alumina (Al₂O₃) mixed with synthesized tricalcium phosphate (β-TCP) and commercial titania powder (TiO₂). The effect of β-TCP and TiO₂ addition on the mechanical performance was investigated. After a sintering process at 1600 °C for 1 h, various mechanical properties of the samples have been studied, such as compressive strength, flexural strength, tensile strength, elastic modulus, and fracture toughness. The measurements of the elastic modulus (E) and the tensile strength (σ _t ) were conducted using the modified Brazilian test while the compressive strength (σ _c ) was determined through a compression test. Also, semi-circular bending (SCB) specimens were used to evaluate the flexural strength (σ _f ) and the opening mode fracture toughness (K _IC). From the main results, it was found that the best mechanical performance is obtained with the addition of 10 wt.% TCP and 5 wt.% TiO₂. Alumina/10 wt.% tricalcium phosphate/5 wt.% titania composites displayed the highest values of mechanical properties and a good combination of compressive strength (σ _c ?≈?352 MPa), flexural strength (σ _f ?≈?98 MPa), tensile strength (σ _t ?≈?86.65 MPa), and fracture toughness (K _IC?≈?13 MPa m^1/2).     

Environmental Effects on the Tribology and Microstructure of MoS<Subscript>2</Subscript>–Sb<Subscript>2</Subscript>O<Subscript>3</Subscript>–C Films

The tribology of molybdenum disulfide (MoS₂)–Sb₂O₃–C films was tested under a variety of environmental conditions (ambient 50% RH, 10⁻⁷ Torr vacuum, 150 Torr oxygen, and 8 Torr water) and correlated with the composition of the surface composition expressed while sliding. High friction and low friction modes of behavior were detected. The lowest coefficient of friction, 0.06, was achieved under vacuum, while sliding in 8 Torr water and ambient conditions both yielded the highest value of 0.15. Water vapor was determined to be the environmental species responsible for high friction performance. XPS evaluations revealed a preferential expression of MoS₂ at the surface of wear tracks produced under vacuum and an increase in Sb₂O₃ concentration in wear tracks produced in ambient air (50% RH). In addition, wear tracks produced by sliding in vacuum exhibited the lowest surface roughness as compared to those produced in other environments, consistent with the picture of low friction originating from well-ordered MoS₂ layers produced through sliding in vacuum.     

Fabrication In Situ TiB<Subscript>2</Subscript>–TiC–Al<Subscript>2</Subscript>O<Subscript>3</Subscript> Multiple Ceramic Particles Reinforced Fe-Based Composite Coatings by Gas Tungsten Arc Welding

A Fe-based composite coating reinforced by multiple TiB₂–TiC–Al₂O₃ ceramic particles was developed by gas tungsten arc welding (GTAW) melting process. Mixture of aluminum (Al), boron carbide (B₄C), and titanium dioxide (TiO₂) powders was used as precursors, and as a consequence TiB₂–TiC–Al₂O₃ multiple ceramic particles were in situ synthesized during GTAW melting process. Microstructural investigations showed that TiB₂ particles exhibit a blocky morphology, TiC particles are of flower-like shape, and the Al₂O₃ particles exist as small black dots and located in the core of reinforced particles. The hardness and wear resistance of the coatings increased drastically in comparison with that of the substrate.     

Impact of Wire-EDM on Tribological Characteristics of ZrO<Subscript>2</Subscript>-based Composites in Dry Sliding Contact with WC–Co-Cemented Carbide

In the present investigation, experiments were conducted by unidirectional sliding of pins made of FCC metals (Pb, Al, and Cu) with significantly different hardness values against the steel plates of various surface textures and roughness using an inclined pin-on-plate sliding apparatus in ambient conditions under both the dry and lubricated conditions. For a given material pair, it was observed that transfer layer formation and the coefficient of friction along with its two components, namely adhesion and plowing, are controlled by the surface texture of the harder mating surfaces and are less dependent of surface roughness (R _a) of the harder mating surfaces. The effect of surface texture on the friction was attributed to the variation of the plowing component of friction for different surfaces. It was also observed that the variation of plowing friction as a function of hardness depends on surface textures. More specifically, the plowing friction varies with hardness of the soft materials for a given type of surface texture and it is independent of hardness of soft materials for other type of surface texture. These variations could be attributed to the extent of plane strain conditions taking place at the asperity level during sliding. It was also observed that among the surface roughness parameters, the mean slope of the profile, Δ _a, correlated best with the friction. Furthermore, dimensionless quantifiable roughness parameters were formulated to describe the degree of plowing taking place at the asperity level.     

Dry-Sliding Tribological Properties of Bronze–Graphite Composites

Bronze-uncoated and nickel-coated graphite composites were fabricated by powder metallurgy route. The tribological behaviors of composites sliding against AISI52100 steel ball under dry sliding condition were studied using a ball-on-disk tribometer. The nickel-coated graphite composites showed much better tribological properties in comparison with bronze and uncoated graphite composite. The friction coefficient of nickel-coated graphite composites decreased with increasing nickel-coated graphite content. However, the specific wear rate increased with the increase in nickel-coated graphite. The composite containing 15?wt% nickel-coated graphite showed the best self-lubricating properties because the compacted and stable mechanical mixed layer was formed on the worn surfaces. The wear mechanism of bronze 663 is adhesive wear and abrasive wear. The uncoated nickel-coated graphite composite shows the adhesive wear and delamination characteristics. However, the wear mechanism of nickel-coated composites is mildly abrasive wear.     

Assessment of critical level of shear stresses in tribocouples of Аl<Subscript>2</Subscript>O<Subscript>3</Subscript> and metal details of ITER blanket modules

The shear strength of plasma-sprayed electroinsulating Аl₂O₃ coating has been determined for blanket modules of a thermonuclear reactor in a friction couple with 316L(N)-IG steel and BrAZhNMts9-4-4-1 bronze. An analysis of the experimental and calculated data on the influence of shear stresses on the electric insulation of blanket modules has revealed the need to decrease the coefficient of friction to permissible level [f] = 0.28 in the range of contact pressures Р = 3–500 MPa.     

A photo-thermally stimulated exoemission technique used to study the properties of HTSC ceramics based on YBa<Subscript>2</Subscript>Cu<Subscript>3</Subscript>O<Subscript>7−δ</Subscript>

The method of photo-thermally stimulated exoelectron emission (PTSE) is used to study the processes in the surface layers of HTSC ceramics based on YBa₂Cu₃O_7–. A correlation is observed between variations of the exoemission current and the transition to the superconducting state. The experimentally detected hysteresis in the PTSE intensity of YBa₂Cu₃O_7– ceramics, when thermally cycled in the range T=80–160 K, is limited by two processes. Below T=90 K, the chemisorption has a significant effect on the physical phenomena under study, thus impeding the search for new PTSE regularities in HTSC ceramics. At the same time, exoemission properties of the ceramics considerably change in the range 80–160 K. It is also shown that the superconducting transition and the thermal absorption phenomena for an YBa₂Cu₃O_6.8 specimen are split in the studied temperature range, which allows the PTSE technique to detect the superconducting state and to observe the transition dynamics.Translated from Defektoskopiya, Vol. 40, No. 12, 2004, pp. 54–59.Original Russian Text Copyright © 2004 by Syurdo, Kortov, Milman, Slesarev, Mikhailovich.This revised version was published online in April 2005 with a corrected cover date.     

Tribological Properties of Self-Lubricating Polymer–Steel Laminated Composites

Self-lubricating polymer–steel laminated composites (SLC) consisting of matrix zones and filled zones were fabricated by a laminating–bonding process. The matrix zones were silicon steel sheets and the filled zones were polymer matrix filled with MoS₂ and graphite, respectively. The control specimen was prepared by spraying a polymer composite coating on a GCr15 disc. The tribological properties of SLC were investigated using a ball-on-disc tribometer under different loads and frequencies. Compared to the control specimen, the friction coefficient and wear rate of SLC was reduced by 57% and threefold at 4 N and 6 Hz, respectively. In addition, the friction coefficient of SLC was low and stable under low reciprocating frequency, and it was high and fluctuating under high reciprocating frequency. In addition, the wear rate increased with increasing applied load and reciprocating frequency. Scanning electron microscopy (SEM) images show that the lubricating mechanism of SLC was that solid lubricants embedded in filled zones expanded and smeared a layer of transfer film on the sliding path to lubricate the surface. The thermal expansion of solid lubricants was simulated using ANSYS software with thermal-stress coupling. The simulation results showed the maximum temperature of the filled zones was 130°C, and the maximum normal displacement of solid lubricants was approximately 10 μm. This confirmed that the solid lubricants expanded effectively by the aid of frictional heat.     

Spectrometry analysis of fumes of (U<Subscript>0.80</Subscript>Pu<Subscript>0.20</Subscript>)O<Subscript>2</Subscript> hybrid nuclear fuel samples heated to a temperature of 2000°C

The results of the spectrometry analysis of a gaseous cloud that forms over (U_0.80Pu_0.20)O₂ hybrid uranium-plutonium fuel samples for reactors, which were heated to a temperature of >2000°C, are described. Samples were heated using a laser facility designed for conducting out-of-pile experiments with the nuclear fuel. The obtained results will make it possible to empirically forecast the isotopic composition of volley emissions from the reactor core during accidents on the 1000-MW power reactor with the (U_0.80Pu_0.20)O₂ hybrid fuel.     

Sliding Wear of Electrically Conductive ZrO<Subscript>2</Subscript>−WC Composites Against WC–Co Cemented Carbide

ZrO₂-based composites with WC addition can be successfully machined by electrical discharge machining (EDM) in demineralised water. ZrO₂ composites with 40 vol.% WC were produced from nanocrystalline and micrometre sized WC starting powders in order to compare their tribological behaviour. Friction and wear data are obtained on wire-EDM’ed ZrO₂–WC composite flats sliding against a WC–Co cemented carbide pin using a small-scale pin-on-plate testing rig. Correlations between wear volume, wear rate and friction coefficient on the one hand and material properties and test conditions on the other hand were elucidated. The experimental results revealed that the grain size of the electro-conductive WC-phase exhibits a strong influence on the friction and wear behaviour of the ZrO₂-based composite.     

Microstructure,chemical composition,wear, and corrosion resistance of FeB–Fe<Subscript>2</Subscript>B–Fe<Subscript>3</Subscript>B surface layers produced on Vanadis-6 steel using CO<Subscript>2</Subscript> laser

The paper presents the study results of laser modification of FeB–Fe₂B surface layers produced on Vanadis-6 steel using pack cementation method. Microstructure, x-ray phase analysis, chemical composition study using wave dispersive spectrometry method, microhardness, corrosion resistance as well as surface condition, roughness, and wear resistance were investigated. The diffusion boronizing processes were performed at 900 °C for 5 h in the EKabor® powder mixture. The boronized layers had a dual-phase microstructure composed of two types of iron borides, FeB and Fe₂B, and their microhardness ranged from 1800 to 1400 HV. The laser surface modification was carried out on specimens after diffusion boronizing process using CO₂ laser with a nominal power of 2600 W. Laser beam power used in this experiment was equal to 1040 W and was constant. While the three values of scanning speed were used: 19, 48, and 75 mm/s. During laser modification, the multiple tracks were made where distance between of axis tracks was equal to 0.5 mm. As a result of this process, microstructure consisted of remelted zone, heat-affected zone, and substrate was obtained. In remelted zone, the boron-martensite eutectic was observed. Boronized layers after laser modification were characterized by the mild gradient of microhardness from surface to the substrate and their value was dependent on the scanning speed used and was between 1700 and 1100 HV. Corrosion resistance tests revealed reducing the current of corrosion in case of laser modification process. Wear resistance of laser modified specimens was improved in comparison to diffusion boronized layers.     

Effects of Deposition Conditions and Counter Bodies on the Tribological Properties of Pulsed DC Magnetron Sputtered TiN–MoS<Subscript><Emphasis Type="Italic">x</Emphasis></Subscript> Composite Coating

In the current study, TiN–MoS _x composite coatings were deposited by co-sputtering of MoS₂ and Ti targets under a mixture of Ar and N₂ gas environment using pulsed DC closed-field unbalanced magnetron sputtering. The tribological response of TiN–MoS _x composite coatings was studied against two different counter bodies: cemented carbide (WC–6% Co) ball and pin made of aluminium alloy (AlSiMg). First, the effect of substrate bias was studied on tribological properties using cemented carbide ball. Lowest coefficient of friction in the range of 0.03–0.04 was obtained for the specimen deposited at a substrate bias of −60 V. Wear coefficient was also found to be minimum for the same specimen. Coatings were further deposited at an optimum bias of −60 V in order to vary MoS _x content of TiN–MoS _x composite coating. Effect of variation of chemical composition of the coating was then studied on tribological performance of the coating against aluminium alloy counterface. Excellent anti-sticking property of MoS _x was found to have enabled the TiN–MoS _x composite coating to achieve considerably low coefficient of friction against aluminium alloy. It was shown that with optimum MoS _x content of TiN–MoS _x composite coating, it was possible to attain as low coefficient of friction as 0.09 against aluminium alloy even under normal atmospheric condition.     

Abrasive and Adhesive Wear Behavior of Arc-Evaporated Al<Subscript>1−<Emphasis Type=Italic>x</Emphasis></Subscript>Cr<Subscript><Emphasis Type=Italic>x</Emphasis></Subscript>N Hard Coatings

During the last decade, the usage of difficult-to-machine materials such as austenitic stainless steels has increased continuously in various industrial applications. Tools such as blind hole taps, punches, or deep drawing molds are often exposed to severe wear while machining/forming these materials, mainly due to excessive adhesion and material transfer. On combination with abrasive wear due to work-hardened wear debris, tool lifetime in these applications is often limited. In this study, ball-on-disc experiments were carried out with arc-evaporated AlCrN coatings with different Al/(Al + Cr) ratios against Al₂O₃ and austenitic stainless steel balls in ambient atmosphere. Test temperatures of 25, 500, and 700°C were chosen for the hard Al₂O₃ balls simulating severe abrasive loads, whereas 25, 150, and 250°C were used for the softer stainless steel material to evaluate the adhesive wear behavior. Characterization of the wear tracks was done by scanning electron microscopy in combination with energy-dispersive X-ray analysis and optical profilometry. The best abrasive wear resistance during testing against Al₂O₃ was observed for the coating with the highest Al content. In the case of the austenitic stainless steel balls, sticking of the ball material to the coating surface was the dominating wear mechanism. The influence of test temperature, chemical composition, and surface roughness was studied in detail.     

Development of a time-of-flight measurement technique in plasma induced by a СO<Subscript>2</Subscript> laser

Experiments on the irradiation of a carbon target with СО₂-laser pulses in the free-running mode at a radiation-flux density of 1.3 × 10¹¹ W/cm² and the time-of-flight technique for measuring the characteristics of the plasma ion component are described. The characteristics of the ion component of plasma that expands along the normal to the target and the statistical spread of the mean values were obtained. As a result of the measurements, the energy spectra of the plasma expansion and the partial ion currents at a chosen distance of the plasma drift from the target were reconstructed. The high time resolution of this technique made it possible to reconstruct the escape times of individual groups of ions from a heated region on the scale of the duration of the heating laser pulse.     

Dependences of the optical characteristics of Al<Subscript><Emphasis Type="Italic">x</Emphasis></Subscript>Ga<Subscript>1−<Emphasis Type="Italic">x</Emphasis></Subscript>N films on the substrate composition and polarity

Optical properties of Ga- and N-polar triple nitrides Al _x Ga_1−x N with molar fractions of aluminum from 0 to 0.6 are studied by a nondestructive contactless method of spectroscopic ellipsometry. Correlation dependences of the shift of the fundamental absorption edge and the behavior of the real and imaginary parts of the pseudodielectric function on the composition x and polarity of the Al _x Ga_1−x N layers are revealed. It is verified that the polarity of the layers grown by molecular beam epitaxy is defined by the formation of the AlN nucleating layer.     

Dry Sliding Wear Behavior of (Cr,Fe)<Subscript>7</Subscript>C<Subscript>3</Subscript>-γ(Cr,Fe) Metal Matrix Composite (MMC) Coatings: The Influence of High Volume Fraction (Cr,Fe)<Subscript>7</Subscript>C<Subscript>3</Subscript> Carbide

The high volume fraction (Cr, Fe)₇C₃ carbide particle-reinforced metal matrix composite (MMC) coatings with different Cr/C ratios were produced by flux-cored arc welding (FCAW). The in situ synthesized effectiveness of (Cr, Fe)₇C₃ carbide in the coatings was studied by the aid of CALPHAD and differential scanning calorimeter. The microstructure of the coatings was observed by optical microscope and field emission scanning electron microscope, and their phases were determined by the X-ray diffraction. Meanwhile, the hardness and wear resistance of the coatings were measured. The results show that the (Cr, Fe)₇C₃ carbide can be in situ synthesized in the coatings. With decreased Cr/C ratio, the in situ synthesized effectiveness of (Cr, Fe)₇C₃ carbide is improved and the mass fraction of the (Cr, Fe)₇C₃ carbide is increased. The microstructure of the coatings consists of in situ synthesized (Cr, Fe)₇C₃ carbide and eutectic (Cr, Fe)₇C₃/ γ (Cr, Fe) matrix. The hexagonal-rod-form (Cr, Fe)₇C₃ carbide can be fractured and segregated from austenite-matrix under a relatively high load force (50 N), and transforms the wear state from two-body-abrasion to three-body-abrasion, which facilitates the coating be seriously abraded and even adhered. The wear resistance of the MMC coatings can be effectively improved by the formation of high volume fraction of (Cr, Fe)₇C₃ carbide.     

Tribological Properties and Wear Mechanisms of NiCr–Al2O3–SrSO4–Ag Self-Lubricating Composites at Elevated Temperatures

NiCr–Al₂O₃–SrSO₄–Ag self-lubricating composites were prepared by powder metallurgy method and the tribological properties of composites were evaluated by a ball-on-disk tribometer against alumina ball at wide temperature range from the room temperature to 1,000 °C in air. The linear coefficient of thermal expansion was evaluated for investigation of thermal stability of composites. The tribo-chemical reaction films formed on the rubbing surfaces and their effects on the tribological properties of composites at different temperatures were addressed according to the surface characterization by SEM, XRD, and XPS. The results show that the NiCr–Al₂O₃ composite with addition of 10 wt% SrSO₄ and 10 wt% Ag exhibits satisfying friction and wear properties over the entire temperature range from room temperature to 1,000 °C. The composition of the tribo-layers on the worn surfaces of the composites is varied at different temperatures. The synergistic lubricating effect of SrAl₄O₇, Ag, and NiCr₂O₄ lubricating films formed on worn surfaces were identified to reduce the friction coefficient and wear rate from room temperature to 800 °C. Meanwhile, at 1,000 °C, the SrCrO₄ and NiAl₂O₄ was formed on the worn surfaces during sliding process, combining with the NiCr₂O₄, Al₂O₃, Cr₂O₃, Ag, and Ag₂O, which play an important role in the formation of a continuous lubricating film on the sliding surface.     

Dynamics of Growth of the Native Oxide of Cd<Subscript><Emphasis Type="Italic">x</Emphasis></Subscript>Hg<Subscript>1−<Emphasis Type="Italic">x</Emphasis></Subscript>Te

The growth of the native oxide of the Cd_xHg_1?xTe (MCT) compound is studied by methods of laser and spectral ellipsometry. It is found that a non-absorbing oxide film is formed from the very beginning in the case of MCT oxidation with hydrogen peroxide vapors, whereas oxidation with atmospheric oxygen leads to the formation of absorbing layers on the surface at the first stages of the process. When the oxide film thickness reaches 1–2 nm, the oxidation rate drastically decreases. If MCT samples that were stored for a long time (for years) in air at room temperature are heated at T = 200 °C, the optical thickness of the oxide film decreases.     

Characteristics of a pulse–periodic CO<Subscript>2</Subscript> laser for applications in the field of laser-produced plasma

The design of a pulse–periodic СО₂ laser oscillator that operates at a high level of the specific energy deposition into a self-sustained discharge is described. The laser is intended for generating pulses with a high-density radiation flux in a laser-plasma generator of multiply charged ions at the Institute of Theoretical and Experimental Physics (ITEP). The results of investigations of the spatiotemporal and energy characteristics of laser output radiation in a wide range of the discharge excitation level and the mixture composition are presented. The optimal conditions are determined under which the oscillator provides an output energy of >10 J in a pulse with a duration of ~28 ns and a record specific peak radiation power of 190 MW per liter of the active volume of a CO₂: N₂: He mixture. The high quality of the spatial characteristics was confirmed in measurements of the radial energy-density distribution in the far-field zone, whose characteristic size is close to the diffraction limit.