Wear Behavior of Composites Based on ZA-27 Alloy Reinforced by Al<Subscript>2</Subscript>O<Subscript>3</Subscript> Particles Under Dry Sliding Condition

In present study, the effect of Al₂O₃ particle reinforcement on the sliding behavior of ZA-27 alloy composites was investigated. The composites with 3, 5, and 10 wt% of Al₂O₃ particles were produced by the compocasting procedure. Tribological properties of unreinforced alloy and composite were studied, using block-on-disk tribometer under unlubricated sliding conditions at different specific loads and sliding speeds. The worn surfaces of samples were examined by the scanning electron microscopy (SEM). The test results revealed that those composite specimens exhibited significantly lower wear rate than the ZA-27 matrix alloy specimens in all combinations of applied loads and sliding speeds. The difference in the wear resistance of composite with respect to the matrix alloy, increased with the increase of the applied load/sliding speed and Al₂O₃ particle content. The highest degree of improvement of the ZA-27 alloy tribological behavior corresponded with change of the Al₂O₃ particles content from 3 to 5 wt%. At low sliding speed, moderate lower wear rate of the composites over that of the matrix alloy was noticed. This has been attributed to micro cracking tendency of the composites. Significantly reduced wear rate, experienced by the composite over that of the matrix alloy at the higher sliding speeds and loads, could be explained due to enhanced compatibility of matrix alloy with dispersoid phase and greater thermal stability of the composite in view of the presence of the dispersoid. Level of wear rate of tested ZA-27/Al₂O₃ samples pointed to the process of mild wear, which was primarily controlled by the formation and destruction of mechanical mixed layers (MMLs).     

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.     

Tribological behaviors and mechanisms of Ti<Subscript>3</Subscript>AlC<Subscript>2</Subscript>

Tribological behaviors and the relevant mechanism of a highly pure polycrystalline bulk Ti₃AlC₂ sliding dryly against a low carbon steel disk were investigated. The tribological tests were carried out using a block-on-disk type high-speed friction tester, at the sliding speeds of 20–60 m/s under a normal pressure of 0.8 MPa. The results showed that the friction coefficient is as low as 0.1∼0.14 and the wear rate of Ti₃AlC₂ is only (2.3–2.5) × 10⁻⁶ mm³/Nm in the sliding speed range of 20–60 m/s. Such unusual friction and wear properties were confirmed to be dependant dominantly upon the presence of a frictional oxide film consisting of amorphous Ti, Al, and Fe oxides on the friction surfaces. The oxide film is in a fused state during the sliding friction at a fused temperature of 238–324 °C, so it takes a significant self-lubricating effect.     

Influence of Al2O3 reinforcement on the abrasive wear characteristic of Al2O3/PA1010 composite coatings

In the present study, the abrasive wear characteristics of Al₂O₃/PA1010 composite coatings were tested on the turnplate abrasive wear testing machine. Steel 45 (quenched and low-temperature tempered) was used as a reference material. The experimental results showed that when the Al₂O₃ particles have been treated with a silane coupling agent (γ-aminopropyl-triethoxysilane), the abrasive wear resistance of Al₂O₃/PA1010 composite coatings has a good linear relationship with the volume fraction of Al₂O₃ particles in Al₂O₃/PA1010 composite coatings and the linear correlation coefficient is 0.979. Under the experimental conditions, the size of Al₂O₃ particles (40.5-161.0 μm) has little influence on the abrasive wear resistance of Al₂O₃/PA1010 composite coatings. By treating the surface of Al₂O₃ particles with the silane coupling agent, the distribution of Al₂O₃ particles in PA1010 matrix is more homogeneous and the bonding state between Al₂O₃ particles and PA1010 matrix is better. Therefore, the Al₂O₃ particles make the Al₂O₃/PA1010 composite coatings have better abrasive wear resistance than PA1010 coating. The wear resistance of Al₂O₃/PA1010 composite coatings is about 45% compared with that of steel 45.     

Surface nanostructuring of steel 35 by electrospark machining with electrodes based on tungsten carbide and added Al<Subscript>2</Subscript>O<Subscript>3</Subscript> nanopowder

The formation of an alloyed layer on steel 35 by VK8 hard alloy with added Al₂O₃ increases its wear resistance. Effective conditions for this process are determined. The formation of regular tungsten-carbide nanostructure is observed.     

Wear Resistance of the La<Subscript>62</Subscript>Cu<Subscript>12</Subscript>Ni<Subscript>12</Subscript>Al<Subscript>14</Subscript> Bulk Metallic Glass Under Dry Friction Conditions

The wear properties of a La₆₂Cu₁₂Ni₁₂Al₁₄ bulk metallic glass (BMG) using sliding wear system under the various normal loads and the annealing conditions have been investigated. Although the La₆₂Cu₁₂Ni₁₂Al₁₄ BMG is brittle during the tensile testing, it exhibits ductile behaviors during the sliding wear process. The SEM and the EDS analyses of the wear tracks and the debris after the sliding wear processes indicate that the wear mechanism is a combination of abrasion, adhesion, and oxidation. It is found that the wear resistance is significantly affected by the normal loads. With the increases in the wear load, the wear loss and the friction coefficient decrease. In addition, it is found that the wear properties are significantly affected by the annealing conditions. Compared with the annealed BMG alloys, the as-cast BMG alloy with a low hardness exhibits good wear resistance, which is attributed to the better ductility during the wear testing.     

Corrosive Wear and Mechanical Properties of Ni/Al2O3 Micro- and Nanoparticulates-Reinforced Coatings on Ti-6Al-4V Alloy

Nanocomposite coatings can endow a plated surface with various properties such as wear resistance, high-temperature corrosion protection, oxidation resistance, and self-lubrication. This work studies the corrosion and corrosive wear resistance of electroplated nickel nanocomposite coatings on Ti-6Al-4V alloy in a Hank's solution, adding various concentrations of an Al₂O₃ powder in plating solution, with particle diameters of 20–30 nm and 1 μm for comparisons. The experimental results showed that the content of Al₂O₃ incorporated into the electroplated nickel composite coating increased with the concentration of Al₂O₃ powder in the electroplating solution, and increasing the surface hardness, corrosion, and corrosive wear resistance of electroplated nickel micro- and nanocomposite coatings caused smearing of the nodule boundary and elimination of voids in the deposits. The Al₂O₃ nanoparticulates were embedded and distributed more uniformly than the Al₂O₃ microparticulates in the nickel matrix after a heat treatment of 400°C, producing a more continuous and dense coated composite layer on the Ti-6Al-4V substrate. This phenomenon is responsible for the Ni/Al₂O₃ composite coating with superior surface hardness, providing high corrosion resistance and corrosive wear protection to the Ti-6Al-4V alloy substrate in Hank's solution.     

Tribological Property of Ni<Subscript>3</Subscript>Al Matrix Composites with Addition of BaMoO<Subscript>4</Subscript>

The Ni₃Al matrix composites with addition of 10, 15, and 20 wt% BaMoO₄ were fabricated by powder metallurgy technique, and the tribological behaviors were studied from room temperature to 800 °C. It was found that BaAl₂O₄ formed during the fabrication process. The Ni₃Al composites showed poor tribological property below 400 °C, with high friction coefficients (above 0.6) and wear rates (above 10⁻⁴ mm³/Nm). However, the composites exhibited excellent self-lubricating and anti-wear properties at higher temperatures, and the composite with addition of 15 wt% BaMoO₄ had the lowest wear rate (1.10 × 10⁻⁵ mm³/Nm) and friction coefficient (0.26). In addition, the results also indicated that BaAl₂O₄ for the Ni₃Al composites did not exhibit lubricating property from room temperature to 800 °C.     

Comparison of the efficiency of modification of SHMPE by nanofibers (C,Al<Subscript>2</Subscript>O<Subscript>3</Subscript>) and nanoparticles (Cu,SiO<Subscript>2</Subscript>) when obtaining antifriction composites

The effect of various nanofillers (nanofibers of Al₂O₃ and carbon, nanopowders of copper and SiO₂) on the physico-mechanical and tribotechnical properties of superhigh-molecular polyethylene is investigated. It is determined that the modification of superhigh-molecular polyethylene by nanofibers and nanoparticles within the limits of 0.1–05 wt % results in a substantial rise in its deformation-strength characteristics and a multifold increase in its tribotechnical characteristics. By the methods of X-ray structure analysis, infrared spectroscopy, and electron microscopy, it is shown that modification of the polymer by the mentioned nanofillers results in the formation of an ordered (lamellar) permolecular structure. It is revealed that nanofibers form a stable film of friction transfer more quickly in comparison with nanoparticles. The optimum compositions of nanofillers, which determine the high wear resistance and the low constant of friction for polymer, are determined. The mechanical activation of the binder and filler powders provides a uniform distribution of the nanopowder within the binder and additionally enhances the physico-mechanical and tribotechnical properties of the composite.     

Reciprocating Sliding Friction and Wear Property of Fe<Subscript>3</Subscript>Si Based Alloys Containing Cu in Water Lubrication

Fe₃Si, Fe₃Si alloys containing Cu were fabricated by arc melting followed by hot-pressing. The friction and wear behaviors of Fe₃Si based alloys with and without Cu addition against Si₃N₄ ball in water-lubrication were investigated. The friction coefficient and the wear rates of Fe₃Si based alloys decreased as the load increased. The wear rate of Fe₃Si was higher than that of AISI 304. The addition of Cu can significantly improve the friction and wear properties of Fe₃Si based alloys and substantially reduce the wear rates of Si₃N₄ ball. The wear rate of Fe₃Si–10%Cu was 2.56 × 10⁻⁶ mm³ N⁻¹ m⁻¹ at load of 20 N and decreased to 1.64 × 10⁻⁶ mm³ N⁻¹ m⁻¹ at load of 90 N. The wear rate of Si₃N₄ ball against Fe₃Si–10%Cu was 1.41 × 10⁻⁶ mm³ N⁻¹ m⁻¹, while the wear rate of Si₃N₄ ball against AISI 304 was 5.20 × 10⁻⁶ mm³ N⁻¹ m⁻¹ at load of 90 N. The wear mechanism was dominated by micro-ploughing. The combination of mechanical action (i.e., shear, smear and transference of Cu) and tribochemical reaction of Si₃N₄ with water was responsible for the improved tribological behavior of Fe₃Si alloys containing Cu under high loads.     

Study on the Synthesis and Tribological Property of Fe<Subscript>3</Subscript>O<Subscript>4</Subscript> Based Magnetic Fluids

In this paper, Fe₃O₄ based magnetic fluids with different particle concentrations were prepared by the co-precipitation technique. The size of the Fe₃O₄ nanoparticles is about 13 nm and their shape is spherical. The tribological performances of the fluids with different concentration Fe₃O₄ nanoparticles were evaluated in a MMW-1A four-ball machine. The results show that the tribological performance of magnetic fluids with proper Fe₃O₄ nanoparticles can be improved significantly. The maximum nonseized load (P _B) has been increased by 38.4% compared with carrier liquid. The wear scar diameter has been reduced from 0.68 mm to 0.53 mm and the relative percentage in friction coefficient has decreased to 31.3%. The optimal concentration of the Fe₃O₄ nanoparticles in the carrier liquid is about 4 wt.%.     

Comparative study on tribology and microhardness of laser synthesized Ti-Al2O3/Zn coatings on Ti-6Al-4V alloy

ABSTRACT

The study of laser cladding of 90Ti-10Al₂O₃, 90Ti-8Al₂O₃-2Zn and 90Ti-4Al₂O₃-6Zn coatings onto Ti-6Al-4V alloy, with intention to produce defect-less, high microhardness and wear resistant coating was carried out. The coatings were deposited onto Ti-6Al-4V alloy at 900 W laser power and 0.6 m/min laser scan speed. Microstructures and phase constituents of the developed coatings were investigated by using a scanning electron microscope (SEM) and X-ray diffractometer correspondingly. Vickers microhardness tester and pin-on-disk tribometer were employed to characterize microhardness and wear behaviour of the Ti-Al₂O₃/Zn coatings respectively. SEM was also used to examine the worn track. It was observed that 90Ti-10Al₂O₃ coating yielded optimal microhardness along with maximal wear resistance in comparison to the other coatings and Ti-6Al-4V alloy. It has been established that laser cladding of Ti-Al₂O₃ coating with Zn contents on Ti-6Al-4V alloy alleviates the formation of cracks, however, microhardness and wear properties are negatively affected.     

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.     

Tribological duality of Ti<Subscript>3</Subscript>SiC<Subscript>2</Subscript>

We report here on the friction behavior of fine- and coarse-grained Ti₃SiC₂ against steel and Si₃N₄ balls. Two successive friction regimes have been identified for both grain sizes and both counterparts. First, Type I regime is characterized by a relatively low (0.1–0.15) friction coefficient, and very little wear. Sliding occurs between a tribofilm on the ball and the Ti₃SiC₂ plane when against steel. Then, a Type II regime often follows, with increased friction coefficients (0.4–0.5) and significant wear. Compacted wear debris seems to act as a third body resulting in abrasion of the ball, even in the case of Si₃N₄. The transition between the two regimes occurs at different times, depending on various factors such as grain size, type of pin, and normal load applied. Some experiments under vacuum showed that the atmosphere plays also a major role. The reason for this evolution is not fully clear at that time, but its understanding is of major technological importance given the unusual good properties of this material.     

A study on friction and wear characteristics of nanometer Al2O3 /PEEK composites under the dry sliding condition

The friction and wear properties of the polyetheretherketone (PEEK) based composites filled with 5 mass% nanometer or micron Al₂O₃ with or without 10 mass% polytetrafluroethylene (PTFE) against the medium carbon steel (AISI 1045 steel) ring under the dry sliding condition at Amsler wear tester were examined. A constant sliding velocity of 0.42 m s⁻¹ and a load of 196 N were used in all experiments. The average diameter 250 μm PEEK powders, the 15 or 90 nm Al₂O₃ nano-particles or 500 nm Al₂O₃ particles and/or the PTFE fine powders of diameter 50 μm were mechanically mixed in alcohol, and then the block composite specimens were prepared by the heat compression moulding. The homogeneously dispersion of the Al₂O₃ nano-particles in PEEK matrix of the prepared composites was analyzed by the atomic force microscopy (AFM). The wear testing results showed that nanometer and micron Al₂O₃ reduced the wear coefficient of PEEK composites without PTFE effectively, but not reduced the friction coefficient. The filling of 10 mass% PTFE into pure PEEK resulted in a decrease of the friction coefficient and the wear coefficient of the filled composite simultaneously. However, when 10 mass% PTFE was filled into Al₂O₃/ PEEK composites, the friction coefficient was decreased and the wear coefficient increased. The worn scars on the tested composite specimen surfaces and steel ring surfaces were observed by scanning electron microscopy (SEM). A thin, uniform, and tenacious transferred film on the surface of the steel rings against the PEEK composites filled with 5 mass% 15 nm Al₂O₃ particles but without PTFE was formed. The components of the transferred films were detected by energy dispersive spectrometry (EDS). The results indicated that the nanometer Al₂O₃ as the filler, together with PEEK matrix, transferred to the counterpart ring surface during the sliding friction and wear. Therefore, the ability of Al₂O₃ to improve the wear resistant behaviors is closely related to the ability to improve the characteristics of the transfer film.     

Dry-sliding Tribological Properties of Nano-Eutectic Fe<Subscript>83</Subscript>B<Subscript>17</Subscript> Alloy

This paper reports the tribological performance of the nano-eutectic Fe₈₃B₁₇ alloy under dry sliding against Si₃N₄ ceramic ball in ambient environment with varying applied loads and sliding speeds. Worn surfaces of the nano-eutectic Fe₈₃B₁₇ alloy were examined with a scanning electron microscope (SEM) and an X-ray energy dispersive spectroscope (EDS). The wear debris of the samples were also analyzed by X-ray diffractometer (XRD). The wear rate of the nano-eutectic Fe₈₃B₁₇ alloy was of the magnitude of 10⁻⁴ mm³/m, which was lower than that of the coarse grained Fe₈₃B₁₇ alloy. The friction coefficient of the nano-eutectic Fe₈₃B₁₇ alloy was almost the same as that of the coarse grained Fe₈₃B₁₇ alloy. The Fe₂SiO₄ oxide layer was formed on the worn surface of the nano-eutectic Fe₈₃B₁₇ alloy. However, on the worn surface of the coarse grained Fe₈₃B₁₇ alloy was found only a little Fe₂SiO₄. These results demonstrated that the nanostructure improved the wear resistance of the Fe₈₃B₁₇ alloy, but did not significantly affect the friction coefficient. The wear mechanism of the nano-eutectic Fe₈₃B₁₇ alloy was delamination abrasion mainly.     

Sliding wear characteristics of plasma-sprayed Al2O3 and Cr2O3 coatings against copper alloy under severe conditions

Al₂O₃ and Cr₂O₃ coatings were deposited by atmospheric plasma spraying and their tribological properties dry sliding against copper alloy were evaluated using a block-on-ring configuration at room temperature. It was found that the wear resistance of Al₂O₃ coating was superior to that of the Cr₂O₃ coating under the conditions used in the present study. This mainly attributed to its better thermal conductivity of Al₂O₃ coating, which was considered to effectively facilitate the dissipation of tribological heat and alleviate the reduction of hardness due to the accumulated tribological heat. As for the Al₂O₃ coating, the wear mechanism was plastic deformation along with some micro-abrasion and fatigue-induced brittle fracture, while the failure of Cr₂O₃ coating was predominantly the crack propagation-induced detachment of transferred films and splats spallation.     

Tribological Properties of a Nano-Eutectic Fe<Subscript>1.87</Subscript>C<Subscript>0.13</Subscript> Alloy Under Water Environment

Tribological properties of a nano-eutectic Fe_1.87C_0.13 alloy were investigated under distilled-water lubrication against AISI52100 steel ball for various applied loads and sliding speeds. For comparison, the tribological behavior of annealed coarse-grained Fe_1.87C_0.13 alloy was also examined under the same testing conditions. Worn surfaces of both alloys were analyzed by using a scanning electron microscope (SEM). The wear rate of nano-eutectic Fe_1.87C_0.13 alloy was on the order of 10⁻⁵ mm³/m. The wear rate of nano-eutectic Fe_1.87C_0.13 alloy was higher than that of annealed Fe_1.87C_0.13 alloy at lower load, but lower under higher load. The friction coefficients of the two alloys were similar and exhibited a slight increase with increasing sliding speed, but a small decrease with increasing applied load. The wear mechanism of the nano-eutectic Fe_1.87C_0.13 alloy was transformed from plowing and corrosion wear to slight fatigue cracking with increasing applied load, whereas that of the annealed coarse-grained Fe_1.87C_0.13 alloy was transformed from plowing and corrosion wear to severe fatigue flaking.     

Tribological Performance of Fe<Subscript>67</Subscript>B<Subscript>33</Subscript> Alloy Prepared by a Self-Propagating High-Temperature Synthesis Technique

A bulk Fe₆₇B₃₃ alloy was prepared by a self-propagating high-temperature synthesis technique that is convenient, low in cost, and capable of being scaled up for tailoring the bulk materials. The Fe₆₇B₃₃ alloy is composed of dendrites with the t-Fe₂B phase and eutectic matrix with the α-Fe and t-Fe₂B phases. The content of the dendrite t-Fe₂B is above 80 vol.%. The compressive fractured strength and Vickers microhardness are 3400 MPa and 12.4 GPa, respectively. The tribological performance of the Fe₆₇B₃₃ alloy is investigated under dry sliding and water lubricant against Si₃N₄ ceramic ball. The wear rates of the Fe₆₇B₃₃ alloy are of the magnitude of 10⁻⁵ to 10⁻⁴ mm³/m under water lubricant. It is lower than that of the Fe₆₇B₃₃ alloy under dry sliding (10⁻⁴ mm³/m). But both the friction coefficients are almost identical. Oxide layers form in both environments via different tribochemical mechanisms, which led to significant differences in wear behavior.     

Cutting performance of Si<Subscript>3</Subscript>N<Subscript>4</Subscript> based SiC ceramic cutting tools

Composites of Si₃N₄-SiC containing up to 30 wt% of dispersed SiC particles were fabricated via hot-pressing with an oxynitride glass. To determine the effect of sintering time and SiC content on the mechanical properties and the cutting performance, the composites with fixed 8 hr-sintering time and 20 wt% SiC content were fabricated and tested. Fracture toughness of the composites increased with increasing sintering time, while the hardness increased as the SiC content increased up to 20 wt%. The hardness of the composites was relatively independent of the grain size and the sintered density. For machining heat-treated AISI4140, the insert with 20 wt% SiC sintered for 8 hr showed the longest tool life while the insert with 20 wt% SiC sintered for 12 hr showed the longest tool life for machining gray cast iron. An effort was made to relate the mechanical properties, such as hardness, fracture toughness and wear resistance coefficient with the tool life. However, no apparent relationship was found between them. It may be stated that tool life is affected by not only the mechanical properties but also other properties such as surface roughness, density, grian size and the number of the inherent defects in the inserts.