超音速火焰喷涂WC-Co涂层耐磨性研究

利用超音速火焰喷涂（HVOF）工艺制备了WC-Co涂层，测定了涂层孔隙率、显微硬度及干摩擦磨损过程中涂层材料失重，得出涂层干摩擦因数随时间的变化关系，分析了涂层摩擦磨损机制。结果表明，WC-Co涂层致密，平均孔隙率为1．29％，显微硬度达1140HV（测试载荷2．94N），干摩擦条件下材料失重低于电镀Cr镀层2个数量级；摩擦初期，干摩擦因数迅速增加，主要磨损特征是粘结相富Co区的犁沟切削，摩擦中后期，摩擦副间实际接触面积增大，摩擦因数变化较小，磨损趋于稳定。WC-Co涂层的主要磨损机制是疲劳磨损和犁沟切削。     

Wear mechanisms in ball-cratering tests with large abrasive particles

Three-body abrasive wear resistance of mild steel and 27%Cr white cast iron was investigated using a ball-cratering test. Glass beads, silica sand, quartz and alumina abrasive particles with sizes larger than 200 μm were used to make slurries. It was found that the wear rates of mild steel increased with sliding time for all abrasive particles tested, while the wear rates of 27%Cr white cast iron were almost constant with sliding time. This increase in the wear rates of mild steel was mainly due to the gradual increase in ball surface roughness with testing time. Abrasive particles with higher angularity caused higher ball surface roughness. Soft mild steel was more affected by this ball surface roughness changes than the hard white cast iron. Generally, three-body rolling wear dominated. The contribution of two-body grooving wear increased when the ball roughness was significant. The morphological features of the wear scars depended on the shape of the abrasive particles and also on the hardness and microstructure of the wear material. Angular particles generated rough surfaces similar to those usually observed in high angle erosion tests. Rounded particles generated smoother surfaces with the middle area of the wear craters having similar morphology to those observed in low angle erosion.     

Fretting wear behavior of nanocrystalline surface layer of pure copper under oil lubrication

Lubricated fretting tests in mineral oil were performed with a nanocrystalline surface layer on a pure bulk Cu prepared by surface mechanical attrition treatment (SMAT) against a WC-Co ball. It was found that the nanocrystalline surface layer exhibited a markedly enhanced fretting wear resistance and higher friction coefficient relative to the coarse-grained (CG) form. The wear volume of the SMAT Cu is one order of magnitude lower than that of the CG Cu. The friction coefficient of the SMAT Cu increases with an increasing load and frequency, while for the CG Cu, the friction coefficient increases with an increasing fretting frequency up to 100 Hz and thereafter decreases. The higher hardness of the SMAT Cu is suggested to be the main factor causing its improved wear resistance and higher friction coefficient. A discontinuous metal transfer layer can be found on the WC-Co ball only after fretting against the SMAT Cu, which may partly account for the higher wear resistance of the SMAT Cu in comparison with the CG Cu.     

Ball-cratering abrasion tests with large abrasive particles

The application of a ball-cratering method to test three-body abrasive wear of bulk materials in the presence of large abrasive particles has been investigated. Four types of abrasive particles of different sharpness were used to make slurries: glass beads, silica sand, crushed quartz and alumina. All the particles were sieved to a size of 250–300 μm. Two common industrial materials, mild steel and 27% Cr white cast iron, were used as wear samples. Wear rates of metallic samples were determined and the worn surfaces were examined by optical microscopy, SEM and Talysurf profilometry.It was found that the surface roughness of the ball significantly affects the wear rates and the wear mechanisms of the metallic samples. The surface roughness of the ball steadily increased with testing time and was mainly affected by the angularity of abrasive particles. More angular particles generated higher ball surface roughness. It was found that the gradual increase in the ball surface roughness was responsible for non-linearity of wear rates with sliding time. The increasing depth of the wear craters also contributed to this non-linearity as deeper craters facilitate particle entrainment. Three-body rolling wear dominated when the ball was smooth and the contribution of two-body grooving wear increased with increasing the ball roughness. Softer mild steel samples were more affected by the ball roughness changes than the harder white cast iron samples. Wear surface morphology was also affected by the angularity of particles and by the material properties of wear samples. Particle fracture was found in all four groups of abrasives and the angularity of the particles was slightly altered. Therefore, the ball-cratering test, under the testing conditions used, can be considered as a high-stress abrasion test.     

Dynamic SEM Wear Studies of Tungsten Carbide Cermets

Dynamic friction and wear experiments were conducted in a scanning electron microscope. The wear behavior of pure tungsten carbide and composite with 6 and 15 weight percent cobalt binder was examinded. Etching of the binder was done to selectively determine the role of the binder in the wear process. Dynamic experiments were conducted as the WC and bonded WC cermet surfaces were transversed by a 50 micron radiused diamond stylus. These studies show that the predominant wear process in WC is fracture initiated by plastic deformation. The wear of the etched cermets is similar to pure WC. The presence of the cobalt binder reduces both friction and wear. The cementing action of the cobalt reduces granular separation and promotes a dense polished layer because of its low shear strength film-forming properties. The wear debris generated from unetched surface is approximately the same composition as the bulk.     

The interaction between two wearing surfaces I: Copper sliding on Cu-Be and Cu-Be sliding on Cu-Be

The work reported in this paper is an investigation of the interaction of the two components of a wear system with reference to the physical properties of both components. Copper sliding on Cu-Be and Cu-Be sliding on Cu-Be were studied using a ball-on-disc machine, Auger spectroscopy and microhardness measurements. The two systems are found to be qualitatively similar classic examples of severe wear. The wear of a Cu-Be disc sliding under a copper ball is, however, greater than the wear of a Cu-Be disc sliding under a Cu-Be ball. This is attributed to work hardening of the copper ball resulting from an interaction between the two wearing surfaces. Microhardness measurements show that the surface of a Cu-Be ball and a Cu-Be disc are not work hardened during a wear experiment. The surface of a copper ball is work hardened, however, and becomes significantly harder than the wear scar on a Cu-Be ball. As a result the Cu-Be disc wears at a faster rate when sliding under a copper ball than it does when sliding under a Cu-Be ball.     

Influence of electrical discharge machining on the reciprocating sliding wear response of WC-Co cemented carbides

A number of commercially available WC-Co-based cemented carbides with 6 up to 12 wt.% Co were machined and surface finished by grinding as well as by wire electrical discharge machining (EDM) in demineralised water through a number of consecutive gradually finer EDM regimes. Comparative dry reciprocating sliding wear experiments on both wire-EDM and ground samples against WC-Co pins were conducted, using a pin-on-plate test rig, in order to investigate the influence of the EDM process on the tribological behavior. The worn surfaces of the investigated cemented carbides were scanned topographically and characterised by scanning electron microscopy (SEM). The post-mortem obtained wear volumes were compared to the online measured wear in order to determine correlations between wear volume and wear rate on the one hand and sliding distance on the other hand. The experimental results revealed a profound influence of surface finish conditions and distinctive EDM regimes on the wear behavior of WC-Co cemented carbides.     

电场对WC-Co/Ti6Al4V摩擦磨损性能的影响

为了研究电场对摩擦副摩擦磨损性能的影响,在自行设计的高速摩擦磨损试验装置上,进行了WC-Co/Ti6Al4V摩擦副的摩擦磨损试验。结果表明：断开摩擦副热电回路可以有效地减小热电流对WC-Co/Ti6Al4V摩擦副摩擦磨损的影响,静电冷却环境下形成的强电场的效果更加明显,在抑制摩擦副磨损的同时还可以改善
Ti6Al4V磨损表面质量。通过扫描电镜及EDS能谱分析可知,静电冷却条件下的列宾捷尔效应削弱了钛合金的黏着能力,从而有效地减小了WC-Co的黏着磨损;WC-Co在高速摩擦时主要以黏着磨损、氧化磨损为主,同时伴有微裂纹的产生。
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Scuffing Performance of Amorphous Carbon During Dry-Sliding Contact

Scuffing is a major problem that limits the life and reliability of sliding tribo-components. When scuffing occurs, friction force rises sharply and is accompanied by an increase in noise and vibration; severe wear and plastic deformation also occur on the damaged surface. Attempts have been made over the years to combat scuffing by enhancing the surface properties of the machine elements, and by methods involving lubricant formulation and coating application.

In this study, the authors evaluated the scuffing performance of an amorphous, near-frictionless carbon (NFC) coating that provides super-low friction under dry sliding conditions. The test configuration used a ball-on-flat contact in reciprocating sliding. The coating was deposited on HI3 steel. An uncoated 52100 steel ball was tested against various coated flats in room air. Compared to uncoated surfaces, the carbon coating increased the scuffing resistance of the sliding surfaces by two orders of magnitude. Microscopic analysis shows that scuffing occurred on coaled surfaces only if the coating had been completely removed. It appears that depending on coating type, the authors observed that coating failure occurs before scuffing failure by one of two distinct mechanisms: the coating failed in a brittle manner and by spoiling, or by gradual wear.     

Sliding wear behavior of nanocrystalline nickel coatings: Influence of grain size

In the present study the sliding wear behavior of pulse electrodeposited nanocrystalline Ni coatings as a function of grain size including bulk annealed Ni has been systematically studied using pin-on-disc configuration against the WC-Co counter body. The sliding wear has been analyzed with respect to wear rate, coefficient of friction, subsurface deformation and composition of wear debris. The result indicates that the sliding wear rate and coefficient of friction of Ni decreases with decreasing grain size. The subsurface beneath the worn pin surface is composed of a near surface shear region and beneath it a region of bulk plastic deformation. The ratio of the depth of the shear region to the depth of bulk deformed region decreases with decreasing grain size indicating a greater localization of near surface deformation with decreasing grain size.     

Effects of Normal Load,Sliding Speed,and Surface Roughness on Tribological Properties of Niobium under Dry and Wet Conditions

The effects of normal load, sliding speed, and surface roughness on the friction and wear of high-purity niobium (Nb) during sliding without and with an introduction of water were systematically investigated. Increasing the normal load or sliding speed decreased the friction of the Nb under the both dry and wet conditions because the increased wear of the Nb decreased the interfacial shear strength between the steel ball and Nb by promoting the surface roughening and the production of wear debris. However, the Nb tested at the lowest sliding speed under the lowest normal load with water exhibited the lowest friction and wear due to the formation of oxide layer on the wear track. The friction and wear of the Nb tested under the dry condition decreased with increased surface roughness because the higher interfacial shear strength between the steel ball and smoother Nb resulted in the earlier breakdown of the native oxide layer and direct contact between the steel ball and Nb. However, increasing the surface roughness of the Nb increased its friction and wear under wet conditions, probably due to the easier breakdown of the oxide layer that formed on the rougher surface during sliding. The tribological results clearly showed that the introduction of water during sliding had a significant influence on the tribological properties of the Nb.     

Fine-particle slurry wear resistance of selected tungsten carbide thermal spray coatings

The surface degradation of tungsten carbide based thermal spray coatings when exposed to fine-particle slurry abrasion has been investigated. The coatings that were studied contain binder-phase constituents consisting of either nickel or cobalt. The coatings were deposited onto test cylinders using a detonation gun device. After applying approximately 0.15 mm thickness of thermal spray coating, the coatings were ground, then diamond polished to achieve surface roughnesses of 0.03 μm Ra or less. The coatings were exposed to a three-body abrasive wear test involving zirconia particles (less than 3 μm diameter) in a water-based slurry. Results show that preferential binder wear plays a significant role in the wear of these tungsten carbide coatings by fine abrasives. In the comparison presented here, the coating containing nickel-based binder with a dense packing of primary carbides was superior in terms of retaining its surface finish upon exposure to abrasion. The coating containing a cobalt binder showed severe surface degradation.     

Friction and dry sliding wear behaviour of cermets

The friction and wear behaviour of cermets/steel rubbing pairs were investigated. Friction and wear tests were carried out using three different crèmets on the base of tungsten, titanium and chromium carbides under dry sliding conditions against steel disk (0.45% C). Sliding wear tests were carried out using modified block-on-ring equipment at a sliding speed of 2.2 m/s and normal load 40 N.It is shown that wear resistance and coefficient of friction depend on the type and chemical composition of the cermets. The WC–Co cermets have the highest wear resistance. The wear rate of WC–Co and TiC–NiMo cermets increased with increasing binder content in the cermets. The wear of Cr₃C₂–Ni cermets is more complicated and depends on the composition of cermets. The wear of WC–Co cermets is caused mainly by preferential removal of the cobalt binder, followed by fracture of the intergranular boundaries and fragmentation of the carbide grains. The main wear mechanism in the TiC–NiMo cermets is polishing (micro-abrasion) and adhesion, resulting in a low wear rate. The main wear mechanism of Cr₃C₂–Ni cermets involves thermal cracking and fatigue-related crushing of large carbide grains and carbide framework and also adhesion.     

Tribochemical effects on the friction and wear behaviors of diamond-like carbon film under high relative humidity condition

Friction and wear behaviors of diamond-like carbon (DLC) film in humid N₂ (RH-100%) sliding against different counterpart ball (Si₃N₄ ball, Al₂O₃ ball and steel ball) were investigated. It was found that the friction and wear behaviors of DLC film were dependent on the friction-induced tribochemical interactions in the presence of the DLC film, water molecules and counterpart balls. When sliding against Si₃N₄ ball, a tribochemical film that mainly consisted of silica gel was formed on the worn surface due to the oxidation and hydrolysis of the Si₃N₄ ball, and resulted in the lowest friction coefficient and wear rate of the DLC film. The degradation of the DLC film catalyzed by Al₂O₃ ball caused the highest wear rate of DLC film when sliding against Al₂O₃ ball, while the tribochemical reactions between DLC film and steel ball led to the highest friction coefficient when sliding against steel ball.     

Wear durability studies of ultra-thin perfluoropolyether lubricant on magnetic hard disks

This paper presents wear and friction studies on ultra-thin (~2 nm) film of perfluoropolyether (PFPE) coated on glass substrate magnetic hard disks. The lubricant was coated on the disk by the dip-coating method and the tribological tests were carried out by sliding a 3 mm diameter glass ball slider (normal load=20 mN) on the rotating disk surface. Lube thickness and lube wear profile were measured using an ellipsometer whereas the worn disk surface was studied using a surface reflectivity analyzer. The sliding speed and the lube bonding conditions were varied during the test. From the results, it is concluded that about 80% bonding of the lube to the disk surface leads to an increase in the wear durability of the lubricant by a factor of 2 when compared to the as-lubed condition. Lube bonding has an effect on increasing the coefficient of friction. Initially, increasing sliding speed increases both friction and wear but for very high sliding speed these values tend to decrease. The glass ball surface showed wear due to asperity interactions as well as lube transfer from the disk to the glass surface.     

Quantification of wear,strain and heat energy consumption rates for sliding steel ball against diamond-like carbon coatings

Abstract

In this work, we evaluated the different energy consumption rates associated with the total frictional energy for a ball sliding on a flat surface. The energy generated by the sliding two bodies in contact is dissipated into the materials in various forms. The wear consumption energy for a steel ball against a diamond-like carbon surface was evaluated by the wear coefficient of the wear volume–energy input equation. The strain energy generated in the steel ball as a result of being made to slide under a certain load was calculated using the Hertzian theory. The chemical reaction energy was estimated based on iron oxidation. Finally, the frictional energy dissipated as heat was obtained by subtracting the wear and the strain energies from the total frictional energy.     

Influence of Surface Roughness on the Transfer Film Formation and Frictional Behavior of TiC/a-C Nanocomposite Coatings

Influence of surface roughness on the friction of TiC/a-C nanocomposite coatings while sliding against bearing steel balls in humid air was examined by detailed analyses of the wear surfaces and the wear scar on the ball counterparts by atomic force microscopy, optical, and confocal microscopy. It was observed that the surface roughness of the coatings essentially determines the wear behavior of the ball counterpart, which consequently influences the transfer film formation. A rough coating causes abrasive wear of the steel ball during the running-in period, which impedes the formation of a stable transfer film and leads to higher values of coefficient of friction (CoF). Moreover, the CoF does not show a decreasing trend after the running-in period, although the roughness of the coating was greatly reduced. Replacing the worn ball with a new one after the running-in period yields lower CoF values similar to that observed for a smooth coating. In both of the cases, no wear of the steel ball occurs and a stable transfer film forms and effectively covers the contact area. The influence of the wear debris on the formation of the transfer film is also discussed.     

General aspects for tribological applications of hard particle coatings

Hard coatings, consisting of WC, TiC or Cr₃C₂ particles with a nickel or cobalt matrix were compared with conventional wear-resistant materials like hardened steel 100 Cr6, Ferro TiC P143, WC-Co hard metal and a widely used thermal spray layer NiCrBSi. The coating procedure was flame spraying and diffusion welding. Some layers were remelted using an electron beam to improve their microstructural properties, porosity and binding to the bulk material.

Wear tests were performed under different degrees of severity to qualify the resistance of the coating, using abrasive, sliding and impact test methods representing different wear mechanisms. It is shown that the benefit of the hard particle content depends on the acting loading situation. Under abrasive and sliding conditions the advantage of a high hardness level, i.e. a high concentration of hard phases, could be demonstrated. For impact loading, causing severe surface fatigue, homogeneous materials with high toughness, such as martensitic steels, are beneficial; followed by coatings with a high concentration of ductile matrix. In some cases, the weaknesses, such as brittleness and limited strength of binding to the bulk, could be improved by electron beam remelting.     

Wear of water lubricated silicon nitride in ball on disc test

Abstract

The ball on disc test configuration is preferred to the flat ended pin on disc because the ball is self-aligned and measurement of wear on the ball is of higher accuracy, compared to the pin. Silicon nitride, sliding on itself in water, was tested with the ball on disc tribometer. Misalignment of the test ball from its proper position behind the disc axis of rotation leads to friction measurement errors, which were analysed. The disc wears non-uniformly, the wear track depth and width vary in longitudinal direction by a factor of 2–3. The uneven wear of the disc is explained by the combined effects of sliding surface anisotropy and disc material non-homogeneity on the one hand and by the friction force and the normal load periodic variation on the other hand. During the running-in process at particular sliding velocity amplitude modulated friction force was observed and an explanation by the mechanical vibration 'beating' phenomenon was suggested. Predictive model of the running-in process is presented, which describes the evolution of the ball wear scar area, the contact pressure and the wear rate. The model predictions are consistent with the experimental data.     

A scanning electron microscope study of attrition wear in tungsten carbide taper pin reamers

The wear of tungsten carbide taper pin reamers used to ream holes in a composite structure of aluminium alloy plate overlaying a plate of ultra-high strength steel was examined under the scanning electron microscope. The predominant process of wear was by attrition, which involved the mechanical detachment of individual or groups of tungsten carbide grains from the reamers by both the swarf and workpiece material.This process of attrition wear was initiated by the removal of the cobalt binder phase, resulting in the undermining and subsequent removal of tungsten carbide grains. A mechanism is described for explaining how the cobalt binder phase is initially removed, and the means by which tungsten carbide grains are then removed are discussed. Consequent on the removal of tungsten carbide grains some cobalt binder phase attached to these grains is also removed, and this subsequently becomes an important mechanism of cobalt binder phase removal.