Abrasive wear behavior of boronized AISI 8620 steel

In this study, AISI 8620 steel was boronized using the solid state boronizing technique. Processes were carried out at the temperatures of 850, 900 and 950 °C for 2, 4 and 6 h of treatment. Abrasive wear behavior of the samples boronized at different temperatures and treatment durations have been examined. Using boronized and unboronized samples, abrasive tests were conducted using pin on disc test apparatus. 80 and 120 mesh aluminum oxide (Al₂O₃) abrasive papers were used in the abrasion experiments and the samples were subjected to abrasion under 10, 20 and 30 N loads. Boronized steels exhibited an improvement in abrasive wear resistance reaching up to 500%. Microstructures and wear surfaces of the samples were inspected using SEM microscopy. SEM examinations revealed that the thickness of the boride layer on the steel surfaces changes with changing process durations and temperatures. The presence of boride formed in the borided layer at the surface of the steels were determined by XRD analysis and microhardness values of the iron borides (FeB, Fe₂B) formed on the steel surface were found to be over 1600 HV.     

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.     

Wear studies on boronized mild steel

Unlubricated dry sliding wear tests were carried out using a pin-on-disc machine on boronized mild steel pins containing FeB, Fe₂B and both phases in the surface layers. The discs were made of hardened tool steel. Singlephase boride layers exhibited better wear resistance than two-phase boride layers. The wear debris contained essentially Fe₂B, α-Fe, Fe₃O₄ and Fe₂O₃. The untreated mild steel substrates and the FeB layers undergo oxidation and mechanical abrasion during wear tests. The two-phase borides show adhesive transfer and oxidation. The Fe₂B layers fail by fatigue.     

Sliding wear behaviour of an electrochemically modified austenitic high-nitrogen steel surface

Wear debris from artificial metallic implant joints is known to provoke detrimental foreign-body reactions in the surrounding human tissue. Although commonly used biotolerant metals generate only a little amount of particles, wear is still a major cause for concern. It is the aim of this work to evaluate the sliding wear resistance of a topologically modified high-nitrogen austenitic stainless steel. A disc-on-pin test in self-mating contact is performed in distilled water. Submicron particles are trapped by the structured topography and form together with the plastically deformed metal a hybrid surface which has the potential to significantly improve the tribological behaviour of the tested high-nitrogen steel.     

Sliding wear rig

As a preliminary to studies on cam and follower systems, a rotating cylinder on reciprocating flat wear rig has been developed. This has turned out to possess a number of useful characteristics not available in more conventional rigs. The rig has been particularly useful in that it has produced wear areas large enough for detailed comparison of a range of quantitative surface analysis methods. Esca, sem/empa, sem/edax have been compared for the quantification of antiwear surface elements.     

Sliding wear behavior of electron beam surface-melted 0–2 tool steel

Studies were carried out on the dry sliding wear behavior of electron beam melted surface layers on a type 0–2 tool steel and on annealed and conventionally hardened 0–2 steel specimens for comparison. Wear tests were conducted in a flowing argon atmosphere at a sliding speed of 20 cm s^?1 and a load of 10 N against a 52100 bearing steel ring. Wear surface morphology was studied along with subsurface structure using optical and electron microscopy methods. The study concentrated on the wear of this steel after different processing treatments. Electron beam surface melting and subsequent rapid solidification in situ of the steel produced a highly refined martensitic microstructure having higher hardness values and better wear resistance than obtained using conventional quench hardening of that steel. Carbide distribution and martensite phase morphology were affected by this surface melting process; those microstructural characteristics influenced the wear behavior. Variations in electron beam power and surface speed during melting were explored in terms of their effect on the resulting surface layer. The wear test system used was computer interfaced and controlled, permitting continuous measurements of wear depth and friction force.     

Sliding/rolling wear performance of plasma nitrided H11 hot working steel

H11 steel discs were tested by considering sliding/rolling friction under dry and lubricated conditions. The H11 discs were plasma nitrided at 500 °C and 550 °C for 9 h. Wear tests were conducted at different slip ratios of 1.79%, 10.53% and 22.22%. The test loads were 100 N, 150 N and 200 N. It was determined that plasma-nitrided H11 discs had a surface hardness of 1200–1400 HV0.1. Plasma nitriding produced wear performance much higher than those of the un-nitrided but hardened samples. The wear mechanism of the plasma-nitrided discs was a mixture of adhesive wear, abrasive wear and plastic yielding.     

Sliding wear of quasicrystalline coatings

The mass loss during sliding wear of several quasicrystalline (QC) coatings has been measured. QC coatings of the Al–Cu–Fe, Al–Cu–Fe–Cr and Al–Pd–Mn systems have been investigated and compared with a hardened tool steel and a WC–6% Co hardmetal. The wear rates of the coatings are in general comparable to conventional metallic materials. There is some variation in sliding wear behaviour of different QC coatings. This revised version was published online in August 2006 with corrections to the Cover Date.     

Sliding wear of polymeric composites

The wear mechanisms of two different polymeric composites sliding against metal were investigated experimentally. The sliding distance, normal force and sliding speed were the test variables.Microscope observations showed that the mode of wear of the two materials is similar. Subsurface deformation, crack nucleation at the matrixharder particle or matrix-glass fibre interface, crack propagation parallel to the surface at a depth corresponding to the friction coefficient and crack shearing to the surface were found in both materials. The wear particles often have the shape of thin sheets. Comparison of the metal subsurfaces and wear particles with those of the polymers indicates that the mechanism of wear of semicrystalline composites is similar to delamination wear. Since film transfer greatly influences friction and wear it should be considered together with crack growth in fatigue in the prediction of wear of polymeric composites.     

Sliding wear behavior of stainless steel parts made by metal injection molding (MIM)

The wear resistance of stainless steel parts, which were fabricated by a metal injection molding (MIM) process, was studied under self-mating, dry sliding conditions, using a pin-on-disk type wear configuration. The materials used were an austenitic stainless steel 316L (of MIM and wrought steel), a precipitated stainless steel 17-4PH (of MIM and wrought steel) and a widely used ball-bearing steel (DIN 100Cr6). Two surface conditions, i.e. as sintered and as polished, were considered in the wear tests of the MIM samples. In summary, the wear resistance of 316L was lower than 17-4PH, and the latter was almost the same as 100Cr6. Further, the wrought materials showed a better wear resistance than the MIM materials. The mechanisms responsible for these tendencies were discussed by means of microscopical observations and chemical inspections of the worn surfaces and the microstructures of the samples.     

Dry sliding wear characteristics of some industrial polymers against steel counterface

In this investigation, the influence of test speed and applied pressure values on the friction and wear behaviour of polyamide 66 (PA 66), polyoxymethylene (POM), ultrahigh molecular weight polyethylene (UHMWPE), 30% glass fibre reinforced polyphenylene-sulfide (PPS+30%GFR) and aliphatic polyketone (APK) polymers were studied. Friction and wear tests of PA 66, POM, UHMWPE, PPS+30%GFR and APK versus AISI D2 steel were carried out at dry condition on a pin-on-disc arrangement. Tribological tests were performed at room temperature at different pressures (0.35–1.05 MPa) and sliding speeds (0.5–2.0 m/s). The results showed that, for all polymers used in this investigation, the coefficient of friction decreases linearly with the increase in pressure. The specific wear rate for UHMWPE, PPS+30%GFR and APK were in the order of 10⁻⁵ mm³/N m, while the wear rate value for PA 66 was in the order of 10⁻⁶ mm³/N m. In addition to this, the wear rate value for POM was in the order of 10⁻³ mm³/N m. Furthermore, as the results of this investigation, the wear rate showed very little sensitivity to the applied pressures and test speed.     

Sliding wear of calcium α-sialon ceramics

The sliding wear behaviour of calcium α-sialon ceramics having two distinct microstructures, large elongated-grained and fine equiaxed-grained was revealed by observing the evolution of wear rate, wear track and debris as a function of apparent contact pressure and sliding speed, using a ball-on-disc type wear tester. The thresholds for the transition from mild to severe wear in terms of apparent contact pressure and the controlling material removal mechanisms were identified for both microstructures. The large elongated-grained microstructure had a higher wear transition threshold and exhibited a reduced wear rate in the severe wear regime, compared to the fine equiaxed-grained microstructure. This behaviour is attributed to a greater resistance to crack extension arising from the large elongated-grained microstructure. As the apparent contact pressure decreased, mild wear occurred at pressures below the thresholds for each of the microstructures. The material removal for the large elongated-grained microstructure was controlled by transgranular fracture, whereas grain pull-out prevailed in the fine equiaxed-grained microstructure. Consequently, a greater wear rate results for the fine equiaxed-grained microstructure in mild wear regime. An increase in sliding speed caused a slight increase in wear rate for both microstructures, more evidently in the mild wear regime. Models were developed to clarify the effect of microstructure on severe and mild wear of Ca α-sialon. They revealed that grain aspect ratio plays a more important role than grain diameter in the control of wear behaviour.     

Sliding wear resistance of metallic coated surfaces

The role of metallic coatings in sliding wear is examined experimentally. The results indicate that the tribological behavior of soft coatings is consistent with the delamination theory of wear, especially the critical nature of the plating thickness. It is shown that a reduction in wear rate of three orders of magnitude is possible when the coating material is softer than the substrate and thinner than a critical thickness. The optimum plate thickness is found to be of the order of 0.1 μm for cadmium, silver, gold or nickel plated on various types of steel. Cadmium, silver and nickel reduce wear only in non-oxidizing environments, whereas gold reduces wear both in air and in inert atmospheres.The roughness of the substrate surface prior to plating and the nature of the coating/substrate bond have significant effects on the life of these coatings. The life of the coatings is increased by polishing the substrate to 0.1 μm (c.l.a.) prior to plating, and also by diffusion of the plated material into the substrate, which increases the coating/substrate bond strength.     

Sliding wear performance of different polyimide formulations

Sliding wear studies on different polyimide (PI) formulations against hardened, smooth steel were conducted using a pin-on-ring testing facility. Contact pressure p was varied in such a way that for three different sliding velocities v (0.6, 1.5 and 3.0 m s⁻¹) two pv levels could be maintained (1.7 and 5.0 MPa m s⁻¹). The best results were achieved with a PI formulation containing 15 wt% graphite filler and 10 wt% fluorocarbon resin having a wear factor

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. This material was also superior to newly developed high performance thermoplastics, in particular polyetheretherketone (PEEK) and thermotropic liquid crystal polymers (LCP), even when the latter contained about 20 vol.% of short glass or carbon fibre reinforcement.     

Abrasive wear behavior of different case depth gas carburized AISI 8620 gear steel

In this study, abrasive wear behaviors of gas carburized AISI 8620 steels with different case depths were examined. AISI 8620 steels yield excellent carburizing results and are used in manufacturing of gears. Two carburized and quenched specimens with different case depths were produced. Specimens were prepared at HEMA Gear Factory. Wear tests were carried out using pin-on disc test machine. Specimens were abraded under 10, 25 and 40 N loads by using 80 grid Al₂O₃ and SiC abrasive papers. Mass losses were measured using an electronic balance with accuracy of 10⁻⁴ g. Results of this study reveal that data on laboratory samples can be used to interpret the abrasive wear performance of AISI 8620 gas carburized steel gears. It has been observed that gas carburizing time affects the case depth, and in turn, specimen with higher case depth has shown better wear resistance. In addition to this, as the case depth has increased, the hardness of the material has increased as well.     

Sliding wear behaviour of some Fe-, Co- and Ni-based metallic glasses during rubbing against bearing steel

The sliding wear behaviour of several compositions of Fe-, Co- and Ni-based metallic glasses have been studied while rubbing against AISI 52100 bearing steel under reciprocating-sliding conditions. The wear resistances of Fe-based metallic glasses and Ni-based metallic glass (MBF 50) have been found to be superior to that of the mating AISI 52100 bearing steel. The examination of worn surfaces indicates that the superior wear resistance of metallic glasses is not merely owing to their high hardness but it is determined by phenomena of material transfer vis-à-vis the mating material and the formation of protective oxide layers on the metallic-glass surface during sliding. This revised version was published online in August 2006 with corrections to the Cover Date.     

Effects of ultrasonic vibration on the wear characteristics of a carbon steel: Analysis of the wear mechanism

To explain the fact that the wear rate of a carbon steel subjected to ultrasonic vibration decreases with an increase in the amplitude of vibration, a simple equation for the wear rate was derived using the theories of adhesive wear and analytical results of vibration. Analytical predictions were in good agreement with experimental results. One of the main factors affecting the wear behaviour under vibration is the contact time between specimens during 1 cycle of vibration. The amount of oxygen adsorbed on rubbing surfaces with repeated dynamic contact loading also affects the wear rate. The activation energy of oxygen adsorption with vibration is considered to be lower than that found in the process of ordinary wear without vibration. The variation in hardness of worn surfaces due to repeated friction passes has little effect on the wear rate with vibration.     

Sliding wear of 304 and 310 stainless steels

Blocks of 304 (metastable) and 310 (stable) austenitic stainless steels were tested in argon against M2 tool steel rings. Scanning, transmission and scanning transmission electron microscopy analysis, together with microhardness measurements, showed that the strain-induced martensite transformation in 304 steel affects the form and composition of the wear debris and the nature of the transfer layer. The hardness of the transfer layer relative to the hardness of the adjacent deformed base material is also important, as shown in earlier work on Cu-Be. During early stages of sliding, the friction values for both alloys are similar, but whereas the friction continues to rise smoothly to a steady state value for 310 steel, the formation of α'-martensite in 304 steel gives a lower average value of friction coefficient with large fluctuations.     

Sliding wear behavior of dedicated iron-based SLS materials

Systematic investigation of wear behavior of selective laser sintering (SLS) materials is lacking in SLS/selective laser melting research. The present research is an effort to fill the gap by performing sliding wear tests under plastic and elastic contact conditions upon proprietary iron-based SLS materials: LaserForm and DirectSteel. It is found that LaserForm is a better SLS wear material. It is concluded that wear performance is governed not by the hardness of the materials but by their composition.     

Sliding and abrasive wear behaviour of boride coatings

Polyphase boride coatings constituted by an inner layer of Fe₂B and an outer layer of FeB were thermochemically grown on iron and medium carbon steel by a pack cementation process. The tribological behaviour of borided samples was investigated under both sliding and abrasion testing conditions. Considerably different values of wear rate were found in different regions of the coatings. The differences were explained on the basis of the crystallographic order of iron borides. The resistance to both types of wear was initially poor due to the presence on the coatings of a thin, friable layer constituted by disordered crystals. Then the resistance increased to a maximum value in regions constituted by compact, highly ordered crystals of Fe₂B. The resistance to dry sliding of borided samples was better than that displayed by samples submitted to alternative surface treatments (e.g. gas nitriding) and lower that that measured for a WC-Co hard metal coating.