Fretting wear behaviors of steel wires under friction-increasing grease conditions

Fretting wear tests were performed on the self-made fretting wear rig to investigate fretting wear behaviors of steel wires under friction-increasing grease conditions. The results demonstrated that the fretting regimes were dependent on displacement amplitudes and normal loads. The friction coefficient exhibited different variation trends in different fretting regimes. Friction-increasing grease changed the fretting running behavior and had a very good wear resistance for steel wires. Wear was slight in partial slip regime. Mixed regime was characterized by plastic deformation, fatigue cracks and abrasive wear. Slip regime presented main damage mechanisms of abrasive wear, fatigue wear and oxidation.     

Fretting wear

This review covers developments in fretting wear over the past three years. The threshold amplitude of slip at which fretting damage becomes apparent is found to be in the region of 0.5 μm. Very low amplitudes of slip and low frequencies (0.001 Hz) are particularly damaging in electrical contacts, leading to high resistances resulting from oxide build-up. In high temperature fretting, oxide formation can give protection. In titanium alloys this can be improved by ion implantation, particularly with bismuth. In aqueous solutions, such as sea water, fretting stimulates the chemical dissolution of material, which accounts by far for the major part of the wear.     

Experimental study on wear and spalling behaviors of railway wheel

The current researches of the wear and spalling behaviors of wheel/rail materials focus on the field investigation rather than the mechanism. However, it is necessary and significant for clarifying the mechanism and relationship between the wear and spalling damage of railway wheel to test and reproduce the wheel damages in laboratory. The objective of this paper is to investigate the wear and spalling damage behaviors of railway wheel using a JD-1 wheel/rail simulation facility, which consists of a small wheel serving as rolling stock wheel, and a larger wheel serving as rail. The damage process of wheel roller is explored in terms of the creep ratio, axle load, and carbon content by means of various microscopic examinations. The experimental results show that the wear volume growth of wheel roller is proved to be proportional to the increase of the creep ratio and normal load between simulating wheel and rail. The increase of carbon content of wheel material causes a linear reduction in the wear volume. The microscopic examinations indicate that the rolling wear mechanism transfers from abrasive wear to adhesive and fatigue wear with an increase of tangential friction force, which results in the initiation of fatigue crack, and then aggravates spalling damage on the wheel roller surface. The surface hardness of material depends strongly upon its carbon content. The decrease of the carbon content of wheel material may alleviate spalling damage, but can cause a significant growth in the wear volume of wheel roller. Therefore, there is a competitive relationship between the wear and spalling damage of wheel material. This research proposes an important measure for alleviating or preventing the wear and spalling damage of railway wheel material.     

Fretting wear behaviors of mandibular condylar cartilage of nature temporomandibular joint in vitro

Torsional fretting tests of condylar cartilage against a ZrO₂ ball were carried out. The damage characteristics were discussed based on an analysis of frictional kinetics behavior, SEM observations, and histological stainings. The results indicated that fretting behaviors were strongly dependent on the angular displacement amplitudes and the number of cycles. The worn surface was characterized by netlike shape ridges along the radial direction, and three parts were detected. The wear mechanism of condylar cartilage performed mainly as delamination and micro-fracture of collagenous fibers. As the damage characters are very special, a model of the condylar cartilage surface damage was established.     

Fretting wear in seawater

Fretting tests of bearing steel (SUJ-2) and ceramics (Al₂O₃ and Si₃N₄) were carried out in the following environments: air, deionized water, 3.07% NaCl solution, synthetic seawater and natural seawater. Also, investigations to determine the optimum fretting wear resistant material for ships, marine equipment and offshore structures were conducted. The results showed that (1) the corrosion products formed in seawater behaved as a lubricant and reduced the fretting damage at large amplitudes, but the fretting damage was not greatly influenced by the different environments at very small amplitudes (such as 14 μm), (2) instead of natural seawater, synthetic seawater was adequate for the investigations of fretting wear, but 3.07% NaCl solution was found not to be and (3) the ceramic Al₂O₃ was a potentially useful material against fretting wear under light loads in seawater.     

Fretting wear of sintered alumina

Cylinders of alumina, carbon steel, glass and tungsten carbide have been fretted against rectangular specimens of sintered alumina. The damage caused has been assessed by four-point loading bend tests. Coefficients of friction of the contacting surfaces have been measured. These vary from 0.32 to 0.85 but do not correlate with the strength results. Alumina, glass and tungsten carbide produce no effect in fretting. This is due to the absence of adhesion between the surfaces. Fretting against steel increases the bend strength owing to blocking of the surface pores by iron.     

Fretting wear behaviors of nanometer Al2O3 and SiO2 reinforced PEEK composites

The influence of diameter and content of Al₂O₃ particles on the tribological behaviors under fretting wear mode was investigated. The surface of PEEK composite and steel ball were examined by SEM and EDS, to identify the topography of wear scar and analyze the distribution of chemical elements in the friction counterparts, respectively. It can be found that the filling of Al₂O₃ powder improves the fretting wear resistance of PEEK composite. With the increase of Al₂O₃ diameter, the area of wear scar on specimen increases first and decreases afterward. However, the wear of composites increases monotonically with increasing Al₂O₃ content. Although the filling of 10 wt.% and 200 nm PTFE powder in PEEK makes the lowest wear of all specimens, no synergistic effect was found when Al₂O₃ and PTFE were filled into PEEK composite together. For the friction pair of PEEK composite and steel ball, abrasive wear and adhesive wear dominate the fretting wear mechanism during fretting. Thermal effect plays a very important role during fretting; thus the property of temperature resistance for polymer material would affect the wear degree on the surface of wear scar.     

Fretting wear of thin steel wires. Part 2: Influence of crossing angle

The wear behaviour of thin steel wires has been analyzed under oscillating sliding conditions in crossed cylinders contact geometry. The focus of this analysis was the influence of the crossing angle between the wires on the wear. The wires used had 0.45 mm in diameter and the material was cold-drawn eutectoid carbon steel (0.8% C) with a tensile strength higher than 2800 MPa. Two different types of tests were carried out, the first one representing the influence of the crossing angle for a constant load and the second one representing the influence of the crossing angle with constant contact pressure. In the first type of tests it was seen that as the contact angle decreases the contact pressure decreases too and hence less energy specific wear resistance is observed. As a consequence less wear is produced, thus increasing the life of the wires. In the second type of tests it was seen that with constant contact pressure but different crossing angles, nearly the same energy specific wear resistance was observed. This points at an identical wear behaviour in both type of tests but with a running-in and a steady state period as two different wear periods. The tests showed that the running in period may play an important role in the overall wear particle generation and hence the wear occurring in the steady state period is rather mild.     

Fretting wear of laterally supported tube

The fretting wear of a tube, which is in contact with a lateral support, is examined experimentally. A fretting wear tester is specifically designed. Elastic springs are used as the support, which can simulate the contact between a spacer grid and a fuel rod in pressurized water reactor fuel. The tubes and the springs are made of Zircaloy-4. The experiments are conducted in air at room temperature. The experimental conditions, i.e. the normal and shear forces on the contact, the slip range and the number of cycles, are set to be the same. To investigate the influence of the contact geometry on the wear, the spring supports have a concave, a flat or a convex contour. The influence on the axial and transverse slip directions is investigated to incorporate the actual tube motion caused by such a flow-induced vibration in the reactor. The wear on the tube is examined by the surface roughness tester, which measures the depth, and the contour of the worn surface of the tube. Since the shape and the distribution of wear are found arbitrary, a method for evaluating the wear volume is proposed using the signal processing technique. It is found that wear can be restrained when the slip direction is transverse, and if the support has a concave contour.     

Fretting wear of Al-Si alloy matrix composites

Ball-against-disk type fretting wear tests for Al-Si alloy matrix composites in contact with bearing steel were conducted in wet air to investigate the effects of relative slip amplitude on friction and wear of the composites. In the larger range of relative slip amplitude, the Al-Si alloy-impregnated graphite composite (ALGR-MMC) shows lower friction coefficients than those of alumina short fiber-reinforced composite (ASFR-MMC) and hollow silica particle-reinforced composite (HSPR-MMC). Although the wear rate of the ALGR-MMC is higher than that of the ASFR-MMC and HSPR-MMC, the composite hardly causes damage to the mating material due to adhesion of compacted films of graphite powder and Al-Si alloy wear particles.     

Fretting behaviour of galvanised steel

The present work describes research conducted on the fretting behaviour of S 355 MC galvanised steel sheet. In order to study the influence of the normal load and the displacement effect, some of the specimens were galvanised by hot dipping and the rest were only polished before being tested. Fretting tests were carried out on a specially developed fretting rig prototype under ‘crossed-cylinders’ contact geometry. Tests were done during 0.72×10⁶ cycles in laboratory air conditions. The tangential force and the displacement were measured in order to establish the fretting cycles for each fretting condition. The fretted surfaces were analysed by means of optical and scanning electron microscopes to identify the main wear mechanisms. Three different fretting regimes were identified: the stick regime; the slip regime; and the mixed stick–slip regime, which depended mainly on the influence of the normal load and the stroke.     

Friction and wear behaviors of nanocrystalline surface layer of medium carbon steel

A nanocrystalline (nc) surface layer, which is about 30 μm thick, was fabricated on a medium carbon steel plate using high-energy shot peening (HESP). The tribological behavior of the nanocrystalline surface layer was investigated under the unlubricated slide using a ring-on-disc tester. The observation of the surface topography shows that the nanocrystalline surface layer may reduce the effect of fatigue wear and improve the friction and wear properties of medium carbon steel. Experimental results show that the friction coefficient and wear weight loss decrease and the wear resistance increases with the surface nanocrystallized samples under lower loads.     

Fretting wear and friction behaviour of engineering ceramics

Friction and wear characteristics of partially stabilized zirconia (PSZ) fretted against itself and against high carbon steel were investigated. The results for the transformation toughened PSZ ceramics are compared with the behaviour of more brittle alumina ceramic under the same test conditions. Fretting tests in air were carried out on a high frequency wear test rig at room temperature using a cross-cylinder configuration. It was found that both the oxide ceramics were more resistant to fretting wear than the steel. Surface cracking was observed on the alumina wear scars while microfracture and delamination dominated on the PSZ wear scars. When metallic samples were fretted against ceramics, metallic film transfer to the ceramic surfaces occurred.     

铁路起重机车轴疲劳断裂原因分析

就一起铁路起重机车轴断裂事故，从车轴材质、车轴承重和轴颈过渡圆弧尺寸三个方面分析了其原因，并提出了改进措施。     

Impact wear of a tool steel

Results from wear studies in repetitive impact sliding are described in this paper. The material pair studied consisted of steel CPM-10V (specimen) (where CPM denotes crucible particle metallurgy) and 17-4 precipitationhardened (PH) steel (counterface) with transverse sliding velocities of 4 and 8 m s^?1. By means of scanning electron microscopy, energy-dispersive analysis of X-rays and X-ray diffraction methods it is shown that the wear is due to a material transport of the counterface 17-4 PH steel to the CPM-10V surface. In the wear process, a change in microhardness of the counterface substrate is apparent, and X-ray diffraction of debris confirms the presence of transformed metal. These products include γ-Fe together with trace amounts of α-Fe₂O₃; however, virtually no carbide from the CPM-10V steel was detected.     

Fretting wear behavior of TiB2-based materials against bearing steel under water and oil lubrication

Lubricated fretting tests in water and paraffin oil were performed with a monolithic TiB₂, a TiB₂-based cermet with 16 vol.% Ni₃(Al, Ti) binder, a sialon–TiB₂ (60/40) composite and a ZrO₂–TiB₂ (70/30) composite against ball bearing grade steel. Based on the measured friction and wear data, the ranking of the investigated fretting couples was evaluated. Furthermore, the morphological investigations of the worn surfaces and transfer layers are carried out and the wear mechanisms for the investigated friction couples are elucidated. While fretting in water, experiments revealed that tribochemical reactions, coupled with mild abrasion, played a major role in the wear behavior of the studied material combinations. ZrO₂–TiB₂ (70/30)/steel wear couple has been found to have the highest fretting wear resistance among the different tribocouples under water lubrication. Under oil lubrication, extensive cracking of the paraffin oil at the fretting contacts, caused by tribodegradation, leads to the deposition of a carbon-rich lubricating layer, which significantly reduced friction and wear of all the investigated tribosystems.     

Fretting wear characteristics of cold gas-dynamic sprayed aluminum alloys

Process selection for repair of mechanical components due to wear and corrosion, e.g. damage of aluminum casting housings of fuel injection systems, is based on cost and response time factors, provided that the mechanical performance is maintained within acceptable limits. One of the promising and emerging repair technologies is Cold Gas-Dynamic Spray (CGDS) coating, where a high-pressure gas propels fine powder particles to very high velocities to produce surface coating. It is essential to identify the optimum process conditions and powder composition to produce repaired surfaces with tribological properties close to those of the originally manufactured part (without coating). The objective of this work is to compare the dynamic friction and fretting wear properties of the repaired surfaces using various types of coating composition and spraying techniques. Eight types of CGDS coatings, applied to AMS 4260 aluminum specimens, were fretted against 440C stainless steel specimens at low and high nominal loads to assess their fretting wear resistance, dynamic friction properties and damping capacity. The optimum coating composition and process conditions were identified. In comparison to the uncoated specimen, this optimum coating offered tribological characteristics close to the uncoated material and even better dynamic friction properties.     

基于小样本耐久强度区的疲劳失效数据推定车轴钢的疲劳强度分布

为了对50#车轴钢疲劳可靠性问题进行评估,本研究在室温大气环境下用四连式悬臂梁型旋转弯曲疲劳实验机对该材料开展了超长寿命疲劳问题的研究,并根据实验得到的数据提出使用小样本耐久强度疲劳实验数据推定50#车轴钢的疲劳强度分布的统计方法.具体的方法如下:(1)假设在不同的应力循环周次下疲劳强度的分布近似相同;(2)确定均值S-N曲线倾斜部向水平部转移点处的应力循环周次No;(3)基于线性累计损伤原理,将耐久强度区的应力值换算为对应于No的一组应力值;(4)通过换算后的应力数据确定疲劳强度的概率分布.本方法推定的疲劳极限分布结果与本实验获得的疲劳极限区实验数据的分散程度基本一致.     

Fretting fatigue strength estimation considering the fretting wear process

In fretting fatigue process the wear of contact surfaces near contact edges occur in accordance with the reciprocal micro-slippages on these contact surfaces. These fretting wear change the contact pressure near the contact edges. To estimate the fretting fatigue strength and life it is indispensable to analyze the accurate contact pressure distributions near the contact edges in each fretting fatigue process.So, in this paper we present the estimation methods of fretting wear process and fretting fatigue life using this wear process. Firstly the fretting-wear process was estimated using contact pressure and relative slippage as follows:

W=K×P×S,