Influence of load and speed on wear characteristics of grey cast iron in dry sliding — selection for minimum wear

The wear of grey cast iron in dry sliding conditions has been studied with the aims of (1) finding the influence of working conditions on the wear rate, and (2) determining the region of speed and load where low wear is accomplished. Grey cast iron with flake and nodular graphite was submitted to investigation using a pin-on-disc machine. The results indicate that the flake graphite cast iron is more suitable for applications at speeds greater than 4 m s⁻¹ and lower loads, while nodular cast iron has greater wear resistance at lower speeds in the range of loads investigated - from 50 N cm⁻² to 200 N cm⁻²     

Dry sliding wear response of zinc-based alloy over a range of test speeds and loads: a comparative study with cast iron

This study pertains to the observations made during the sliding wear response of a zinc-based alloy in different test conditions. The effects of sliding speed and load on the wear behaviour of the alloy have been studied. The properties evaluated were wear rate, frictional heating and coefficient of friction. The wear performance of the zinc-based alloy has been compared with that of a conventional cast iron in identical test conditions. The wear rate of the samples increased with applied load and sliding speed while the seizure resistance (load) deteriorated with speed. The zinc-based alloy exhibited less wear rate and reduced frictional heating than that of the cast iron while friction coefficient followed a reverse trend. Observed wear response of the samples has been discussed in terms of specific features like lubricating, load carrying, microcracking and thermal stability of various microconstituents of the samples, and substantiated further through the features of wear surfaces, subsurface regions and debris.     

The influence of surface oxidation on the wear resistance of cast iron

This paper reports a study of the influence of surface oxidation on the wear resistance of ductile iron, grey iron and vermicular iron during dry sliding friction. The mechanisms of wear are also reported. This study shows that the effect of surface oxidation (formed under normal atmospheric conditions) on the wear rate depends on the complex functions of graphite morphology and matrix structure. Generally the presence of surface oxidation decreases the wear rate of grey iron but increases the wear rate of ductile iron and vermicular iron when the cast iron has high hardness. This trend is reversed for low hardness cast iron.     

Sliding wear response of a grey cast iron: Effects of some experimental parameters

This investigation pertains to the influence of some test parameters like applied load, sliding speed and test environment on the sliding wear behaviour of a grey cast iron. Properties studied were wear rate, frictional heating and friction coefficient in dry and oil lubricated conditions. The wear response of the samples has been discussed in terms of specific characteristics like load bearing, lubricating and cracking tendency of different microconstituents of the cast iron. Examination of wear surfaces, subsurface regions and debris particles has also been carried out to understand the operating wear mechanisms and further substantiate the observed response of the samples.     

The effects of alumina fibres on the sliding wear of a cast aluminium alloy

Dry sliding wear performance of a squeeze cast aluminium alloy-alumina fibre composite has been examined in this investigation using a pin-on-disc machine. A composite in the form of a pin was evaluated against a rotating EN 25 steel disc. The wear response of the base alloy was also studied to assess the influence of a reinforcing phase over a range of applied pressures until the onset of seizure. Incorporation of alumina fibres resulted in superior wear performance of the base alloy, i.e. reduced wear loss, improved seizure pressure and reduced rise in temperature near contact surfaces. Onset of seizure in general caused significantly higher wear loss and temperature rise and large adhesion of the specimen material to the disc surface. A longitudinal cross-section of worn samples suggested nominal wear-induced microstructural changes and deformation in the subsurface regions. The wear surfaces revealed smooth and continuous grooves with less damaged regions prior to onset of seizure, while severe surface damage was observed thereafter. Similarly, debris particles generated during onset of seizure were coarser. The presence of deeper grooves on the wear surfaces and iron mass in the debris particles indicated abrasion to be one of the wear mechanisms in addition to adhesion. That the debris particles were mainly of flake type consisting of microcracks indicated that material removal occurred mainly by delamination.     

Friction and wear of grey cast iron against Si3N4 in emulsion and water

Friction and wear tests of Si₃N₄ against cast iron were carried out using a ring-on-block tester lubricated by emulsion. To provide a comparison with emulsion, distilled water was also used as a lubricant in the tests. The results show that emulsion can prevent the formation of an SiO₂·2H₂O film on the iron surface. Although the friction coefficient of Si₃N₄/ iron pairs in emulsion is much greater than in distilled water, the wear of Si₃N₄ in emulsion is less.     

Mechanism of ploughing wear of martensite nodular cast iron

The mechanism of ploughing wear of martensite nodular cast iron has been investigated by means of elastic contact theory, stress interferometry, and scanning electron microscopy. Stress distributions in the contact area are plotted through numerical quadrature. The results show that the formation of cracks is between 0.2a and 0.5a (a is the radius of the contact curve). The driving force to produce crack extension along the Y axis is τ_yzmax and the extension direction is 45° to the horizontal. The driving force to produce crack extension along the X axis is either τ_x or τ_xzmax and the direction of crack extension is 37° to the horizontal.     

Effect of carbide fraction and matrix microstructure on the wear of cast iron balls tested in a laboratory ball mill

The effect of carbide volume fraction from 13 to 41% on the wear resistance of high chromium cast irons was evaluated by means of ball mill testing. Martensitic, pearlitic and austenitic matrices were evaluated.

The 50-mm diameter balls were tested simultaneously in a 40 cm diameter ball mill. Hematite, phosphate rock and quartz sand were wet ground. The tests were conducted for 200 h.

Quartz sand caused the highest wear rates, ranging from 6.5 to 8.6 μm/h for the martensitic balls, while the wear rates observed for the phosphate rock ranged from 1.4 to 2.9 μm/h.

Increasing the carbide volume fraction resulted in decreased wear rates for the softer abrasives. The almost complete protection of the matrix by carbides in eutectic microstructures caused the eutectic alloy to present the best performance against hematite or phosphate rock. The opposite effect was observed for the quartz sand. The quartz abrasive rapidly wears out the matrix, continuously exposing and breaking carbide branches. A martensitic steel presented the best performance against the quartz abrasive.

With phosphate rock, the wear rate of 30% carbide cast irons increased from 1.46 to 2.84 and to 6.39 μm/h as the matrix changed, respectively, from martensitic to austenitic and to pearlitic. Wear profiles of worn balls showed that non-martensitic balls presented deep subsurface carbide cracking, due to matrix deformation. Similar behavior was observed in the tests with the other abrasives.

In pin-on-disc tests, austenitic samples performed better than the martensitic ones. This result shows that pin tests in the presence of retained austenite can be misleading.     

Friction and wear properties of Kevlar pulp reinforced epoxy composites under dry sliding condition

In this work, the friction and wear properties of Kevlar pulp reinforced epoxy composites against GCr15 steel under dry sliding condition were evaluated on a reciprocating ball-on-block UMT-2MT tribometer. The effects of Kevlar pulp content on tribological properties of the composites were investigated. The worn surface morphologies of neat epoxy and its composites were examined by scanning electron microscopy (SEM) and the wear mechanisms discussed. The results show that the incorporation of Kevlar pulp into epoxy contributed to improve the friction and wear behavior considerably. The maximum wear reduction was obtained when the content of Kevlar pulp is 40 vol%. The friction coefficient of epoxy and its composites increased with load while increase in the sliding frequency induced a reverse effect. Fatigue wear and scuffing were notable for the neat epoxy. The fatigue cracks were greatly abated when the filler content was 40 vol%. The wear grooves appeared on the worn surface at higher filler content.     

The particle size effect on abrasive wear of high-chromium white cast iron mill balls

Granite grinding tests, under dry and wet conditions, were performed to assess the influence of abrasive particle size to the wear behavior of martensitic high-chromium white cast iron mill balls. The tests were performed, at first, using raw granite particle sizes between 0.074 and 19.1 mm, and then with coarse and fine granite fractions obtained after screening the raw granite in a 3.36 mm sieve. It is demonstrated that the relative particle/ball size relationship is the determining parameter to ball wear. The highest ball wear rates were observed for fine granite grinding under dry (120 mg/cycle) and wet (129 mg/cycle) conditions. The lowest wear rate (ca. 50 mg/cycle) was observed for coarse granite grinding (dry and wet). These different results were attributed to the different size relationships between grinding body diameter and granite particles size. For wet-grinding of raw granite, the mineral components may influence significantly the wear behavior. Feldspar can act as a bonding agent, gluing fine quartz particles to the coarse granite and to the balls surface and turning the dependence of the relationship between the relative sizes of ball and granite particle less important to the wear process. This explains why wet-grinding of raw granite results in a ball wear two times greater (106 mg/cycle) than dry-grinding (51 mg/cycle).     

Abrasive wear study of white cast iron with different solidification rates

The abrasive wear resistance of white cast iron was studied. The iron was solidified using two solidification rates of 1.5 and 15 °C/s. Mass loss was evaluated with tests of the type pin on abrasive disc using alumina of different sizes. Two matrices were tested: one predominantly austenitic and the other predominantly martensitic, containing M₃C carbides. Samples with cooling rate of 15 °C/s showed higher hardness and more refined microstructure compared with those solidified at 1.5 °C/s. During the test, the movement of successive abrasives gave rise to the strain hardening of the austenite phase, leading to the attainment of similar levels of surface hardness, which explains why the wear rate showed no difference compared to the austenite samples with different solidification rates. For the austenitic matrix the wear rate seems to depend on the hardness of the worn surface and not on the hardness of the material without deformation. The austenitic samples showed cracking and fracture of M₃C carbides. For the predominantly martensitic matrix, the wear rate was higher at the solidification rate of 1.5 °C/s, for grain size of 66 and 93 μm. Higher abrasive sizes were found to produce greater penetration and strain hardening of austenitic matrices. However, martensitic iron produces more microcutting, increasing the wear rate of the material. The analysis of the worn surface by scanning electron microscopy indicated abrasive wear mechanisms such as: microcutting, microfatigue and microploughing. Yet, for the iron of austenitic matrix, the microploughing mechanism was more severe.     

The influence of topography on the specific dissipated friction power in ultra-mild sliding wear: Experiment and simulation

Current political, economic and ecological guidelines demand the increase of power densities of nearly all machinery parts. In order to further lower the wear rate towards the ultra-mild sliding wear regime, an integral approach is needed, which has to regard contact conditions, surface topography, surface chemistry, as well as sub-surface properties. Still, there are no simple parameters to classify the performance of a tribosystem. In this study the area affected by tribocontacts is calculated by means of a three dimensional elastic–ideal plastic contact model. The surfaces are prepared by means of conventional machining procedures and characterized by scanning white light interferometry. The further input data as to normal and friction forces are derived by reciprocating sliding wear tests under boundary lubrication conditions of carburized steel against carburized steel and 52100 steel against case-hardened spheroidal cast iron. This contribution will depict the distinct influence of the topography on friction and ultra-mild sliding wear of common Fe-base materials and point out the marked importance of highly localized effects, which govern the acting mechanisms.     

Modelling sliding wear: From dry to wet environments

Corrosive species in various forms exist widely in the environment and can significantly affect wear behaviour of materials, usually accelerating wear. Under conditions where the environments are seemingly non-deleterious in terms of corrosivity, some species from the environment can still affect the tribological behaviour of materials. It is thus extremely important to recognise the roles of reactive species in affecting the tribological processes and to understand the processes of tribo-corrosion interactions. In this paper, the mechanisms of wear debris generation and the roles of reactive species in the generation of wear debris during sliding wear in gaseous or aqueous environments are discussed. The effect of environment on the development of wear-protective layers is described. Based on the proposed mechanisms, mathematical models for sliding wear in both dry and aqueous environments are outlined, and the validity of the models is assessed against experimental data in sliding conditions.     

整体PCBN刀片高速切削灰铸铁的研究

通过实例介绍整体PCBN刀片在高速切削灰铸铁时的特性 ,并着重分析灰铸铁的金相组织对加工性能的影响     

Dry sliding wear behaviour of polyamide 66 and polycarbonate composites

A study has been made of the reciprocating dry sliding wear behaviour of polyamide 66 and polycarbonate containing glass fibres, ultra high molecular weight polyethylene (UHMWPE) and polytetrafluoroethylene (PTFE/2% Si oil). Studies have been conducted at sliding loads of 2 kg and 10 kg at an average velocity of 0.33 m s⁻¹ against a hardened stainless steel counterface with a surface roughness of 0.3 μm.It has been shown that additions of 10–15% of filler/reinforcement lead to greatly improved sliding wear behaviour. PTFE/2% Si oil filled polyamide 66 has been shown to have the best overall wear performance whilst the high glass filled variants of polyamide 66 and polycarbonate have the best combination of wear resistance and mechanical strength. These findings are discussed with reference to composite constitution and properties, thermal effects and counterface interactions. Explanations are advanced to account for the differences in behaviour inter alia the composite materials.     

Investigations on the influence of graphite filler on dry sliding wear and abrasive wear behaviour of carbon fabric reinforced epoxy composites

In this experimental study, the dry sliding wear and two-body abrasive wear behaviour of graphite filled carbon fabric reinforced epoxy composites were investigated. Carbon fabric reinforced epoxy composite was used as a reference material. Sliding wear experiments were conducted using a pin-on-disc wear tester under dry contact condition. Mass loss was determined as a function of sliding velocity for loads of 25, 50, 75, and 100 N at a constant sliding distance of 6000 m. Two-body abrasive wear experiments were performed under multi-pass condition using silicon carbide (SiC) of 150 and 320 grit abrasive papers. The effects of abrading distance and different loads have been studied. Abrasive wear volume and specific wear rate as a function of applied normal load and abrading distance were also determined.The results show that in dry sliding wear situations, for increased load and sliding velocity, higher wear loss was recorded. The excellent wear characteristics were obtained with carbon-epoxy containing graphite as filler. Especially, 10 wt.% of graphite in carbon-epoxy gave a low wear rate. A graphite surface film formed on the counterface was confirmed to be effective in improving the wear characteristics of graphite filled carbon-epoxy composites. In case of two-body abrasive wear, the wear volume increases with increasing load/abrading distance. Experimental results showed the type of counterface (hardened steel disc and SiC paper) material greatly influences the wear behaviour of the composites. Wear mechanisms of the composites were investigated using scanning electron microscopy. Wear of carbon-epoxy composite was found to be mainly due to a microcracking and fiber fracture mechanisms. It was found that the microcracking mechanism had been caused by progressive surface damage. Further, it was also noticed that carbon-epoxy composite wear is reduced to a greater extent by addition of the graphite filler, in which wear was dominated by microplowing/microcutting mechanisms instead of microcracking.     

Frictional hardening and softening of steel 52100 during dry sliding

The behavior of frictional hardening and softening of steel 52100 with different microstructures during dry sliding was studied based on dynamic metallographic analysis. It was demonstrated that such frictional behavior significantly affected wear resistance of the steel. The results showed that anti-softening microstructures exhibited a rather better wear resistance; the difference in the wear resistance of various steels with different microstructures was caused by the difference in the energy consumption in surface layers during wear. These results indicate that the original structures and properties of steels should not be taken as the only criterion for judging the wear resistance. It is necessary to consider the influence of dynamic microstructural changes under specific wear conditions in order to evaluate the wear resistance.     

Sliding wear of graphite crystallized chromium white cast iron

The effects of sliding velocity, heat-treatment and graphite shape on sliding wear of graphite crystallized chromium white cast iron were studied. Two types of graphite crystallized chromium white cast irons having flaky or spheroidal and another type of 2.6C–15Cr white cast iron were prepared for this study. The effect of sliding velocity on wear resistance was studied by the Okoshi type and pin-on-disk type wear tests on materials which have experienced “as cast” and “heat-treated” conditions. The Okoshi type wear test results are divided into two relationships depending on sliding velocity or distance. Two regimes, initial wear and steady-state wear, existed for wear loss and sliding distance. A characteristic form of wear curve with a peak and a minimum was obtained when correlating wear loss and sliding velocity. The wear resistance of graphite crystallized chromium white cast irons were superior to that of 2.6C–15Cr white cast iron. In the results of pin-on-disk tests, there was no clear difference in the reported wear loss and friction coefficient among the alloys. However, an opposite tendency has appeared in the wear loss and friction coefficient: the wear loss value reached a peak in the wear curve at 0.52 m/s, while the friction coefficient reached a minimum at 0.52 m/s.     

Tempering temperature effects on abrasive wear of mottled cast iron

The effects of different tempering temperatures (300–600 °C) on abrasive wear resistance of mottled cast iron were studied. Abrasive wear tests were carried out using the rubber-wheel test on quartz sand and the pin test on Al₂O₃ abrasive cloths. The retained austenite content of the matrix was determined by X-ray diffraction. The wear surface of the specimens was examined by scanning electron microscopy for identifying the wear micromechanism. Bulk hardness and matrix hardness before and after the tests were measured. The results showed that in the two-body (pin-on-disc test) system, the main wear mechanism was microcutting and high matrix hardening was presented. The wear rates presented higher correlation with the retained austenite than with the bulk and matrix hardness. In the three-body system (sand–rubber wheel), the wear surfaces presented indentations due to abrasive rolling. The wear rates had better correlation with both the bulk and matrix hardness (before and after the wear test) than with the retained austenite content. There are two groups of results, high and low wear rates corresponding to each tribosystem, two-body abrasive wear and three-body abrasive wear, respectively.     

The friction and wear of automotive grey cast iron under dry sliding conditions Part 1-relationships between wear loss and testing parameters

The material investigated in this study is automotive grey cast iron (SAE G-3500) used for the manufacture of cylinder liners in a range of diesel engines. A comprehensive model for the understanding of wear and friction of this type of materials is presented here for the first time. This model takes into account the cumulative contribution of various mechanisms of wear and friction (truncation, adhesion, delamination and ploughing) to the overall phenomenon of wear loss. Quantitative aspects and statistical modelling were employed to develop a mathematical relationship between measurements of friction and wear under varying conditions of load, number of cycles and velocity (rev min⁻¹).