Recent advances in wheel–rail RCF and wear testing

The wear and rolling contact fatigue (RCF) testing approaches for wheels and rails have been reviewedand evaluated in this study. The study points out the advantages and limitations of the existing approaches. Thebroad analysis revealed that scaled laboratory-based wear testing is widely applied. However, it is necessary topredetermine the input parameters and observing parameters for scaled wear testing for three reasons: first, toemulate the real-world scenarios as closely as possible;second, to postprocess the results received from the scaledtesting and transfer them into real practice at full scale;third, to present the results in a legible/appropriate format.Therefore, most of the important parameters required for wear testing have been discussed with fundamental andsystematic explanations provided. Additionally, the transition of the parameters from the real-world into the testdomain is explained. This study also elaborates on the challenges of the RCF and wear testing processes andconcludes by providing major considerations toward successful testing.

A dual-axis chewing simulator for in vitro wear test of dental restoration materials

The wear rate of dental restoration materials on fixed, removable, and implant prostheses is important in the maintenance of cuspate form, masticatory efficiency and occlusal stability. Many permanent restoration materials such as composite, amalgam, gold, or porcelain show enough resistance to wear, but the wear rates of newly developed materials are generally unknown. To evaluate the wear rate of these dental materials, in vivo (clinic) and in vitro methods can be used. Since in vivo investigations are expensive, time consuming, and difficult to standardize, various in vitro methods have been developed. The use of a chewing machine is considered the best method, because a variety of wear mechanisms, temperature changes, and chemical effects of food and drink can be simulated simultaneously. This paper describes a dual axis chewing simulator for in vitro wear test of dental restoration materials. It consists of 8 test chambers, two stepper motors and related mechanism, a hot and cool water circle system, and a control unit. In the chambers, samples and antagonists make chewing movements vertically and Albert Ludwigs University, School of dentistry, Freiburg, Germany (Lü XY, Kern M and Strub JR) horizontally driven by the stepper motors so that the gnashing and slippage of two teeth against each other is simulated. A weighted test object is programmed to collide with a sample under precise operator control. The antagonists strike against the samples at various speeds from a slow nudge to snapping. Sample holders are designed for installation of varying samples, from single teeth to complete dentures. Two baths, six valves, and a group of pipes are used for the thermocycling. The machine can simulate various chewing modes in the mouth, including fully programmable thermal water cycling between 5℃ and 60℃ The control unit consists of a computer system with a built in specific program. Important operations such as “Start”, “Zero point”, and “Stop” are carried out by pressing the function keys on the front board of the unit. During the programming process and the simulation, several test modes and relevant test parameters are shown on the monitor. The control unit is connected via a series of interfaces to different controlled parts of the machine, such as the stepper motors and the pumps of cool and warm water.

Dry sliding friction and wear behaviors of Mg_2B_2O_5 whisker reinforced 6061Al matrix composites

The friction and wear properties of Mg2B2O5 whisker reinforced 6061Al matrix composite fabricated via power ultrasonic-stir casting process were investigated using a ball-on-disk wear-testing machine against a GCr45 steel counterface under dry sliding conditions. The reinforcements include as-received Mg2B2O5 whiskers and Mg2B2O5 whiskers coated with CuO and ZnO. The volume fraction of the composites is 2%. The relationship between the wear rate and the coefficient of friction was discussed. The results indicate that the wear rate of the Mg2B2O5 whiskers coated with ZnO reinforced aluminum matrix composites is the lowest among the materials. As the applied load and sliding speed steadily increase the coefficients of friction and wear rates of the as-received matrix alloy and the fabricated composites decrease. As the applied load and sliding speed increase, the wear mechanisms of the composites shift from a mild to a severe regime.

Comparison of wear behaviour of LM13 Al−Si alloy based composites reinforced with synthetic(B_(4)C)and natural(ilmenite)ceramic particles

Dry sliding wear behaviour of stir-cast aluminium matrix composites(AMCs)containing LM13 alloy as matrix and ceramic particles as reinforcement was investigated.Two different ceramic particle reinforcements were used separately:synthetic ceramic particles(B_(4)C),and natural ceramic particles(ilmenite).Optical micrographs showed uniform dispersion of reinforced particles in the matrix material.Reinforced particles refined the grain size of eutectic silicon and changed its morphology to globular type.B_(4)C reinforced composites(BRCs)showed maximum improvement in hardness of AMCs.Ilmenite reinforced composites(IRCs)showed maximum reduction in coefficient of friction values due to strong matrix−reinforcement interfacial bonding caused by the formation of interfacial compounds.Dry sliding wear behaviour of composites was significantly improved as compared to base alloy.The low density and high hardness of B_(4)C particles resulted in high dislocation density around filler particles in BRCs.On the other hand,the low thermal conductivity of ilmenite particles resulted in early oxidation and formation of a tribo-layer on surface of IRCs.So,both types of reinforcements led to the improvement in wear properties of AMCs,though the mechanisms involved were very different.Thus,the low-cost ilmenite particles can be used as alternative fillers to the high-cost B_(4)C particles for processing of wear resistant composites.

Influence of niobium and molybdenum addition on microstructure and wear behavior of laser-borided layers produced on Nimonic 80A-alloy

Laser alloying was used for production of thick layers on surface of Nimonic 80A-alloy.For laser surface modification,three types of pre-coated pastes were applied:with amorphous boron,with amorphous boron and molybdenum as well as with amorphous boron and niobium.The microstructure,hardness and wear resistance of produced layers were studied in details.The presence of different types of borides in re-melted zone depended on the paste composition and caused an increase in hardness up to about HV 1000.The wear resistance was evaluated by calculation of mass wear intensity factor Imw and relative mass loss of specimen and counter-specimen.The wear behavior of the tested frictional pairs was determined by 3D interference microscopy,scanning electron microscopy equipped with EDS microanalyzer.The significant increase in abrasive wear resistance was observed in comparison to untreated Nimonic 80A-alloy.The lowest mass loss intensity factor was characteristic of laser-alloyed Nimonic 80A-alloy with boron and niobium(Imw=1.234 mg/(cm2?h)).Laser alloyed-layers indicated abrasive wear mechanism with clearly visible grooves.Laser alloying with boron and niobium resulted in the additional oxidative wear mechanism.In this case,EDS patterns revealed presence of oxygen on the worn surface of specimen.

Friction and Wear Behavior of Ti-6Al-7Nb Biomaterial Alloy

Titanium has been increasingly applied to biomedical application because of its improved mechanical characteristics, corrosion resistance and biocompatibility. However their application remains limited, due to the low strength and poor wear resistance of unalloyed titanium. The purpose of this study is to evaluate the friction and wear behavior of high-strength titanium alloys: Ti-6Al-7Nb used in femoral stem (total hip prosthesis). The oscillating friction and wear tests have been carried out in ambient air with oscillating tribotester in accord with standards ISO 7148, ASTM G99-95a, ASTM G 133-95 under different conditions of normal applied load (3, 6 and 10 N) and sliding speed (1, 15 and 25 mm.s-1), and as a counter pair we used the ball of 100C 6, 10 mm of diameter. The surface morphology of the titanium alloys has been characterized by SEM, EDAX, micro hardness, roughness analysis measurements. The behavior observed for both samples suggests that the wear and friction mechanism during the test is the same for Ti alloys, and to increase resistance to wear and friction of biomedical titanium alloys used in total hip prosthesis (femoral stems) the surface coating and treatment are required.

Study on Preparation and Engine Bench Test of Friction-Reducing and Repairing Additive to Lubricating Oils

A new kind of friction-reducing and repairing additive containing nano-scale copper and rare earth compounds were prepared by means of synthesis and compounding methods. The performance of the said additive was investigated by engine bench test, and was compared to the performance of similar domestic and imported additives. The deterioration of lube oils containing additives over different time intervals was studied by means of plasma spectrometry and mass spectrometry, and the effect of additive package on engine power was also studied. Test results have revealed that the synthetic additive package can provide good anti-wear performance to the tribo-pairs. In particular, after 300 hour application of the said additive package the connection rod shaft and copper sleeve showed 'zero wear' to achieve the in situ dynamic repairing of tribo-pairs. Application of the said synthetic additive can effectively improve the engine power performance and extend the engine service life.

Topside Axial Bearing Wear Under the Eccentric Load of a Single-Anchor Leg Mooring System in Bohai Bay

Because the applications of single-anchor leg mooring yoke systems(SYSs)are rarely studied in the offshore industry,the design of such systems features some uncertainties.This paper investigated the effect of eccentricity on the wear of the topside axial bearing of a SYS.The eccentricity of the topside was verified by on-site inspection,and the axial bearing wear was found to be far more serious than the original design.The contact status between the axial bearing and flange surface was studied on the basis of the actual topside load by using nonlinear finite element analysis.Wear tests of the topside bearing under uniform and eccentric loads were also performed to study the effect of eccentric loads on the wear rate.The key parameters obtained from numerical simulations and experimentation were used to calculate the wear depth via a simplified linear wear model based on the product of the pressure and sliding distance.Results showed that eccentric loads are the main factor responsible for the excessive wear of topside axial bearings.

A Comparative Study on Dry Sliding Wear Characteristics of Al2O3 and Bone Powder Filled Hybrid Composites

The aim of the research was to develop E-glass/jute fiber reinforced epoxy composites with an addition of Al2O3 and bone powder by using hand layup technique and to compare tribological properties of these composites under similar test conditions. The wear experiments were designed according to Taguchi’s (L27) orthogonal array with three control variables such as sliding velocity, filler content and normal load. The results indicated that the normal load for Al2O3 and filler content for bone powder emerged as the significant factors affecting specific wear rate of hybrid composites. An addition of 10 wt% of bone powder or Al2O3 into E-glass/jute fiber reinforced epoxy composites increased the wear resistance considerably, and natural waste bone powder can be used instead of ceramic filler Al2O3 in hybrid composites. After the analysis of control factors, an optimal factor setting has been suggested for specific wear rate and coefficient of friction. Further, the scanning electron microscopy (SEM) images for worn surfaces of hybrid composites were studied. Finally, a confirmation test was carried out to validate the results.

Mechanical Characterization of Rubber Latex-Based Carpets (Hevea bresiliensis): Influence of Rubber Latex Content and Fiber Fabrics (Cotton and Mosquito Nets) on Wear Resistance of Rubber Latex-Based Carpets

This work focuses on the development of carpets from sand, fabrics of cotton fiber and mosquito nets and rubber latex. Following a study on the choice of the best formulations, the quantity of rubber latex used for shaping varies between 14% and 18% (latex/sand + latex ratio) for the carpet with the fabric of mosquito nets and between 16% and 18% for the one made with the fabric of cotton fiber. Thus, with a mixture of sand, fiber fabrics (cotton and mosquito nets) and rubber latex, carpets were developed. In addition, the wear test carried out on these samples indicates that it is possible to produce carpets with the new material made of rubber sand and latex: SABLATEX At room temperature. Following the characterization test, it resorts to only 16% latex with cotton fiber fabric, allowing to have carpets with good mechanical characteristics.

Mechanical Characterization and Micro-Wear of FeB-Fe₂B Layers on Boriding AISI D2 and AISI 4340 Steels

The mechanical behavior and wear of the different hardened phases with bore-induced changes in AISI 4340 and AISI D2 steels were investigated. The hardness and modulus of elasticity were measured by nanoindentation and the values obtained for the layers in AISI D2 steel were 18 GPa and 325 GPa in the Fe2B boride phase, and 20 GPa and 360 GPa in the FeB boride phase, respectively. The AISI 4340 steel presented mainly the Fe2B phase. It was then possible to analyze the coefficient of friction obtained in the Fe2B phase of the steel AISI 4340 presented a range of 0.04 to 0.06. The AISI D2 steel presents two different phases in the boride layer being the coefficient of friction higher for the test in the FeB phase than for Fe2B, and the values vary from 0.065 to 0.075. These parameters were obtained with micro-wear tests. No adhesion failures were observed after the sliding tests in the interface of the two different boride layers. Cracks in the FeB phase after the sliding test were much more frequent.

Microstructure and wear characteristics of ATZ ceramic particle reinforced gray iron matrix surface composites

The alumina toughened zirconia(ATZ) ceramic particle reinforced gray iron matrix surface composite was successfully manufactured by pressureless infi ltration. The porous preform played a key role in the infi ltrating progress. The microstructure was observed by scanning electron microscopy(SEM); the phase constitutions was analyzed by X-ray diffraction(XRD); and the hardness and wear resistance of selected specimens were tested by hardness testing machine and abrasion testing machine, respectively. The addition of high carbon ferrochromium powders leads to the formation of white iron during solidifi cation. The wear volume loss rates of ATZ ceramic particle reinforced gray iron matrix surface composite decreases fi rst, and then tends to be stable. The wear resistance of the composite is 2.7 times higher than that of gray iron matrix. The reason is a combination of the surface hardness increase of gray iron matrix and ATZ ceramic particles and alloy carbides protecting effect on gray iron matrix.

Wear of MgO-C Refractories in EBT Type Furnaces Experienced at Iranian Mobarakeh Steel Plant

Mobarakeh Steel Company produces 3 million tons of steel annually with eight 180 tons EBT furnaces. Different types of magnesia-carbon refractories have been employed at slagline during last 5 years. In the present study the wear and corrosion of MgO-C refractories of these furnaces have been studied via post-mortem analysis of used bricks and the observation of operational effects. Laboratory corrosion tests were also arranged to investigate the effect of slag chemistry and the mechanism of chemical corrosion . Characterization of different magnesia-carbon bricks clarified that the crystal size , type and chemistry of magnesia as well as graphite structure have the main influence on corrosion resistance. The CaO: SiO2 ratio in slag also plays a vital role in the wear of slagline refractories. The iron oxide content of slag also has a major role in graphite oxidation. Of metallurgical parameters , the electric power input and the contact time have great influence on refractories life. The results will be discussed with emphasis on particular operational factors in Mobarakeh steel plant.

Experimental investigations on wear properties of Palm kernel reinforced composites for brake pad applications

The use of asbestos material is being avoided to manufacture the brake pads as it is harmful and toxic in nature. Further it leads to various health issues like asbestosis, mesothelioma and lung cancers. These brake pads can be replaced by natural fibers like Palm kernel (0-50%), Nile roses (0-15%) and Wheat (0-10%) with additives like aluminum oxide (5%-20%) and graphite powder (10%-35%). Phenolic resin of 35% is utilized as a binder. Particulated Nile roses are used to increase the friction coefficient and wheat powder is used to reduce the wear rate. Aluminum oxide and graphite are abrasive in nature. This helps to make brake pads with high friction co-efficient and less wear rate with low noise pollution. The wear of the proposed composites have been investigated at different speeds. Various tests like wear on pin-ondisc apparatus, hardness on the Rockwell hardness apparatus and oil absorption test have been conducted. Phenolic resin produces good bonding nature to fiber. Thus, Fibers found to have performed palatably among all commercial brake pads. The objective of the research indicates that Palm kernal shell could be a conceivable alternative for asbestos in friction coating materials.

Wear analysis of a side dam in twin-roll strip casting

Reducing wear on a side dam can prolong the casting operation life of a twin-roll strip casting process,thus reducing production cost and improving casting stability.To lengthen the service life of the side dam,it is necessary to understand the wear performance of the side dam material.To investigate the wear behavior mechanism of the side dam,in this study,the UMT-2 friction and wear tester was used to determine the relationship between the wear rate of the side-dam material and various parameters.Based on the roughness of the contact area between the side dam and the end of the casting rolls as well as on the amount of deformation of the side dam,which was derived using a thermal-deformation simulation model,the reasons for the uneven wear of the side dam were obtained.

A STUDY OF TESTS ON GLASS FIBER RESIN FRICTION MATERIALS

The relationships between the microstructure, the composition, the friction temperature and the form of a new kind of friction material which is a glass fibre resin friction materials (GFRF) are studied through a series of tests on machine as EPMA, STM, DTG-DTA,an optical microscope and a friction test machine. The tests show that the rising rate in temperature and the heat conductivity of GFRF are lower than that of asbestos friction material. In GFRF, the heat-decline is slowed down or even eliminated. the distribution of heat- stress is improved and the life span is extended. Raising the temperature of resin resolution and enhancing the stickness between resin and glass fibre are the two important procedures to improve the friction and wear performance of GFRF.A discription about the friction and wear mechanism of GFRF is given in this paper.

Fretting wear of steel wires in hoisting ropes

To investigate the fretting wear of steel wires in hoisting ropes, specimenswere made of 6X19 point contact ropes. A model for the fretting ear was developed and a frettingwear test rig was deigned in laboratory. A series of experiments were performed on this test rig.The wear volume was taken as a characteristic parameter to describe the fretting wear in relation tothe contact load, reciprocating cycles and amplitude. Moreover, the wear mechanisms were discussedin the fretting process.

基于超声强化研磨加工的GH4099合金耐磨服役性能提升研究

GH4099合金具有优异的高温热稳定性、高温力学性能和高温抗蠕变性能,用于航空发动机涡轮盘和涡轮叶片的制造,常处于高温、重载、高频的工作环境,但因耐磨服役性能差导致其使用寿命较短。通过超声强化研磨加工技术对GH4099合金分别进行0、3、6、9 min的加工,实现其耐磨服役性能提升。采用超声强化研磨加工技术对GH4099合金板表面进行不同时间的加工处理,并对加工前后的截面显微硬度、金相组织以及表面形貌进行分析。同时,通过往复式摩擦磨损试验对加工前后的试样耐磨性能进行对比分析。研究结果表明:随着加工时间的增加,材料表面显微硬度逐渐增大,最大为432.83 HV,比未加工试样增加43.8%。当加工时间为6 min时,GH4099合金试样的摩擦系数为0.47,磨损率为5.78×10^(-14)m^(3)/(N·m),与未加工试样相比,分别降低24.2%、68.59%,表明超声强化研磨可有效提升GH4099合金耐磨服役性能。

高碳铬铁渣微表处混合料路用性能研究

针对道路养护工程优质石料资源匮乏,高碳铬铁渣大多采用堆存处理且利用率低等问题,将高碳铬铁渣分别以0%、20%、30%、40%、50%、60%的掺量替换常规微表处混合料,通过湿轮磨耗试验、车辙试验、黏聚力试验和构造深度试验研究不同高碳铬铁渣掺量下的微表处混合料的路用性能。试验结果表明:高碳铬铁渣掺量为20%时,混合料的耐磨耗性能和水稳定性与常规微表处混合料相近,抗车辙性能略有下降,早期强度和抗滑性能均优于常规微表处混合料。