Research on the mechanism of the two-dimensional ultrasonic surface burnishing process to enhance the wear resistance for aluminum alloy

The gradient nanostructure is machined on the aluminum(Al)alloy by the two-dimensional ultrasonic surface burnishing process(2D-USBP).The mechanism of why the gradient nanostructure enhances wear resistance is investigated.The mechanical properties and microstructure characterization for the gradient nanostructure are performed by operating a nanoindenter,transmission electron microscopy(TEM),and electron backscattered diffraction(EBSD).Dry wear tests are performed on the samples before and after machining to evaluate the wear resistance and mechanisms.The effect of the gradient nanostructure on the wear resistance is explored by developing the crystal plasticity(CP)finite element and molecular dynamics(MD)models.The characterization results show that the 2D-USBP sample prepared a gradient structure of~600μm thick on the aluminum surface,increasing the surface hardness from 1.13 to 1.71 GPa and reducing the elastic modulus from 78.84 to 70.14 GPa.The optimization of the surface microstructure and the increase of the mechanical properties effectively enhance the wear resistance of the sample,with 41.20%,39.07%,and 54.58% of the wear scar areas for the 2D-USBP treated samples to the original samples under 5,10,and 15 N loads,respectively.The gradient nanostructure hinders the slip of dislocations inside the sample during the wear process and reduces the size and scope of plastic deformation;meanwhile,the resistance to deformation,adhesion,and crack initiation and propagation of the sample surface is improved,resulting in enhanced wear resistance.

Accumulated damage process of thermal sprayed coating under rolling contact by acoustic emission technique

The accumulated damage process of rolling contact fatigue （RCF） of plasma-sprayed coatings was investigated. The influences of surface roughness, loading condition, and stress cycle frequency on the accumulated damage status of the coatings were discussed. A ball-on- disc machine was employed to conduct RCF experiments. Acoustic emission （AE） technique was introduced to monitor thc RCF process of the coatings. AE signal characteristics were investigated to reveal the accumulated damage process. Result showed that the polished coating would resist the asperity contact and remit accumulated damage. The RCF lifetime would then extend. Heavy load would aggravate the accumulated damage status and induce surface fracture. Wear became the main failure mode that reduced the RCF lifetime. Frequent stress cycle would aggravate the accumulated damage status and induce interface fracture. Fatigue then became the main failure mode that also reduced the RCF lifetime.