Effect of fretting amplitudes on fretting wear behavior of steel wires in coal mines

Given that fretting wear causes failure in steel wires, we carried out tangential fretting wear tests of steel wires on a self-made fretting wear test rig under contact loads of 9 and 29 N and fretting amplitudes ranging from 5 to 180 μm. We observed morphologies of fretted steel wire surfaces on an S-3000N scanning electron microscope in order to analyze fretting wear mecha-nisms. The results show that the fretting regime of steel wires transforms from partial slip regime into mixed fretting regime and gross slip regime with an increase in fretting amplitudes under a given contact load. In partial slip regime, the friction coefficient has a relatively low value. Four stages can be defined in mixed fretting and gross slip regimes. The fretting wear of steel wires in-creases obviously with increases in fretting amplitudes. Fretting scars present a typical morphology of annularity, showing slight damage in partial slip regime. However, wear clearly increases in mixed fretting regime where wear mechanism is a combination of plastic deformation, abrasive wear and oxidative wear. In gross slip regime, more severe degradation is present than in the other regimes. The main fretting wear mechanisms of steel wires are abrasive wear, surface fatigue and friction oxidation.

A STUDY OF CONTINUOUS EXTRUSION-CLADDING PROCESSFOR PRODUCTION OF ALUMINUM-CLADDING STEEL WIRE

In this study the process of cladding steel wires with aluminum is investigated experimentally. It is studied how the cladding process and the quality of products are influenced by the aluminum deformation temperature, the wheel speed, the temperature of steel wire, the wire speed and the steel wire tensile force. The relation among the process parameters above is discussed, and the effect of the aluminum deformation temperature on the coating microstructure is analyzed. This paper suggested a reasonable range of process parameters for producing aluminum cladding steel wires.

Thermodynamic analysis of the compositional control of inclusions in cutting-wire steel

Data from a thermodynamic database and the calculation software FactSage were used to investigate the phase diagrams of the MnO？CaO？SiO2？Al2O3 system in cutting-wire steel and the effects of oxide components on the low-melting-point （LMP） zone in the cor-responding phase diagrams. Furthermore, the activities of oxide components in the quaternary system at an Al2O3 content of 25wt%were calculated. The contents of dissolved [Al] and [O] in liquid steel in equilibrium with LMP inclusions in the MnO-CaO-SiO2-Al2O3 system were optimized. The results show that the MnO-CaO-SiO2-Al2O3 system possesses the largest LMP zone （below 1400℃） at an Al2O3 content of 25wt%and that the CaO content should be simultaneously controlled in the range of 40wt%to 45wt%. The activities of the oxide components CaO, MnO, and SiO2 should be restricted in the ranges of 0 to 0.05, 0.01 to 0.6, and 0.001 to 0.8, respectively. To obtain LMP inclusions, the [Al] and [O] contents in cutting-wire steel must be controlled within the ranges of 0.5 ×10^-6 to 1.0 ×10^-5 and 3.0 ×10^-6 to 5.0 × 10^-5, respectively.

Electrochemical corrosion behavior of steel wires in a coalmine with a corrosive medium

A6×19 point-contact hoisting cable was used as our research object to examine the progress of corrosion of steel wires in a laboratory,simulating the actual working conditions in a coalmine.An electrochemical method was used to investigate the corrosion behavior of steel wires with different surface treatments of a corrosive acid solution.The results show that anode activation of steel wire mainly occurs during pre-corrosion,where the anode activation process of bare steel wires is the fastest as is their corresponding corrosion speed,while the anode activation process of oil coated steel wires and their corresponding corrosion speed are the lowest.During the intermediate and late immersion periods, a passive film is generated on the surface of steel wires,which are gradually damaged with the passage of time.Local pitting corrosion occurs easily on the surface of steel wires with a high-polarization potential. Suitable equivalent circuits were chosen to fit the electrochemical impedance spectroscopy（EIS）of steel wires over various corrosive times and different surface treatments,which indicate good fitting results. The double electrical layer charge-transfer resistance increases in the sequence：bare steel wire, untreated steel wire and oil coated steel wire and their corrosion resistance decreases in turn,which is consistent with their polarization curves.The oil layer provides a certain protective effect on untreated steel wires,but its effect is not entirely clear.

Characteristic of Near-surface Microstructure and Its Effects on the Torsion Performance of Cold Drawn Pearlitic Steel Wires for Bridge Cables

The characteristic of near-surface microstructure and its effects on the torsion performance of cold-drawn pearlitic steel wires for bridge cables were investigated by focused ion beam-scanning electron microscope,transmission electron microscopy and differential scanning calorimetry.The samples with similar tensile strength before and after hot-dip galvanizing process are,respectively,characterized as delaminated and non-delaminated in torsion test which indicates that the tensile strength is independent of the toughness value(i e,reduction area and torsion ability).It is interesting to find that there exists submicron granular ferrite on near-surface of the wires,which can be attributed to dislocation rearrangement and sub-grains rotation during cold drawing and hot-dip galvanizing process.And their distribution can suggest homogeneousness of deformation degree to a certain extent:the closer to the surface of their distribution,the more homogeneous deformation of the wires.There is a close relationship between the thermal stability of the cementite layer and distribution of granular ferrite:differential scanning calorimetry(DSC)analysis shows that the sample is accompanied by submicron granular ferrite which is located closer to the surface has higher thermal stability under galvanizing temperature(450°C).A new mechanism of the torsion delamination of pearlitic steel wires is discussed in terms of the thermal stability of the cementite layer and distribution of granular ferrite.

DEFORMATION AND STRENGTHENING OF COLD-DRAWN STEEL WIRES

It was shown by the study of TEM that the fine lamellar pearlite becomes a ductile phase dur- ing cold drawing.There exist many ledges to emit dislocations at Fe_3C/Fe interface.It is one of the reasons that high density of dislocations emerges at the Fe_3C/Fe interface. Furthermore,there are some evidences to support that dislocation cuts through Fe_3C.There- fore,it is necessary to consider the contribution of cementite being sheared strengthening.

DRAWING OF ALUMINUM-CLAD STEEL WIRE BY FORCE-FEED LUBRICATION

The force feed lubrication method is used for drawing aluminum clad steel wire. It is studied how deformation of wire and aspect of the lubricant film are influenced by the die angle, the reduction, the drawing speed and the gap between pressure die and wire. It has been concluded that when the factors above mentioned promote to thicken lubricant film, the drawing force is reduced and this favors the homogenous deformation of aluminum coating and steel core.

Present situation and countermeasure of low-alloy spring steel wire rod for domestic automobile

The variety,inner quality and surface quality of low-alloy spring steel wire rod for domestic automobile is summarized in detail.And according to commercial low-alloy spring steel wire rod variety, product quality level and its actual application situation on automobile supplied by present industrially developed country metallurgy enterprises,it is pointed that the variety of low-alloy spring steel wire rod for domestic automobile can't satisfy the requirements of automobile industry development,compare with overseas advanced technology,product quality has the following gaps:the first is that steel purity is low,the control level of non-metallic inclusions is not steady,there is often large grain difficult deforming non-deformation inclusions existing,the control level of steel purity has big difference,the level of large steel factory is high,but its steady has a large gap compare with foreign advanced level,not to mention small steel factory which research and development powder is low.The second is surface complete decarburization can' t be avoided completely.The third is that surface defects are more.The fourth is that composition segregation and structure segregation are not steady,steel wire can't be drawn normally when the segregation is serious. In all,the segregation of 55SiCrA is superior to 60Si2MnA obviously.The industrialization of domestic high level low-alloy spring steel wire rod can't seek quick success and instant benefits,independent innovation perseveringly must be adopted,the success may be reached after master core technologies and adopt the science way of step by step.

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.

Synthesis and Characterization of ZnO Film on Stainless Steel Wire and Bioaerosol Antimicrobial Activity Evaluation

ZnO thin films were prepared by electrophoretic deposition on stainless steel wire sieve, using zinc acetate as a precursor. The film was sintered and characterised by Scanning Electron Microscopy （SEM）, X-Ray Diffraction （XRD） and chemisorption of oxygen. A culture bacterial consortium composed by gram negative rod-shaped microbes was prepared in a liquid agar in a flask. It was transported by air through a reactor equipped with a UV lamp with 3 and 5 sieves of a stainless steel wire coated with ZnO film. It was exposed in continuous in five experiments to photocatalytic advanced oxidation. The experiments showed a total efficiency for colony forming unit reduction of a maximum of 99.66% for a residence time of 20 seconds with 5 stainless steel wire where exposed in continuous to UV. Also they were evaluated at 7.5 seconds, observing that the contribution of residence time and amount of catalytic for the CFU reduction was quite similar. Variance analysis showed that the efficiency was significant with the no parametric Kruskal-Wallis test with P 〈 0.05. This technology could be used to clean indoor air of closed environments such as hospitals, crowded buildings or public transportation systems where airborne bacteria has been documented.

Influence of Fatigue Loading on the Residual Stress Distribution in Prestressing Steel Wires

This paper analyzes the influence of fatigue loading on the residual stress profile in high strength steel wires. To this end, different sinusoidal loads with diverse values of maximum loading level and number of cycles were simulated on wires in which several residual stress profiles had been previously introduced, some of them with a tensile state and others with a compressive state. An analysis was made of the evolution with time of such residual stress laws by comparing them at key instants of loading, that is, at initial instant, at maximum load, at minimum load and at final instant. Numerical results show only a minor influence of fatigue loading on the residual stress profile.

线棒材和H型钢产品的缺陷组织

选取线棒材HRB400E钢、45钢、Q355B钢中的不合格试样,对其中贝氏体、网状铁素体、魏氏组织、带状组织等缺陷组织产生的原因进行分析。结果表明:采用调整钢材加热温度、出精轧温度、轧后冷却速率等工艺参数的方法,可以避免材料产生缺陷组织。研究结果可为提高钢材产品的合格率提供支持。

Friction and wear of multiple steel wires in a wire rope

The fretting wear among the steel wires aggravates the wire rope’s fatigue damage,affects the service performance of the wire ropes,and threatens mine hoisting safety.In this paper,the practical friction behavior and wear mechanism among the wires in the wire rope are investigated.A series of tests were carried out on multiple steel wires in helical contact and tension–torsion coupling under different fretting parameters,twisting parameters,and lubrication conditions by self-made friction and wear testing machine.The results show that the coefficient of friction(COF)among the steel wires decreases slightly with increasing lateral loads and tension,and the effect of twist angle on the COF has opposite results under different lubrication conditions.Lateral loads,tension of the steel wires,twist angle,and lubrication condition all affect the fretting morphology among the steel wires.Fretting wear with larger twist angle structure leads to more energy loss.The energy loss of fretting is directly related to the fretting morphology among the contact surfaces,and the dissipated energy is lower in the two forms of complete slip and sticking.The wear depth and width increase with the increase of lateral loads,steel wire tension,and twist angle.And the wear width and depth under dry friction conditions are higher than those under oil lubrication conditions.In addition,the wear mechanism under dry friction conditions is mainly abrasive wear,adhesive wear,and fatigue wear.And the wear mechanism under oil lubrication conditions is mainly abrasive wear and fatigue wear.

Tribo-corrosion interaction of the parallel steel wires in the suspension bridges

The effect of contact load and relative displacement on tribo-corrosion interaction of parallel steel wires of main cable in the suspension bridge was investigated in this study.A self-made tribo-corrosion test bench was employed to conduct tribo-corrosion tests of parallel steel wires in 3.5%(wt%)NaCl solution and deionized water under different contact loads and different relative displacements.The friction coefficient and wear coefficient of wires were presented.Electrochemical corrosion behavior(Tafel polarization curves,Nyquist diagram,and equivalent circuit diagram)was characterized by electrochemical analyzer.Wear morphology was observed by scanning electron microscope.Wear volume loss and corrosion‒wear interaction were quantitatively demonstrated by high-precision weighing balance.The results show that the electrochemical corrosion ability of the steel wires increases with the increase of the contact load or relative displacement.The increased contact load or relative displacement increases the volume loss of corrosion‒wear and pure wear,but decreases the wear coefficient.The wear mechanisms in 3.5%NaCl solution are adhesive wear,abrasive wear,and corrosive wear as compared to adhesive wear and abrasive wear in deionized water under different contact loads.The wear mechanisms of parallel steel wires are slightly different under different relative displacements.But the main wear mechanisms are similar to that under different contact loads.The interaction effects of corrosion and wear produced by the contact load and relative displacement are all the synergistic effects.

Effect of rare earth content on microstructure and corrosion resistance of hot-dip Zn-5Al alloy coated steel wire for bridge cables

The effects of the content of rare earth elements on the microstructure and properties of hot-dip Zn-5 Al alloy steel wire for bridge cables were investigated.The microstructure of the hot-dip coating was analyzed using an optical microscope and a scanning electron microscope equipped with an energy-dispersive spectrometer.The bonding force between the hot-dip coating and steel wire was determined by the winding test.The corrosion resistance of the steel wire hot-dip coating was tested by the electrochemical workstation.The hot-dip Zn-5A1 alloy coating has a corrosion-resistant structure composed of a zinc-rich phase and an aluminum-rich phase.Due to the enhanced bonding force,the micro structure of the hot-dip coating of the Zn-5A1 alloy with rare earth elements is more compact and uniform than that without rare earth elements.The addition of rare earth elements improves the corrosion resistance of Zn-5A1 alloy coated steel wire.Due to the rare earth segregation,which prevents the corrosion of the grain boundary and enhances the anti-intergranular corrosion performance,steel wire exhibits the optimum corrosion resistance when the content of rare earth elements is 0.08 wt.%.

Improvement of Inner Quality of High Carbon Wire Rod Steel Using Combined Electromagnetic Stirring

To improve the quality of high carbon wire rods,combined electromagnetic stirring was introduced in the continuous casting of round billets with a diameter of 250mm at Tianjin Rockcheck Steel Group Co.In this paper,the positioning of final electromagnetic stirring(F-EMS)was determined by nail-shooting method.Furthermore,the effect of mold electromagnetic stirring(M-EMS)on the macrostructure and internal defects in the round billets was investigated to find out the optimal operating parameters for continuous casting of SWRH 82B round billets.The results show the desirable positioning of F-EMS locates 9.7m below the mold level where the molten steel can be effectively driven by electromagnetic force and disperse central composition segregation.The shrinkage cavity is totally eliminated with the rotational M-EMS.The ratio and index of central composition segregation and center porosity can be reduced significantly. Furthermore,the equiaxed crystal ratio is considerably increased to 64%under 480A/3Hz M-EMS and 500A/10Hz F-EMS. Fine microstructure and mechanical property of wire rod are presented after optimization of combined electromagnetic stirring.Accordingly,the probability of occurrence of cup-cone fracture of wire rod is reduced dramatically.

金属网在刚性弹头静压下的力学性能分析

金属网是由高强钢丝编织而成的三维网状结构,在近程武器(如火箭弹、迫击炮弹)拦截中应用广泛。为研究分析金属网与弹头间相互作用的力学性能,结合金属网的实弹拦截试验情况和破坏特点,设计了刚性弹头加载装置和金属网静压试验平台,开展了刚性弹头加载装置静压金属网的力学性能试验研究。结果表明:在受到加载装置向下静压的过程中,金属网整体上呈现漏斗型变形,金属网中与弹头接触部分的菱形网孔呈现逐步接近于弹头剖面形状的变形;金属网的破坏位于与弹头接触部分的菱形网孔中钢丝交叉节点处。依据试验现象及相关结果的研究,推导了刚性弹头静压金属网临界荷载的理论计算方法,分析了误差产生的原因,理论方法与试验获得的静压临界荷载吻合较好,误差在±10%以内。研究成果可为金属网拦截弹体的初步设计提供参考。

Effect of fatigue load on the bending tribo-corrosion-fatigue behaviors between the main cable wires

The main cable bent around the saddle of the suspension bridge is subjected to the wind,the vehicle,the bridge’s own weight and the corrosive media.The coupling of the three loads and the environments causes the friction,the corrosion,and the fatigue(tribo-corrosion-fatigue)among the wires inside the main cable.In this paper,a wire bending tribo-corrosion-fatigue test rig was designed and developed.The effect of fatigue load on the bending friction behaviors between the cable wires in ultrapure water and 3.5%NaCl solution was explored.The tribological properties and electrochemical corrosion behaviors under different fatigue loading ranges were investigated.The tribo-corrosion-fatigue interaction between the cable wires was quantitatively characterized,and the mechanism of the interaction was analyzed.The results demonstrate that the increasing fatigue load exacerbates the coupling damage of the cable wires attributed to the enhanced interaction.The findings carry theoretical importance when assessing the main cable’s deterioration and the load-bearing safety of a suspension bridge.

钢丝网高强混凝土抗爆性能试验研究

在同等条件下,用0.6 kg和1.8 kg的TNT药块对体积含量2.15%的钢丝网增强高强混凝土(HSC)试件和体积含量3%和5%的钢纤维增强HSC试件进行接触爆炸试验,并将试验结果进行比较。结果表明,体积含量2.15%的钢丝网增强HSC试件抗爆性能介于体积含量3%、5%的钢纤维增强HSC试件之间,抗爆性能具有优势,但优势略逊于抗侵彻性能。基于试验结果的综合分析,利用钢丝网HSC进行防护工程的抗爆结构设计时,其ka值可取为0.054.

含钢丝网遮弹层的结构靶的力学性能与枪弹射击试验研究

综述了国内外抗侵彻材料的研究现状 ,并借鉴前人研究复合遮弹层的技术和经验 ,提出了一种新型材料———钢丝网遮弹层 ,并以不同的基体材料和不同的钢丝网含量制作多种结构的试件 ,对它们进行了步枪弹射击试验和抗弯、抗压、抗冲击等静动态试验研究 ,并与钢纤维水泥砂浆做性能对比。试验表明 ,钢丝网的使用能显著改善基体材料的抗侵彻性能和静动态力学性能 ;钢丝网水泥细砂浆可作为遮弹层的优选材料且在工艺允许的范围内 ,随钢丝网的层数增加 。