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.

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.

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.

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.

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.

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.

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.

Microstructure and mechanical properties of low carbon steel wires with serial and reverse-direction cold drawing

Low carbon steel wires were prepared by two processes,serial drawing(SD)and reverse-direction drawing(RD).Effects of the two processes on microstructure and mechanical properties in steel wires were investigated by field emissio scanning electron microscopy,electron backscatter diffraction(EBSD),X-ray diffraction and transmission electron microscopy(TEM).Residual compressive stress and more low-angle grain boundaries were introduced into the steel wire by the RD.As a result,the RD wires exhibited a greater tensile strength when drawing strain s<1.18.The SD encouraged grain refinement and texture formation in the wire.The SD wires exhibited a smaller average width of the elongated ferrite grain and a higher intensity of(110)fiber texture at all drawing strains.Therefore,the SD wires showed a bit greater tensile strength and 20%greater torsion performance than the RD wires at c=2.51.TEM and EBSD analysis indicated that dislocation tangle was formed easily in RD wires,and it transformed into twist boundary.This twist boundary impeded the grain refinement in the RD wires,and there were still non-fibrous grains in the RD wires even after heavy drawing.

Torsion Failure Analysis of Galvanized Steel Wires for Transmission and Distribution Lines Based on ANSYS Numerical Simulation

This study provides a detailed failure analysis of galvanized steel wires(3 mm in diameter) for a 35 k V transmission and distribution line, which was carried out by combining the conventional material analysis methods with the finite element method(FEM). It is found that the failed material had good plasticity(5% in elongation),and under the soft torsion loading condition(0.75 in stress state soft coefficient), the ductile fracture should occur on the material. Additionally, the theoretical number of torsions calculated by the FEM was 26.2 times, while the actual number of torsions achieved by the test was only 2.2 times and the local fracture surface exhibited brittle fracture characteristics. The results showed that the local torsion brittle fracture of the material with good plasticity was caused by triaxial stress in the torsion condition, which led to the formation of cavity in the pulling stress area in the material’s center, and the finite element calculation results indicated that the stress state soft coefficient at the cavity was distributed between 0.31 and 0.38, and the stress concentration at the cavity was more than twice the normal value. Besides, the Widmanstatten structure formed as the improper hot working process is the corresponding structural reason.

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.

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.

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.

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.

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.

A novel fiber coating for solid phase microextraction and its application for the extraction of n-alkane from aqueous sample

Base on the previous work in laboratory, a novel polyaniline doped with polydimethylsiloxane coating was developed on a stainless steel wire for solid phase microextraction（SPME） by electroplating method. This electroplating method not only has advantages of ease preparation and simple equipments required, but also increases the lifetime of the SPME fiber. The composite fiber（polyaniline/ polydimethylsiloxane（PANI/PDMS）） was evaluated by analyzing n-tridecane, n-tetradecane and n-pentadecane in aqueous sample. The new fiber coating showed comprehensive abilities to extract alkanes compounds. The relative standard deviations were found to be 6.8%-10.33%.

Long-Term Bending Behaviour of Prestressed Glulam Bamboo-Wood Beam Based on Creep Effect

Creep is an important characteristic of bamboo and wood materials under long-term loading.This paper aims to study the long-term bending beha-viour of prestressed glulam bamboo-wood beam(GBWB).For this,14 pre-stressed GBWBs were selected and subjected to a long-term loading test for 60 days.Then,a comparative analysis was performed for the effects of pre-tension values,the number of pre-stressed wires,and long-term load on the stress variation of the steel wire and the long-term deflection of the beam midspan.The test results showed that with the number of prestressed wires increasing,the total stress of the steel wire in the beam midspan and the ratio of the long-term deflec-tion to the total deflection decreases decreased,but when the number of steel wires exceeded 4,the total stress and long-term deflection was less infuenced;with the pre-tension value increasing,the ratio of the total stress of the steel wire in the beam midspan and the ratio of the long-temm deflection to the total deflec-tion also decreased,but when the prestress force was greater than 3.975 kN,the:total stress and long-term deflection were less affected;with the other parameters unchanged,when the value of the long-term load increased,the total stress of the steel wire decreased,and the long-temm deflection of the beam midspan increased,which shall be more significant with the long-term load greater than 30%of the standard ultimate bearing capacity.After the test,the experimental data were fitted,and the creep coefficient was given.Finally,the long-term stiffness calcula-tion fommula of the pre-stressed GBWB based on creep effect was proposed.The research findings have certain theoretical significance and engineering value.

Application of Low Temperature Liquid Sulfurization Catalyzed with Rare Earth on Cr12 Impacting Die

One kind of quenched Cr12 steel dies for impacting stainless steel wire rope （SSWR） was treated by low temperature liquid sulfurization catalyzed with rare earths, in order to extend their service life for assuring the continuity of production line, and simultaneously improve the surface quality of SSWR obtained. After immerged into the melting sulphur containing 4 % （mass fraction） of LaF3 and 1% of CeCl3 at 463 K for 4 h, the sulfurized dies were very smooth and black, with little distortion and hardness loss. They exhibited a certain extent of corrosion-resistance in air due to the coexisting rare earths in the sulfurized layer. Optical observations showed that the sulfurized layer was uniform and had scale-like structure. The trail of machined SSWR indicated that the production capacity of sulfurized dies had been doubled and the replacing period on line was postponed. SEM morphology also proved that the wear extent of cavities on sulfurized dies decreased greatly and the surface quality of SSWR obtained was improved markedly.

Experimental testing of low-energy rockfall catch fence meshes

Flexible catch fences are widely used to protect infrastructure like railways, roads and buildings from rockfall damage. The wire meshes are the most critical components for catch fences as they dissipate most of the impact energy. Understanding their mechanical response is crucial for a catch fence design. This paper presents a new method for testing the wire meshes under rock impact. Wire meshes with different lengths can be used and the supporting cables can be readily installed in the tests. It is found that a smaller boulder causes more deformation localisation in the mesh. Longer mesh length makes the fence more flexible. Under the same impact condition, the longer mesh deforms more along the impact direction and shrinks more laterally. Supporting cables can reduce the lateral shrinkage of the mesh effectively. Most of the impact energy is dissipated by stretching of the wires.Wire breakage has not been observed.