Multiple Response Optimization of Three-Body Abrasive Wear Behaviour of Graphite Filled Carbon-Epoxy ComPosites Using Grey-Based Taguchi Approach

The three-body abrasive wear behaviour of carbon fabric reinforced epoxy (C-E) composites has been evaluated by the addition of graphite (G) particles as a secondary reinforcement. Three-body abrasive wear test were conducted using dry sand rubber wheel abrasion tester as per ASTM G-65 with three process parameters load, abrading distance and filler content. To assess the abrasive wear behaviour of particulate filled C-E composites satisfying multiple performance measure, grey-based Taguchi approach has been adopted. The experiments were designed according to Taguchi’s orthogonal array (L?27). The grey relational analysis was applied to convert a multi response process optimization to a single response. Using analysis of variance, significant contributions of process parameters have been determined. The results indicate that the addition of graphite particles into C-E composite increased the wear resistance considerably. It was observed that highest wear resistance of C-E composite was achieved with incorporation of 10 wt. % of graphite filler. Results indicate that the filler content and grit size of abrasive paper were found to be the most significant factor which has influence on the abrasive wear of C-E composite. The worn surface features were examined through scanning electron microscope to probe the wear mechanism.

Two-Body Abrasive Wear of the Surfaces of Pangolin Scales

The Pangolin, a soil-burrowing animal, is covered with scales. These scales are often abraded by soil and rock and their surface is corrugated. The abrasive wear of the surface of the scales was examined. The scales were taken from a pangolin that had died of natural causes. The tests were run on a rotary disc abrasive wear tester. The abrasive material was quartz sand （96.5 wt.%） and bentonite （3.5 wt.%）. The morphology of the abraded surfaces and the abrasion were examined by stereoscopic microscopy and scanning electron microscopy. The concepts are proposed of ＂Guiding-Effect＂ and ＂Rolling-Effect＂ on the textured surfaces under free abrasive wear conditions and the critical dimensions of the ＂Rolling-Effect＂ are discussed.

Effects of nano-Al_2O_3 and nano-ZrO_2 on the microstructure, behavior and abrasive wear resistance of WC-8Co cemented carbide

WC-8wt.% Co cemented carbides with varied nano-Al 2 O 3 and nano-ZrO 2 contents were prepared respectively following conventional powder metallurgical procedures. Effects of nano-Al 2 O 3 and nano-ZrO 2 on the microstructure, behavior, and abrasive wear resistance were investigated. The result shows that a finer and more homogenous microstructure can be achieved by increasing nano-Al 2 O 3 , and increasing nano-ZrO 2 makes the microstructure more refined. Nano-Al 2 O 3 and nano-ZrO 2 could both help to give increased hardness. Transverse rupture strength is higher if the above nano-oxides are doped appropriately, whereas excess addition is deleterious. Abrasive wear resistance presents different variations with respect to increasing nano-Al 2 O 3 and nano-ZrO 2 . By contrast, increasing nano-ZrO 2 enhances the abrasive wear resistance more effectively than increasing nano-Al 2 O 3 . The influence of the two nano-oxides contents on the abrasive wear resistance does not almost vary with wear time, and the optimum addition level of nano-Al 2 O 3 in WC-8% Co cemented carbide is 0.3 wt.% from the stand of abrasive wear resistance. In addition, both of the nano-oxides can retard the increase of wear rate in long-term abrasive wear.

Multiphase Flow and Wear in the Cutting Head of Ultra-high Pressure Abrasive Water Jet

Abrasive water jet cutting technology is widely applied in the materials processing today and attracts great attention from scholars, but many phenomena concerned are not well understood, especially in the internal jet flow of the cutting head at the condition of ultra-high pressure. The multiphase flow in the cutting head is numerically simulated to study the abrasive motion mechanism and wear inside the cutting head at the pressure beyond 300 MPa. Visible predictions of the particles trajectories and wear rate in the cutting head are presented. The influences of the abrasive physical properties, size of the jewel orifice and the operating pressure on the trajectories are discussed. Based on the simulation, a wear experiment is carried out under the corresponding pressures. The simulation and experimental results show that the flow in the mixing chamber is composed of the jet core zone and the disturbance zone, both affect the particles trajectories. The mixing efficiency drops with the increase of the abrasive granularity. The abrasive density determines the response of particles to the effects of different flow zones, the abrasive with medium density gives the best general performance. Increasing the operating pressure or using the jewel with a smaller orifice improves the coherency of p articles trajectories but increases the wear rate of the jewel holder at the same time. Walls of the jewel holder, the entrance of the mixing chamber and the convergence part of the mixing tube are subject to wear out. The computational and experimental results give a qualitative consistency which proves that this numerical method can provide a reliable and visible cognition of the flow characteristics of ultra-high pressure abrasive water jet. The investigation is benefit for improving the machining properties of water jet cutting systems and the optimization design of the cutting head.

DEM Numerical Simulation of Abrasive Wear Characteristics of a Bioinspired Ridged Surface

This paper presents numerical investigations into a ridged surface whose design is inspired by the geometry of a Farrer’sscallop.The objective of the performed research is to assess if the proposed Bioinspired Ridged Surface (BRS) can potentiallyimprove wear resistance of soil-engaging components used in agricultural machinery and to validate numerical simulationsperformed using software based on the Discrete Element Method (DEM).The wear performance of the BRS is experimentallydetermined and also compared with a conventional flat surface.Different size of soil particles and relative velocities between theabrasive sand and the testing surfaces are used.Comparative results show that the numerical simulations are in agreement withthe experimental results and support the hypothesis that abrasive wear is greatly reduced by substituting a conventional flatsurface with the BRS.

Abrasive wear characteristics and mechanisms of Al_2O_3/PA1010 composite coatings

The abrasive wear characteristics of Al_2O_3/PA1010 composite coatings on thesurface of quenched and low-temperature temper steel 45 were tested on the template abrasive weartesting machine and the same uncoated steel 45 was used as a reference material. Experimentalresults showed that the abrasive wear resistance of Al_2O_3/PA1010 composite coatings has a goodlinear relationship with the volume fraction of Al_2O_3 particles in Al_2O_3/PA1010 compositecoatings, and the linear correlative coefficient is 0.979. Under the experimental conditions, thesize of Al_2O_3 particles (40.5-161.0 μm) has little influence on the abrasive wear resistance ofAl_2O_3/PA1010 composite coatings. By treating the surface of Al_2O_3 particles with a suitablebonding agent, the distribution of Al_2O_3 particles in matrix PA1010 is more homogeneous and thebonding state between Al_2O_3 particles and matrix PA1010 is better. Therefore, the Al_2O_3particles in Al_2O_3/PA1010 composite coatings make the Al_2O_3/PA1010 composite coatings havebetter abrasive wear resistance than PA1010 coatings. The wear resistance of Al_2O_3/PA1010composite coatings is about 45% compared with that of steel 45.

Effect of flame conditions on abrasive wear performance of HVOF sprayed nanostructured WC-12Co coatings

Nanostructured WC-12Co coatings were deposited by high velocity oxy-fuel (HVOF) spraying with an agglomerated powder. The effect of flame conditions on the microstructure of the nanostructured coatings was investigated. The wear properties of the coatings were characterized using a dry rubber-wheel wear test. The results show that the nanostructured WC-Co coatings consist of WC, W2C, W and an amorphous binder phase. The microstructure of the coating is significantly influenced by the ratio of oxygen flow to fuel flow. Under the lower ratio of oxygen/fuel flow, the nanostructured coating presents a relative dense microstructure and severe decarburization of WC phase occurs during spraying. With increasing ratio of oxygen/fuel flow, the bonding of WC particles in the coating becomes loose resulting from the original structure of feedstock and the decarburization of WC becomes less owing to limited heating to the powder. Both the decarburization of WC particles in spraying and the bonding among WC particles in the coatings affect the wear performance. The examination of the worn surfaces of the nanostructured coatings reveals that the dominant wear mechanisms would be spalling from the interface of WCCo splats when spray particles undergo a limited melting. While the melting state of the spray particles is improved,the dominant wear mechanisms become the plastic deformation and plowing of the matrix and spalling of WC particles from the matrix.

Microstructure, mechanical properties and two-body abrasive wear behaviour of hypereutectic Al-Si-SiC composite

The microstructure,mechanical properties,and the effects of sliding distance and material removal mechanism on two-body abrasive wear behaviour of hypereutectic Al-Si-Si C composite and its matrix alloy were investigated.The hypereutectic Al-Si-Si C composite was prepared by stir casting route.The hardness,ultimate tensile strength and yield strength of the composite are increased by 17%,38%,and 30%respectively compared with those of the matrix alloy,while the elongation of the composite is decreased by 48%compared with that of the matrix alloy.The wear rate of the materials is increased with increasing the abrasive size and the applied load and does not vary with the sliding distance.The wear surfaces and wear debris of the materials were characterized by high-resolution field emission scanning electron microscopy(HR FESEM)and wear mechanism was analyzed for low and high load regimes.

Abrasive Wear Map of Polymer Tapes in Sand Dust Environment

To make clear the wear conditions of ATM (Automatic Teller Machine) tribosystem when servicing in Chi- nese sand dust environment, abrasive wear of two kinds of polymer tapes specified for ATM, PI (Polyimide) and PEN (Polyethylene-2, 6-naphthalenedicarboxylate), was investigated in simulated sand dust environment with ATM tape-scraper tribosystem under various conditions of loads and sliding distances. The surface profiles of worn tape were measured with a surface profiler in order to calculating the wear cross-section areas and the wear volumes. The specific wear rates of polymer tapes were calculated under load conditions of 0.6, 1 and 1.5 N, and wear mechanisms were in- vestigated with optical topography photos. As main results, the specific wear rates show stage variations in the wear process and the wear resistance of polymer tape shows good relationship with the mechanical deformation factors. In consideration of the service life, four wear models are generalized according to the magnitude of specific wear rates, which include no wear, mild wear, normal wear and severe wear model and the corresponding wear mechanisms for the four wear models are discussed with typical worn topographies. Based on the wear models and corresponding wear mechanisms, the abrasive wear maps of two polymer tapes servicing in sand dust environments are concluded for its industrial applications.

Abrasive Wear Mechanisms of Sand Particles Intruding into ATM Roller-scraper Tribosystem

The roller-scraper tribosystem of automatic teller machine（ATM） plays an important role in reliable cash requests.However,the abrasive wear of the polymer tribosystem becomes a prominent problem when operating in sandy environment.The wear behavior of the tribosystem in a simulated sandy environment has been experimentally studied previously.However the abrasive wear mechanism of roller-scraper tribosystems is still unknown to new design.The wear rates of polymer rollers were examined comprehensively and several jumping variations were found in the full data extent.Three wear stages were classified by the magnitude of wear rates,and different dominant wear mechanisms corresponding with different particle diameter were found by examining the worn surfaces.Accordingly a presumption was proposed that wear mechanisms in different stages were correlated with sand particles of different diameter.In a verification experiment,three typical wear mechanisms including cutting,ploughing,and wedging were found corresponding with different wear stages by scanning electron microscope（SEM） examination.A theoretical analysis was carried out with a simplified sphere particle intrusion model and the transfer conditions for different wear mechanisms were studied referring to the slip-field theory.As a main result,three typical wear models versus friction coefficient of particle/roller,and particle radius were mapped with variant hardness of the polymer roller and ratio of contact shear stress to bulk shear stress.The result illuminated the abrasive wear mechanism during particle intrusion.Particularly,the critical transition conditions gave the basis for improving the wear performance of roller-scraper tribosystems in a sandy environment.

Abrasive Wear Characteristics of Carbon and Low Alloy Steels for Better Performance of Farm Implements

The low stress abrasion behaviours of heat treated mild, medium carbon and high C - low Cr steels, which are generally used in making farm implements, have been investigated. The simple heat treatment greatly improves the hardness, tensile strength and abrasion resistance of medium carbon and high C - low Cr steels. The results indicate that the material removal during abrasion is controlled by a number of factors, such as hardness, chemical composition, microstructure and heat treatment conditions. The conclusion is that the heat treated high C - low Cr steel and mild steel carburized by using coaltar pitch provide the best hardness and abrasion resistance and thus appear to be the most suitable materials for making agricultural tools.

Abrasive wear property of laser melting/deposited Ti_2Ni/TiNi intermetallic alloy

A wear resistant intermetallic alloy consisting of TiNi primary dendrites and Ti2Ni matrix was fabricated by the laser melting deposition manufacturing process. Wear resistance of Ti2Ni/TiNi alloy was evaluated on an abrasive wear tester at room temperature under the different loads. The results show that the intermetallic alloy suffers more abrasive wear attack under low wear test load of 7, 13 and 25 N than high-chromium cast-iron. However, the intermetallic alloy exhibits better wear resistance under wear test load of 49 N. Abrasive wear of the laser melting deposition Ti2Ni/TiNi alloy is governed by micro-cutting and plowing. Pseudoelasticity of TiNi plays an active role in contributing to abrasive wear resistance.

Effect of Pearlite Interlamellar Spacing on Predominant Abrasive Wear Mechanism of Fully Pearlitic Steel

The aim of this investigation was the determination of the predominant wear mechanism on three-body abrasion of fully pearlitic low alloy steel. Furthermore, the effect of pearlite interlamellar spacing on wear behavior was investigated. For this purpose, the samples were subjected to the different heat treating to attaining different interlamellar spacing. Mechanical properties such as hardness, yield strength, tensile strength, elongation, and impact toughness were evaluated. Three body abrasion tests were conducted under ASTM standard condition using a rubber wheel abrasion test apparatus. Abraded surface and wear debris were investigated by light optical microscopy and scanning electron microscopy. The results showed that wear resistance of fully pearlitic steel depended to pearlite interlamellar spacing the and lower spacing has the greater wear resistance, so it may be due to subsurface work hardening and interlamellar spacing and cementite in fine and/or coarse pearlite, that influence on surface destruction during wear. Although during wear process the several mechanisms play roles, but study of surface and debris shows that with decreasing interlamellar spacing, the predominant mechanism wear changed from ploughing to cutting mode.

Study on Formation of Gouging-pits in Mn_7Cr_2 Steel underImpact Abrasive Wear Condition

Study on formation of gouging-pits in Mn,Cr, steel under impact abrasive wear condition was conducted by following the theories of elastic crash and contact, through analysis of photoelasticity and by SEM and results show that maximum shear stress occurs at Z=0.48a, and it initiates a crack; the crack propagates at an angle of 45°from the horizontal and a gouging-pit is conical, and observations by SEM are in agreement with theoretic calculations.

Mechanical and Abrasive Wear Properties of Anodic Oxide Layers Formed on Aluminium

Aluminium oxide coatings were formed on aluminium substrates in oxalic acid-sulphuric acid bath. Abrasion tests of the obtained anodic layers were carried out on a pin-on-disc machine in accordance with the ISO/DP 825 specifications. The rickets microhardness, D （HV0.2）, and the abrasion weight loss, Wa （mg） were measured. Influence of oxalic acid concentration （Cox）, bath temperature （T） and anodic current density （J） on D and Wa has been examined, and the sulphuric acid concentration （Csul） was maintained at 100 g.L-1. It was found that high microhardness and abrasive wear resistance of oxide layers were produced under low temperatures and high current densities with the addition of oxalic acid. The morphology and the composition of the anodic oxide layer were examined by scanning electron microscopy （SEM）, atomic force microscopy （AFM）, optical microscopy and glow-discharge optical emission spectroscopy （GDOES）. It was found that the chemistry of the anodizing electrolyte, temperature, and current density are the controlling factors of the mechanical properties of the anodic oxide layer.

Numerical Model of Ultra-High Molecular Weight Polyethylene Abrasive Wear Tests

Ultra-high molecular weight polyethylene (UHMWPE) has been used in orthopedics as one of the materials for artificial joints in knee, hip and spine prostheses, most of the implanted joints are designed so that the metal of the prosthesis is articulate against a polymeric material, however the main problems is the average life time of the UHMWPE due to wear, and the particles generated by the friction of the metal on the articulation of the polymer are the most common inducer of osteolysis, generating a loosening of the implant leading to an imminent failure resulting in the total replacement of the prosthesis. In this investigation a numerical model of abrasive wear was made using the classic Archard wear equation applied to dynamic simulation of finite element analysis (FEA) of the micro-abrasion test using a subroutine written in Fortran language linked to the finite element software to predict the rate of wear. The results of the numerical model were compared with tests of abrasive wear in the laboratory, obtaining a margin of error below 5%,concluding that the numerical model is feasible for the prediction of the rate of wear and could be applied in knowing the life cycle of joint prostheses or for the tribological analysis in industrial machinery or cutting tools. The wear coefficient (K) was obtained from the grinding tests depending on the depth of stroke of the crater, which was analyzed by 3D profilometry to obtain the wear rate and the wear constant.

Relationship among wear-resistance of three-body abrasion, substructure and property in martensite steels

The effects of subsurface hardness on wear-resistance of martensitic steel20Cr, 40CrSi, 60Mn, T8 and T10 in three-body abrasion under static load was investigated. It showsthat the characteristic of the subsurface hardness distribution and the abrasive wear resistance isrelated to the substructure near the worn surface. The substructure of the tested martensite steelhas an apparent relationship with the carbon content and steels with moderate carbon content andhardness exhibit good resistance to abrasive wear. The competition of the work-hardening effect andthe temper softening effect, which resulted from deformation and friction heat generating duringabrasive wear is considered to be a main reason for the relation among wear-resistance, hardness andsubstructure. At the test conditions, the wear-resistance of 40CrSi is the best.

Characteristics and mechanism of abrasive wear for thermoplastic polymers

Abrasive wear characteristics of polyethylene, polystyrene,polymethylmethacrylate, nylon 1010 and polyvinyl chloride were investigated. The volume relativewear resistance coefficients of these thermoplastic polymers are 18%-35% (hardened and lowtemperature tempered steel 45 was used as a comparing material), and have a linear correlation withsquare roots of their cohesive energy densities. The coefficients of linear correlation is 0.949.Wear morphologies were observed by scanning electron microscope (SEM). Main wear mechanism of thethermoplastic polymers includes brittle breaking for the hard and brittle polymers & plowing andfatiguing for the soft and tough ones.

Research on the abrasive wear resistance of YDCrMoV coating produced by CO_2 shielded flux-cored wire surfacing

Caterpillar construction machines play an important part in many fields such as hydraulic and electric engineering, the construction of highway, for its particular of structure. The walking system of caterpillar construction machines is always under the condition of three-body abrasive wear. The abrasive wear of walking system is very severe, which always results in damages of components or structures of walking system of caterpillar construction machines. It is very important to repair the walking system by cladding technique. The abrasive wear properties of four kinds coatings produced by the shielded flux-cored wire surfacing for the repair of the damaged components of walking system of caterpillar construction machines have been studied experimentally on an MLS-23 type wet sand rubber wheel abrasive tester. The surfaces morphologies of the abrasively worn specimens and their microstructures are investigated by transmitting electron microscopy (TEM) after wear testing. Results show that the wear mechanism of cladding metals of the flux-cored wire No.1 and the No.2 is micro-cutting while that of the No.3 and the No.4 is micro-ploughing. The four kinds of flux-cored wire coatings present great potential applications for the repairing of caterpillar construction machines in the Three Gorges Engineering.

Effect of Orientation and Applied Load on Abrasive Wear Property of Brass 60:40

Wear is a continuous process in which material is degraded with every cycle. Scientists are busy in improving the wear resistance. Approximately 75% failure in components or machine parts is due to wear. The present paper investigates experimentally the effect of orientation and normal load on alloy of copper and zinc, i.e. Brass, and calculates weight loss due to wear. To do so, a multi-orientational pin-on-disc apparatus was designed and fabricated. Experiments were carried out under normal load 05-20 N, speed 2000 rpm. Results show that the with-increasing load weight loss increases at all angular positions. The loss in weight is maximum at zero degree (horizontal position) and minimum at ninety degree (vertical position) for a particular load. Maximum wear occurs when the test specimen is held at 0° angle and minimum wear occurs when the specimen is held at 90° angle for given applied load. The circumferential distance travel is constant for all positions and for all loads but still mass loss varies.