Abstract: Around the globe, there is demand for the development of bio-based lubricant which will be biodegradable, non -toxic and environmental friendly. This paper outlines the friction and wear characteristics of Pongamia oil (PO) contaminated bio-lubricant by using pin-on-disc tribometer. To formulate the bio-lubricants, PO was blended in the ratios 15, 30 and 50% by volume with the base lubricant SAE 20 W 40. Tribological characteristics of these blends were carried out at 3.8 m/s sliding velocity and loads applied were 50, 100, 150 N. Experimental results showed that the lubrication regime that occurred during the test was boundary lubrication while the main wear mechanisms were abrasive and the adhesive wear. During testing, the lowest wear was found with the addition of 15% PO, and above this contamination, the wear rate was increased considerably. With increase in load, viscosity of all the bio-lubricants increases and meets the ISO VG 100 requirement at 40 oC except PB 50. The addition of PO in the base lubricant acted as a very good lubricant additive which reduced the friction and wear scar diameter during the test. It has been concluded that the PB 15 can act as an alternative lubricant to increase the mechanical efficiency at 3.8 m/s sliding velocity and contribute in reduction of dependence on the petroleum based products.
Abstract: The sintering step in powder metallurgy (P/M) processes is very sensitive as it determines to a large extent the properties of the final component produced. Spark plasma sintering over the past decade has been extensively used in consolidating a wide range of materials including metallic alloy powders. This novel, non-conventional sintering method has proven to be advantageous offering full densification of materials, high heating rates, low sintering temperatures, and short sintering cycles over conventional sintering methods. Ti6Al4V has been adjudged the most widely used α+β alloy due to its impressive mechanical performance in service environments, especially in the aerospace and automobile industries being a light metal alloy with the capacity for fuel efficiency needed in these industries. The P/M route has been a promising method for the fabrication of parts made from Ti6Al4V alloy due to its cost and material loss reductions and the ability to produce near net and intricate shapes. However, the use of this alloy has been largely limited owing to its relatively poor hardness and wear properties. The effect of sintering temperature on the densification, hardness, and wear behaviors of spark plasma sintered Ti6Al4V powders was investigated in this present study. Sintering of the alloy powders was performed in the 650–850°C temperature range at a constant heating rate, applied pressure and holding time of 100°C/min, 50 MPa and 5 min, respectively. Density measurements were carried out according to Archimedes’ principle and microhardness tests were performed on sectioned as-polished surfaces at a load of 100gf and dwell time of 15 s. Dry sliding wear tests were performed at varied sliding loads of 5, 15, 25 and 35 N using the ball-on-disc tribometer configuration with WC as the counterface material. Microstructural characterization of the sintered samples and wear tracks were carried out using SEM and EDX techniques. The density and hardness characteristics of sintered samples increased with increasing sintering temperature. Near full densification (99.6% of the theoretical density) and Vickers’ micro-indentation hardness of 360 HV were attained at 850°C. The coefficient of friction (COF) and wear depth improved significantly with increased sintering temperature under all the loading conditions examined, except at 25 N indicating better mechanical properties at high sintering temperatures. Worn surface analyses showed the wear mechanism was a synergy of adhesive and abrasive wears, although the former was prevalent.
Abstract: Erosion and abrasion are wear mechanisms reducing
the lifetime of machine elements like valves, pump and pipe systems.
Both wear mechanisms are acting at the same time, causing a
“Synergy” effect, which leads to a rapid damage of the surface.
Different parameters are effective on erosive abrasive wear rate. In
this study effect of particle impact angle on wear rate and wear
mechanism of ductile and brittle materials was investigated. A new
slurry pot was designed for experimental investigation. As abrasive
particle, silica sand was used. Particle size was ranking between 200-
500 μm. All tests were carried out in a sand-water mixture of 20%
concentration for four hours. Impact velocities of the particles were
4.76 m/s. As ductile material steel St 37 with Vickers Hardness
Number (VHN) of 245 and quenched St 37 with 510 VHN was used
as brittle material. After wear tests, morphology of the eroded
surfaces were investigated for better understanding of the wear
mechanisms acting at different impact angles by using Scanning
Electron Microscope. The results indicated that wear rate of ductile
material was higher than brittle material. Maximum wear rate was
observed by ductile material at a particle impact angle of 300 and
decreased further by an increase in attack angle. Maximum wear rate
by brittle materials was by impact angle of 450 and decreased further
up to 900. Ploughing was the dominant wear mechanism by ductile
material. Microcracks on the surface were detected by ductile
materials, which are nucleation centers for crater formation. Number
of craters decreased and depth of craters increased by ductile
materials by attack angle higher than 300. Deformation wear
mechanism was observed by brittle materials. Number and depth of
pits decreased by brittle materials by impact angles higher than 450.
At the end it is concluded that wear rate could not be directly related
to impact angle of particles due to the different reaction of ductile and
brittle materials.
Abstract: In this study, to clarify the effectiveness of an
aluminum/chromium/tungsten-based-coated tool for cutting sintered
steel, tool wear was experimentally investigated. The sintered steel
was turned with the (Al60,Cr25,W15)N-, (Al60,Cr25,W15)(C,N)- and
(Al64,Cr28,W8)(C,N)-coated cemented carbide tools according to the
physical vapor deposition (PVD) method. Moreover, the tool wear of
the aluminum/chromium/tungsten-based-coated item was compared
with that of the (Al,Cr)N coated tool. Furthermore, to clarify the tool
wear mechanism of the aluminum/chromium/tungsten-coating film for
cutting sintered steel, Scanning Electron Microscope observation and
Energy Dispersive x-ray Spectroscopy mapping analysis were
conducted on the abraded surface. The following results were
obtained: (1) The wear progress of the (Al64,Cr28,W8)(C,N)-coated
tool was the slowest among that of the five coated tools. (2) Adding
carbon (C) to the aluminum/chromium/tungsten-based-coating film
was effective for improving the wear-resistance. (3) The main wear
mechanism of the (Al60,Cr25,W15)N-, the (Al60,Cr25,W15)(C,N)-
and the (Al64,Cr28,W8)(C,N)-coating films was abrasive wear.
Abstract: This article presents modeling studies of NiAl alloy
under solid-particle erosion and liquid-drop erosion. In the
solid-particle erosion simulation, attention is paid to the oxide scale
thickness variation on the alloy in high-temperature erosion
environments. The erosion damage is assumed to be deformation wear
and cutting wear mechanisms, incorporating the influence of the oxide
scale on the eroded surface; thus the instantaneous oxide thickness is
the result of synergetic effect of erosion and oxidation. For liquid-drop
erosion, special interest is in investigating the effects of drop velocity
and drop size on the damage of the target surface. The models of
impact stress wave, mean depth of penetration, and maximum depth of
erosion rate (Max DER) are employed to develop various maps for
NiAl alloy, including target thickness vs. drop size (diameter), rate of
mean depth of penetration (MDRP) vs. drop impact velocity, and
damage threshold velocity (DTV) vs. drop size.
Abstract: This work investigates the wear of a steam turbine blade coated with titanium nitride (TiN), and compares to the wear of uncoated blades. The coating is deposited on by physical vapor deposition (PVD) method. The working conditions of the blade were simulated and surface temperature and pressure values as well as flow velocity and flow direction were obtained. This data was used in the finite element wear model developed here in order to predict the wear of the blade. The wear mechanisms considered are erosive wear due to particle impingement and fluid jet, and fatigue wear due to repeated impingement of particles and fluid jet. Results show that the life of the TiN-coated blade is approximately 1.76 times longer than the life of the uncoated one.
Abstract: In this paper, the application of thermal spray
coatings in high speed shafts by a revolution up to 23000 RPM
has been studied. Gas compressor shafts are worn in contact
zone with journal therefore will be undersized. Wear
mechanisms of compressor shaft were identified. The
predominant wear mechanism is abrasion wear. The worn
surface was coated by hard WC-Co cermets using high
velocity oxy fuel (HVOF) after preparation. The shafts were in
satisfactory service in 8000h period. The metallurgical and
Tribological studies has been made on the worn and coated
shaft using optical microscopy, scanning electron microscopy
(SEM) and X-ray diffraction.
Abstract: This paper presents an experimental investigation on
the machinability of laser-sintered material using small ball end mill focusing on wear mechanisms. Laser-sintered material was produced
by irradiating a laser beam on a layer of loose fine SCM-Ni-Cu powder. Bulk carbon steel JIS S55C was selected as a reference steel.
The effects of powder consolidation mechanisms and unsintered
powder on the tool life and wear mechanisms were carried out. Results indicated that tool life in cutting laser-sintered material is
lower than that in cutting JIS S55C. Adhesion of the work material and chipping were the main wear mechanisms of the ball end mill in
cutting laser-sintered material. Cutting with the unsintered powder
surrounding the tool and laser-sintered material had caused major fracture on the cutting edge.
Abstract: In this paper, the residual stress of thermal spray
coatings in gas turbine component by curvature method has been
studied. The samples and shaft were coated by hard WC-12Co
cermets using high velocity oxy fuel (HVOF) after preparation in
same conditions. The curvature of coated samples was measured by
using of coordinate measurement machine (CMM). The metallurgical
and Tribological studies has been made on the coated shaft using
optical microscopy and scanning electron microscopy (SEM)
Abstract: The aim of this investigation is to study the
performance of the new generation of the PVD coated grade and to
map the influence of cutting conditions on the tool life in milling of
ADI (Austempered Ductile Iron). The results show that chipping is
the main wear mechanism which determines the tool life in dry
condition and notch wear in wet condition for this application. This
due to the different stress mechanisms and preexisting cracks in the
coating. The wear development shows clearly that the new PVD
coating (C20) has the best ability to delay the chipping growth. It
was also found that a high content of Al in the new coating (C20)
was especially favorable compared to a TiAlN multilayer with lower
Al content (C30) or CVD coating. This is due to fine grains and low
compressive stress level in the coating which increase the coating
ability to withstand the mechanical and thermal impact. It was also
found that the use of coolant decreases the tool life with 70-80%
compare to dry milling.
Abstract: In this paper, the wear of high speed steel hobs during
hobbing has been studied. The wear mechanisms are strongly
influenced by the choice of cutting speed. At moderate and high
cutting speeds three major wear mechanisms were identified:
abrasion, mild adhesive and severe adhesive. The microstructure and
wear behavior of two high speed steel grades (M2 and ASP30) has
been compared. In contrast, a variation in chemical composition or
microstructure of HSS tool material generally did not change the
dominant wear mechanism. However, the tool material properties
determine the resistance against the operating wear mechanism and
consequently the tool life. The metallographic analysis and wear
measurement at the tip of hob teeth included scanning electron
microscopy and stereoscope microscopy. Roughness profilometery is
used for measuring the gear surface roughness.
Abstract: Titanium alloys like the modern alloy Ti 6Al 2Sn 4Zr 6Mo (Ti-6246) combine excellent specific mechanical properties and corrosion resistance. On the other hand,due to their material characteristics, machining of these alloys is difficult to perform. The aim of the current study is the analyses of wear mechanisms of coated cemented carbide tools applied in orthogonal cutting experiments of Ti-6246 alloy. Round bars were machined with standard coated tools in dry conditions on a CNC latheusing a wide range of cutting speeds and cutting depths. Tool wear mechanisms were afterwards investigated by means of stereo microscopy, optical microscopy, confocal microscopy and scanning electron microscopy. Wear mechanisms included fracture of the tool tip (total failure) and abrasion. Specific wear features like crater wear, micro cracks and built-up edgeformation appeared depending of the mechanical and thermal conditions generated in the workpiece surface by the cutting action.
Abstract: A group of Stellite alloys are studied in consideration
of temperature effects on their hardness and wear resistance. The
hardness test is conducted on a micro-hardness tester with a hot stage
equipped that allows heating the specimen up to 650°C. The wear
resistance of each alloy is evaluated using a pin-on-disc tribometer
with a heating furnace built-in that provides the temperature capacity
up to 450°C. The experimental results demonstrate that the hardness
and wear resistance of Stellite alloys behave differently at room
temperature and at high temperatures. The wear resistance of Stellite
alloys at room temperature mainly depends on their carbon content and
also influenced by the tungsten content in the alloys. However, at high
temperatures the wear mechanisms of Stellite alloys become more
complex, involving multiple factors. The relationships between
chemical composition, microstructure, hardness and wear resistance of
these alloys are studied, with focus on temperature effect on these
relations.
Abstract: In this paper, the bond strength of thermal spray
coatings in high speed shafts has been studied. The metallurgical and
mechanical studies has been made on the coated samples and shaft
using optical microscopy, scanning electron microscopy (SEM).
Abstract: The present work compares the performance of three
turbulence modeling approach (based on the two-equation k -ε
model) in predicting erosive wear in multi-size dense slurry flow
through rotating channel. All three turbulence models include
rotation modification to the production term in the turbulent kineticenergy
equation. The two-phase flow field obtained numerically
using Galerkin finite element methodology relates the local flow
velocity and concentration to the wear rate via a suitable wear model.
The wear models for both sliding wear and impact wear mechanisms
account for the particle size dependence. Results of predicted wear
rates using the three turbulence models are compared for a large
number of cases spanning such operating parameters as rotation rate,
solids concentration, flow rate, particle size distribution and so forth.
The root-mean-square error between FE-generated data and the
correlation between maximum wear rate and the operating
parameters is found less than 2.5% for all the three models.