Wear resistance analysis of duplex interpenetrating ceramic composites via in-situ vibration monitoring

Abstract

Advanced industries demand solutions that provide a deep understanding of the complex tribological behavior of high-performance materials, particularly under extreme wear conditions such as those encountered in dry machining, to ensure reliability, efficiency, and extended component lifespan. This study presents a comprehensive investigation into the wear resistance behavior of duplex interpenetrating ceramic composites (DIPCCs) under dynamic loading conditions, utilizing an in-situ vibration monitoring approach. Four types of composites with “duplex” oxide-carbide structure were prepared by spark plasma sintering (SPS) and tested for tribological behavior. Each of these materials contained oxide phases (58 vol%) Al₂O₃ and ZrO₂ in a constant proportion and one or two of the following carbides (42 vol%): TiC, WC, and ZrC. A custom-designed tribometer was employed to simulate sliding wear, integrated with high-sensitivity accelerometers and vibration analysis software to enable real-time monitoring of wear-induced vibrational signatures. The wear behavior was correlated with material degradation characteristics, surface morphology evolution, and vibration signal patterns. Scanning electron microscopy (SEM) and energy-dispersive X-ray spectroscopy (EDS) were used post-test to characterize wear surfaces and mechanisms. The wear behavior of the composites was analyzed using the Fast Fourier Transform (FFT) of real-time acceleration data collected at three distinct stages of the wear test: the beginning, middle, and end. Among the tested materials, the composite containing 42vol.%WC exhibited the highest mechanical properties and the lowest wear rate of 6.6 × 10⁻⁹mm³m⁻¹ N⁻¹. In contrast, composite with ZrC demonstrated the poorest performance, with the highest wear rate nearly 64 times higher than that of the WC-based.