Wear最新文献

{"title":"Influence of subsurface non-metallic inclusions on rolling contact fatigue behavior in bearing steels - Experimental and numerical investigations","authors":"Agastya Peela ,&nbsp;Adrian Mikitisin ,&nbsp;Florian Steinweg ,&nbsp;Thomas Janitzky ,&nbsp;Alexander Schwedt ,&nbsp;Christoph Broeckmann ,&nbsp;Joachim Mayer","doi":"10.1016/j.wear.2025.205767","DOIUrl":"10.1016/j.wear.2025.205767","url":null,"abstract":"<div><div>The early failures in rolling bearings made of 100Cr6 (SAE 52100) steel have been observed in various industrial applications, which are associated with high maintenance and downtime costs. The damage is usually characterized in the form of axial cracks or volumetric breakouts on the running surface of the bearing components. Metallographic examinations revealed areas below the raceway that do not react to etching with alcoholic nitric acid and therefore appear visually white. These areas are referred to as “white etching areas” or “WEA” for short. Cracks that lead to bearing damage along these WEA are accordingly referred to as “white etching cracks” (WEC). This subsurface damage initiated from non-metallic inclusions has been identified as the dominant initiation mechanism in the formation of butterflies. This study presents a comprehensive analysis of the intricate mechanisms governing the formation of butterflies in SAE 52100 bearing steel, utilizing multiscale finite element modeling and detailed microstructural investigations. The research offers valuable insights into the role of non-metallic inclusions, such as MnS, in butterfly formation, emphasizing that MnS influences butterfly formation through its size, orientation, and interactions with the inclusion-matrix interface. Moreover, it classifies butterflies into propagating and non-propagating types based on their interactions with the inclusion-matrix interface, revealing that non-propagating butterflies can coexist within the steel without causing bearing failure under specific conditions. In contrast, propagating butterflies, which lead to WEA formation, are unequivocally linked with bearing failure.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"566 ","pages":"Article 205767"},"PeriodicalIF":5.3,"publicationDate":"2025-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143140713","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Characterizing the contact evolution through the combination of surface roughness parameters in chemical mechanical polishing using a polyurethane polishing pad","authors":"Jongmin Jeong,&nbsp;Yeongil Shin,&nbsp;Seunghun Jeong,&nbsp;Haedo Jeong","doi":"10.1016/j.wear.2025.205802","DOIUrl":"10.1016/j.wear.2025.205802","url":null,"abstract":"<div><div>The surface texture of the polishing pad used in chemical mechanical polishing (CMP) governs the contact characteristics during material removal. However, quantifying this texture is challenging because of the porous structural characteristics and viscoelastic behavior of polyurethane polishing pads. In this paper, we propose a novel contact characterization parameter that effectively explains material removal by combining it with the polishing pad surface roughness parameter. Experiments were conducted on three types of pads with different surface microstructures, and various combinations of surface roughness parameters were explored using an exhaustive search method based on the coefficient of determination (<span><math><mrow><msup><mi>R</mi><mn>2</mn></msup></mrow></math></span>). A two-dimensional parameter derived as the optimal combination of the root mean square height (<span><math><mrow><msub><mi>R</mi><mi>q</mi></msub></mrow></math></span>) and maximum peak height (<span><math><mrow><msub><mi>R</mi><mi>p</mi></msub></mrow></math></span>) achieved a maximum accuracy of 94.54 % in explaining variations in the material removal rate. This combined parameter demonstrated enhanced explanatory power over single parameters across diverse pad surface conditions and ensured consistently high <span><math><mrow><msup><mi>R</mi><mn>2</mn></msup></mrow></math></span> values without overfitting, even when compared with higher-dimensional combinations. The proposed parameter, representing the relative peak prominence of the overall roughness, enhances our understanding of material removal mechanisms and provides new insights into the contact behavior of surface degradation during continuous wear processes.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"566 ","pages":"Article 205802"},"PeriodicalIF":5.3,"publicationDate":"2025-01-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143140708","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"A method to improve the tribological performance of Cu-based powder metallurgy friction materials for the high-speed trains braking system: Enhancement of the performance of the friction block disc spring","authors":"Jiakun Zhang ,&nbsp;Zaiyu Xiang ,&nbsp;Qixiang Zhang ,&nbsp;Shuangxi Feng ,&nbsp;Zhou Yu ,&nbsp;Xiaocui Wang ,&nbsp;Jiliang Mo ,&nbsp;Deqiang He","doi":"10.1016/j.wear.2025.205751","DOIUrl":"10.1016/j.wear.2025.205751","url":null,"abstract":"<div><div>The tribological performance of Cu-based powder metallurgy (PM) friction materials, commonly known as friction blocks, is vital for ensuring effective braking and ride comfort in high-speed trains. Thus, it is essential to identify effective methods to enhance the tribological properties of these materials. This study proposed a floating structure design for friction materials, enhancing their deformation capacity by altering the disc spring material. This innovative approach is intended to improve the tribological performance of Cu-based PM friction materials, ensuring better braking efficiency and ride comfort in high-speed trains. Drag braking simulations were conducted on a custom-built test rig to evaluate high-speed train braking performance using four different disc spring materials. The study focused on analyzing friction-induced vibration and noise (FIVN), along with interface friction and wear behavior. A wear model incorporating dynamic effects was developed, and finite element models (FEM) based on the experimental setup and conditions were created. These models enabled coupled simulations to analyze braking interface wear and friction-induced vibrations (FIV). The results indicate that the 60SM disc spring significantly reduces FIVN, promotes uniform friction block wear, ensures consistent interface contact, and minimizes FIVN levels. In contrast, the 304 disc spring increases contact stiffness at the braking interface, which leads to abnormal wear and higher FIVN levels. Furthermore, the choice of disc spring material directly influences contact stress and deformation in both friction blocks and disc springs, thereby impacting the braking system's dynamic performance and the tribological behavior of Cu-based PM friction materials. Thus, optimizing the deformation capacity of friction materials through floating structure designs emerges as a practical strategy to enhance the tribological performance of Cu-based PM materials in high-speed train braking systems.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"566 ","pages":"Article 205751"},"PeriodicalIF":5.3,"publicationDate":"2025-01-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143140284","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Investigation on the material removal mechanism of sapphire wafer by novel green slurry in semi-fixed abrasive polishing","authors":"Guangen Zhao ,&nbsp;Jianxiong Chen ,&nbsp;Yongchao Xu ,&nbsp;Cheng Peng ,&nbsp;Qianting Wang","doi":"10.1016/j.wear.2025.205762","DOIUrl":"10.1016/j.wear.2025.205762","url":null,"abstract":"<div><div>It is a great challenge to produce ultra-smooth surface of sapphire wafers at high material removal rate (MRR) using green slurry in semi-fixed abrasive polishing. A novel environmentally friendly polishing slurry was developed by preparing abrasives and complexing agents to improve surface quality and polishing efficiency. The SiO₂ and diamond/SiO₂ composite abrasives were successfully prepared by a simplified sol-gel strategy, exhibiting high purity, homogeneous particle size, and excellent dispersibility. Based on the semi-fixed polishing technology, the green polishing performance of sapphire wafers using different types of abrasives alone and in combination with complexing agents was investigated. The experimental results demonstrated that the novel slurry containing triisopropanolamine (TIPA) and diamond/SiO₂ composite abrasive had superior polishing performance. Compared with the traditional diamond slurry, the surface roughness of the novel slurry was reduced by 24.4 % to 6.2 nm (Ra), while the MRR was increased by 65.4 %. Through electrochemical experiments, molecular simulations, and infrared analysis, the improved polishing performance of the composite abrasives with TIPA may be attributed to the complexation of TIPA and the optimization of interfacial contact behavior. The analysis of wear debris and polished sapphire wafer surface further pointed out that the deformation reduced the indentation depth while enhancing the reactivity of the friction chemistry. The diamond/SiO₂ composite abrasives with TIPA slurry accelerated the generation and removal of the reaction layer consisting of AlOOH, Al-OH, and Al₂Si₂O₇, realizing the optimal synergy between mechanical wear and tribochemistry, which significantly improved the polishing quality.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"566 ","pages":"Article 205762"},"PeriodicalIF":5.3,"publicationDate":"2025-01-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143140714","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Modeling on cutting force considering tool flank wear in ultrasonic vibration-assisted milling Ti3Al","authors":"Guofu Gao,&nbsp;Yunfei Xiang,&nbsp;Huai Qiao,&nbsp;Chenyang Wei,&nbsp;Guangmiao Wang,&nbsp;Daohui Xiang","doi":"10.1016/j.wear.2025.205761","DOIUrl":"10.1016/j.wear.2025.205761","url":null,"abstract":"<div><div>Ti₃Al compounds have potential applications in the aerospace field because of their exceptional mechanical performance at high temperatures, while poor processability becomes the main bottleneck of their applications. This study aims to analyze the tool wear characteristics of the tool flank and their impact on cutting forces during ultrasonic vibration-assisted milling (UVAM) of Ti₃Al compounds, with the goal of optimizing cutting parameters and improving machining efficiency. Based on the oblique cutting theory, a milling force model that accounts for tool flank wear was developed. Ti₃Al workpieces were subjected to side-milling and up-milling on an UVAM platform. The wear characteristics of the tool and the variations in cutting force with respect to different milling lengths, cutting parameters, and ultrasonic amplitudes were analyzed. The results show that the wear condition of tool flank has a direct impact on cutting force. The cutting force prediction model that incorporates tool wear demonstrated higher accuracy, with average relative deviations of 9.13 % and 13.38 % for the <em>F</em>_<em>x</em> and <em>F</em>_<em>y</em> components, respectively. Adhesive wear is the primary type of tool wear throughout the machining process. Compared to conventional milling (CM), UVAM significantly reduces tool wear, with the wear rate decreasing by approximately 38.4 %, but a too-large amplitude causes additional stress and damage to the tool surface. The research demonstrates that reasonably controlling the cutting parameters and ultrasonic amplitude is effective to slow down the tool wear and lower the cutting force, resulting in good surface quality and machining efficiency.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"566 ","pages":"Article 205761"},"PeriodicalIF":5.3,"publicationDate":"2025-01-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143140711","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Particle erosion behavior of La2(ZrxCe1-x)2O7/YSZ double ceramic layers TBCs deposited by electron beam-physical vapor deposition","authors":"Lizhe Wang,&nbsp;Limin He,&nbsp;Rujing Zhang,&nbsp;Zhenhua Xu,&nbsp;Rende Mu","doi":"10.1016/j.wear.2025.205763","DOIUrl":"10.1016/j.wear.2025.205763","url":null,"abstract":"<div><div>La₂(Zr_xCe_1-x)₂O₇/YSZ (LZC/YSZ) double ceramic layers (DCL) thermal barrier coatings (TBCs) have attracted extensive attentions due to their low thermal conductivity and good thermal stability. Particle erosion of DCL TBCs is one of the typical degradation patterns. Here, LZC/YSZ DCL TBCs samples deposited by electron beam-physical vapor deposition (EB-PVD) underwent solid particle erosion test for different time. Characterization of microstructure evolution is implemented using correlative methods, which links together the observations and analysis from X-ray diffraction (XRD), scanning electron microscopy (SEM) and white light scanning interferometry (WLSI). The erosion rates for LZC/YSZ DCL TBCs were determined after exposure to varying durations of erosion. During the initial erosion stages, the predominant degradation mechanism involved the removal of ceramic material. This was attributed to the compaction and cracking of the near-surface columns, causing a progressive thinning of the coating in a layer-by-layer manner. This pattern of degradation also occurred at the LZC/YSZ interface, indicating a relatively good adhesive bond between the LZC and YSZ layers. In the later stages of erosion, the formation of deep cracks, erosion craters, and the emergence of horizontal cracks within the bottom of YSZ layer contributed to block spalling, consequently increasing the erosion rate.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"566 ","pages":"Article 205763"},"PeriodicalIF":5.3,"publicationDate":"2025-01-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143140285","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Influencing factors on high temperature tribology","authors":"Tobias König ,&nbsp;Eduard Wolf ,&nbsp;Philipp Daum ,&nbsp;Dominik Kürten ,&nbsp;Andreas Kailer ,&nbsp;Martin Dienwiebel","doi":"10.1016/j.wear.2025.205758","DOIUrl":"10.1016/j.wear.2025.205758","url":null,"abstract":"<div><div>This study investigates the influence of temperatures, normal force, displacement, frequency and sliding distance on the tribological material behaviour of an unlubricated cobalt-based material pairing, as well as the effects resulting from a change of atmosphere from ambient air to a low-oxygen CO₂/N₂/O₂-atmosphere. The subsequent identification of empirical wear correlations should enable a transfer to other material systems. Reciprocating wear tests were carried out at up to 800 °C with a cylinder-on-plate contact geometry. The test conditions and the material are based on the application as exhaust gas flap plain bearings for combustion engines.</div><div>The temperature has a major influence on the wear behaviour, as it induces the change of tribological mechanisms from abrasion to oxidation and adhesion of wear particles to the formation of a glaze layer in the HT range. The wear particles, required for the tribologically induced sintering process of the glaze layer, are already present in fully oxidised form at low temperatures of 200 °C. The formation of a wear-reducing glaze layer is therefore mainly dependent on the temperature, as this directly influences the sintering process, according to a key finding of this work. The atmospheric influence on the tribological material behaviour is dependent on the temperature related wear regime. For lower temperatures, a mechanism change from abrasion to adhesion takes place in the oxygen-reduced CO₂/N₂/O₂-atmosphere. In contrast, the formation of the glaze layer is not influenced by the change in atmosphere. Moreover, the influence of normal force, displacement and sliding distance differs between the various temperature sections and the related tribological mechanisms.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"566 ","pages":"Article 205758"},"PeriodicalIF":5.3,"publicationDate":"2025-01-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143140707","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Characterizing wear performance of tyre tread rubber","authors":"Chen Liu,&nbsp;David Cebon","doi":"10.1016/j.wear.2025.205754","DOIUrl":"10.1016/j.wear.2025.205754","url":null,"abstract":"<div><div>Understanding the wear of tyre tread rubber is important for tyre design. A ’local wear law’ is needed in models of tyre contact mechanics to quantify wear on tyres. Previous studies on local wear laws faced limitations in temperature control or low frictional power, prompting the design of a new test rig to address these issues. The new rig was designed to measure wear under varying vertical loads, sliding speeds and contact temperature, with wear quantified by the mass loss of rubber samples.</div><div>Results indicated that on different sandpapers, wear rates normalised by area and sliding distance (giving units of kg/m³) were approximately proportional to vertical pressure and changed linearly with sliding speed, with a positive intercept. This is indicative of a ’machining’ process down to zero speed. When the measure of wear was normalised by sliding time (giving units of kg/m²<span><math><mi>⋅</mi></math></span> s), the wear law aligned with power laws measured in previous literature.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"566 ","pages":"Article 205754"},"PeriodicalIF":5.3,"publicationDate":"2025-01-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143140712","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"A comparative analysis of abrasive wear behaviors and mechanisms of pearlitic and carbide-free bainitic steels for grinding mill liners under varied impact loads","authors":"Weiming Liu ,&nbsp;Tao Jiang ,&nbsp;Shizhong Wei ,&nbsp;Liujie Xu ,&nbsp;Chong Chen ,&nbsp;Hua Yu ,&nbsp;Xin Jin ,&nbsp;Huiling Ding ,&nbsp;Chao Zhang ,&nbsp;Kunming Pan","doi":"10.1016/j.wear.2025.205765","DOIUrl":"10.1016/j.wear.2025.205765","url":null,"abstract":"<div><div>A mill liner is a critical wear-resistant component in mineral crushing equipment, and its main failure mode is impact abrasive wear. This study examined carbide-free bainitic steel and pearlitic steel, which are commonly utilized in commercial liners. The wear behavior and wear mechanism of the two wear-resistant steels under different impact loads were revealed through characterization and testing of their microstructure, mechanical properties, and impact abrasive wear performance. The results indicated that under impact loads of 1, 3, and 5 J, the impact abrasive wear resistance of the carbide-free bainitic steel was superior to that of the pearlitic steel. The wear resistance of the pearlitic steel increased nearly linearly with increasing impact load, whereas the wear resistance of the carbide-free bainitic steel exhibited a nonlinear trend, initially decreasing and then increasing with higher impact loads. Under an impact load of 1 J, both samples primarily exhibited micro-cutting as the main wear mechanism, whereas the pearlitic steel demonstrated additional features such as micro-indentation and spalling. Under impact loads of 3 and 5 J, the main wear mechanisms for both samples were micro-cracking and micro-fatigue caused by abrasive impact. Compared with pearlitic steel, carbide-free bainitic steel demonstrated better resistance to delamination, especially under higher impact loads. This study provides guidance for designing tailored liner materials for different impact loads and lays theoretical foundation for extensive application of bainitic steel liners.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"566 ","pages":"Article 205765"},"PeriodicalIF":5.3,"publicationDate":"2025-01-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143140279","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Coating material loss and surface roughening due to leading edge erosion of wind turbine blades: Probabilistic analysis","authors":"Antonios Tempelis,&nbsp;Leon Mishnaevsky Jr.","doi":"10.1016/j.wear.2025.205755","DOIUrl":"10.1016/j.wear.2025.205755","url":null,"abstract":"<div><div>This study presents a novel approach for the prediction of random erosion roughness patterns of leading edge protection coatings for wind turbine blades. The predictions can be used for determining the effect on aerodynamic performance and provide decision support for repairs. The model removes coating material fragments from the surface of the blade based on a Weibull failure probability function. Input from rain erosion tests of a coating material are used to fit the parameters of the failure probability function and the predictions are validated with data from available literature. Predictions for the time required to reach full breakthrough of the coating layer are made for tip speeds between 90–120 m/s. For tip speeds larger than 100 m/s, the examined coating is predicted to experience significant damage within a few months after installation. The sequence of rain events with different rain intensities was also found to have a significant effect on the amount of surface damage. Using droplet size distributions based on measurements was predicted to lead to different coating lifetimes than when using Best’s droplet size distribution. Measurements of erosion craters from rain erosion test samples were used to define a size distribution for failed coating fragments. A machine learning approach for automatic parameter fitting based on erosion depth data from tests is also presented.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"566 ","pages":"Article 205755"},"PeriodicalIF":5.3,"publicationDate":"2025-01-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143140286","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}