IF 6.1 1区工程技术

Wear Pub Date : 2025-09-12 DOI: 10.1016/j.wear.2025.206318

Jun Pan , Jianfeng Ma , Wenhua Chen , Zhengdong Wang , Xiaojun Li , Ye Zhou , Weiliang Zhang

{"title":"Study on the long-term sediment abrasion characteristics of turbines considering geometric gradients","authors":"Jun Pan , Jianfeng Ma , Wenhua Chen , Zhengdong Wang , Xiaojun Li , Ye Zhou , Weiliang Zhang","doi":"10.1016/j.wear.2025.206318","DOIUrl":"10.1016/j.wear.2025.206318","url":null,"abstract":"<div><div>To mitigate the risk of prolonged operational downtime caused by runner abrasion in high-altitude hydropower stations subject to sediment-laden flows, accurate long-term abrasion prediction is essential. However, existing models often overlook the progressive deformation of flow passage boundaries, which can significantly influence local flow structures and particle-wall interactions. In this study, a sediment abrasion prediction method is developed by integrating experimental data from rotating-disk slurry abrasion tests with an abrasion simulation framework that incorporates dynamic mesh deformation and an abrasion rate acceleration factor. The approach couples a CFD-based Euler-Lagrange model with geometry-updating algorithms to reflect evolving surface profiles and feedback effects on particle impact behavior. The method was validated against in-situ measurements from a Francis turbine runner operating continuously for 5723 h. Results show that the proposed model, which accounts for boundary evolution, improves long-term abrasion prediction accuracy by 28.71 % compared to traditional fixed-geometry models. The model also captures the shift of maximum abrasion zones induced by localized vortices formed around abrasion pits which is consistent with experimental observations. This research provides a robust and transferable methodology for abrasion assessment and can serve as a technical reference for the optimization of turbine design and sediment management strategies in sediment-prone hydropower systems.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"582 ","pages":"Article 206318"},"PeriodicalIF":6.1,"publicationDate":"2025-09-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145061189","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}

引用次数: 0

Tire polishing effects on rubber-texture contact and friction characteristics of different asphalt mixtures 轮胎抛光对不同沥青混合料橡胶纹理、接触和摩擦特性的影响

IF 6.1 1区工程技术

Wear Pub Date : 2025-09-12 DOI: 10.1016/j.wear.2025.206328

Xiaoyu Zhang , Hao Wang , Thomas Bennert

{"title":"Tire polishing effects on rubber-texture contact and friction characteristics of different asphalt mixtures","authors":"Xiaoyu Zhang , Hao Wang , Thomas Bennert","doi":"10.1016/j.wear.2025.206328","DOIUrl":"10.1016/j.wear.2025.206328","url":null,"abstract":"<div><div>This study aims to investigate tire polishing effect on rubber-texture contact and friction characteristics on different asphalt mixtures using laboratory experiments and physics-based modeling. By utilizing a Dynamic Friction Tester (DFT) to measure friction and a high-resolution laser scanner to capture three-dimensional (3-D) texture, the friction and texture changes at different polishing cycles are evaluated. The chip seal exhibits better skid resistance performance but lower resistance to polishing, while the Hot Mix Asphalt (HMA) and Open Graded Friction Courses (OGFC) show the opposite trend. The negative texture features of HMA and OGFC and the positive texture feature of chip seal explain their different trends with polishing. Persson's contact theory is used to predict friction coefficient from 3-D surface texture and backcalculate the effective contact depth between tire rubber and texture, which shows good correlation with root mean square height of surface texture. The friction contributions from micro- and macro-texture reveal that polishing affects micro-texture components for each surface type but only influences macro-texture component on chip seal.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"582 ","pages":"Article 206328"},"PeriodicalIF":6.1,"publicationDate":"2025-09-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145061041","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}

引用次数: 0

Analytical prediction of initial wear progress based on a sticking-transition-sliding contact model 基于黏着-过渡-滑动接触模型的初始磨损过程分析预测

IF 6.1 1区工程技术

Wear Pub Date : 2025-09-12 DOI: 10.1016/j.wear.2025.206329

Xiuyan Wei , Kejia Zhuang , Cheng Hu , Kang Zhu , Hui Shi

{"title":"Analytical prediction of initial wear progress based on a sticking-transition-sliding contact model","authors":"Xiuyan Wei , Kejia Zhuang , Cheng Hu , Kang Zhu , Hui Shi","doi":"10.1016/j.wear.2025.206329","DOIUrl":"10.1016/j.wear.2025.206329","url":null,"abstract":"<div><div>Initial tool wear exerts a substantial influence on tool life and machining accuracy, yet this subject remains comparatively under-explored in comparison to the steady wear stage. The present study proposes a novel thermomechanical wear prediction model for the worn tool flank face during the initial wear stage, which is grounded in the tri-zone phenomenon. The model analytically describes the spatial distributions of sliding velocity, normal stress, and interface temperature along the tool–workpiece interface, highlighting their critical roles in wear evolution. The experimental observations confirmed the presence of a tri-zone phenomenon, comprising sticking, transition, and sliding zones, on the worn flank face. Velocity gradients are captured using analytical functions, while normal stress is derived from Waldorf's slip-line theory, incorporating characteristic length parameters. A one-dimensional steady-state thermal model is constructed with both shear and frictional heat sources, and jointly calibrated with simulation data. Subsequently, a calibrated Usui wear rate model is implemented, and the nodal displacement method is employed to simulate the evolution of flank wear morphology. The predicted average interface temperature in each region deviates by less than 3 %, and cutting tests on Inconel 718 using TiAlN-coated tools confirm an overall wear prediction error within 6.24 %. Multi-scale SEM and EDS analyses validate adhesion as the dominant wear mechanism and reveal progressive coating degradation, providing microstructural support for the proposed model. This study proposes a novel framework for mechanistic wear analysis and predictive modeling of tool life during the initial wear stage.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"582 ","pages":"Article 206329"},"PeriodicalIF":6.1,"publicationDate":"2025-09-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145061042","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}

引用次数: 0

Tribocorrosion response of PVD molybdenum nitride (MoN) coated Ti-6Al-4V PVD氮化钼涂层Ti-6Al-4V的摩擦腐蚀响应

IF 6.1 1区工程技术

Wear Pub Date : 2025-09-12 DOI: 10.1016/j.wear.2025.206325

Sarah Galea , Peter A. Dearnley , Bertram Mallia

{"title":"Tribocorrosion response of PVD molybdenum nitride (MoN) coated Ti-6Al-4V","authors":"Sarah Galea , Peter A. Dearnley , Bertram Mallia","doi":"10.1016/j.wear.2025.206325","DOIUrl":"10.1016/j.wear.2025.206325","url":null,"abstract":"<div><div>Ti-6Al-4V is a widely used biomedical alloy, valued for its biocompatibility, high corrosion resistance and mechanical strength. However, its poor tribological performance limits its use in frictional contacts. This limitation can be addressed by enhancing surface properties through coatings that impart enhanced degradation resistance. Molybdenum nitride (MoN) based coatings are promising candidates for bio-tribological use due to their ability to attain high hardness (∼37 GPa), stemming from strong primary bonding. Moreover, even if small amounts of molybdenum ions are released, they are unlikely to elicit adverse biological effects due to the ability of the body to regulate molybdenum level through homeostatic processes. This study investigates the tribocorrosion performance of two MoN PVD coatings, deposited on Ti-6Al-4V substrates at different nitrogen partial pressures via unbalanced reactive magnetron sputtering. Electrochemical behaviour and tribocorrosion response were evaluated in Ringer's solution under elastic contact conditions. A reciprocating sliding configuration against an alumina ball counterface was used and tribocorrosion tests were conducted under both open circuit potential and anodic potential conditions. The MoN coated Ti-6Al-4V variants exhibited a markedly reduced tribocorrosion material loss compared to the untreated alloy under both electrochemical conditions. The coatings exhibited resistance to blister formation and caused minimal damage to the counterface alumina ball during tribocorrosion testing.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"582 ","pages":"Article 206325"},"PeriodicalIF":6.1,"publicationDate":"2025-09-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145097236","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}

引用次数: 0

Thermodynamic characterization of fretting-induced material degradation using degradation entropy generation framework 基于退化熵生成框架的微动诱导材料降解热力学表征

IF 6.1 1区工程技术

Wear Pub Date : 2025-09-12 DOI: 10.1016/j.wear.2025.206341

K.P. Lijesh, M.M. Khonsari

引用次数: 0

Formation mechanism of subsurface white etching area and white etching crack of failed bearings in wind turbine gearbox 风电齿轮箱失效轴承表面下白蚀区及白蚀裂纹形成机理

IF 6.1 1区工程技术

Wear Pub Date : 2025-09-11 DOI: 10.1016/j.wear.2025.206335

R. Dai, H. Long

{"title":"Formation mechanism of subsurface white etching area and white etching crack of failed bearings in wind turbine gearbox","authors":"R. Dai, H. Long","doi":"10.1016/j.wear.2025.206335","DOIUrl":"10.1016/j.wear.2025.206335","url":null,"abstract":"<div><div>Bearings of some wind turbine (WT) gearboxes experienced premature failures due to bearing steel microstructural damage under rolling contact fatigue (RCF). However, the formation mechanism of the microstructural damage and its progression to the final bearing failure is still being debated. In this study, subsurface damage sustained in two bearing raceways of a failed gearbox from a field-operated WT is investigated. The study provides evidence of damage initiation and progression from non-metallic inclusions in the subsurface by using actually failed WT bearings as a case study. Damage characterisation has found various microstructural damage in the raceway subsurface including non-metallic inclusions, butterfly wing cracks, White Etching Areas (WEAs), and White Etching Cracks (WECs). Complex interactions between cyclic rolling contact loading with inclusions and cracks are observed. Their roles in the formation of butterfly wing cracks, WEAs and WECs in the raceway subsurface are evaluated. It has been found that the butterfly wing cracks initiated at damaged inclusions is the original cause of the microstructural damage. The propagation of butterfly wing cracks and WEAs to form subsurface crack networks, with WEAs to create WECs, under RCF loading they have accelerated surface flaking and spalling of the raceways, leading to the final failure of the bearings. The formation mechanism of the subsurface initiated WEAs and WECs is evaluated and a damage progression hypothesis leading to the final bearing failure is proposed, including six stages of the microstructural damage development.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"582 ","pages":"Article 206335"},"PeriodicalIF":6.1,"publicationDate":"2025-09-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145061188","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}

引用次数: 0

A study of galvanic corrosion between carbon fibre reinforced PA6 composites and metals under dry sliding conditions 干滑动条件下碳纤维增强PA6复合材料与金属的电偶腐蚀研究

IF 6.1 1区工程技术

Wear Pub Date : 2025-09-11 DOI: 10.1016/j.wear.2025.206327

Zhiwang Li , Hanyu Li , Li Chang

{"title":"A study of galvanic corrosion between carbon fibre reinforced PA6 composites and metals under dry sliding conditions","authors":"Zhiwang Li , Hanyu Li , Li Chang","doi":"10.1016/j.wear.2025.206327","DOIUrl":"10.1016/j.wear.2025.206327","url":null,"abstract":"<div><div>In the present work, continuous carbon-fibre reinforced polyamide 6 (CCF/PA6) composites were manufactured by fused deposition modelling technology and their tribological behaviour was studied on a pin-on-disc configuration under room conditions. The results showed that galvanic corrosion could take place between the fiber and steels even under nominally dry contact conditions. The severity of the corrosion process is dependent on fibre orientation, environment humidity and the type of counterpart materials. In particular, the specimens with normal fibre orientation (perpendicular to the sliding direction) showed higher values of galvanic current and wear loss than those with parallel fibre orientation (parallel to sliding), especially under high pressure conditions. For instance, with normal fibre orientation against steel counterparts, the specific wear rate of printed CCF/PA6 increased abruptly from 5.32 × 10<sup>−6</sup> mm<sup>3</sup> N<sup>−1</sup> m<sup>−1</sup> at 1 MPa to 12.33 × 10<sup>−6</sup> mm<sup>3</sup> N<sup>−1</sup> m<sup>−1</sup> at 2 MPa; by contrast, a parallel orientation showed only a modest increase, from 1.98 to 2.45 × 10<sup>−6</sup> mm<sup>3</sup> N<sup>−1</sup> m<sup>−1</sup> over the same pressure span. Further, the galvanic current increased with humidity, nearly doubling from 20 % to 80 % RH. However, such a corrosion effect was not observed against titanium counterparts, which may be due to the inherent stability of titanium. These findings highlight the importance of galvanic corrosion for understanding the wear behaviour of carbon fiber reinforced polymers, as well as the design and selection of tribological materials from a systematic point of view by considering the complexity and interconnectedness of the tribological system.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"582 ","pages":"Article 206327"},"PeriodicalIF":6.1,"publicationDate":"2025-09-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145097280","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}

引用次数: 0

Study on cavitation erosion behavior of nano-bainitic GCr15SiMo steels: Experiments and molecular dynamics simulations 纳米贝氏体GCr15SiMo钢空化侵蚀行为研究：实验与分子动力学模拟

IF 6.1 1区工程技术

Wear Pub Date : 2025-09-11 DOI: 10.1016/j.wear.2025.206340

Zhe Li , Chao Tan , Jian Shang , Sidi Zhen , Sanming Du , Xiangdong Wang , Hanzhen Qi , Zhen Li

{"title":"Study on cavitation erosion behavior of nano-bainitic GCr15SiMo steels: Experiments and molecular dynamics simulations","authors":"Zhe Li , Chao Tan , Jian Shang , Sidi Zhen , Sanming Du , Xiangdong Wang , Hanzhen Qi , Zhen Li","doi":"10.1016/j.wear.2025.206340","DOIUrl":"10.1016/j.wear.2025.206340","url":null,"abstract":"<div><div>The nano-bainitic steels were produced by a series of heat treatments applied to GCr15SiMo bearing steels. The microstructure, mechanical properties, and cavitation erosion behavior were investigated and compared with those of martensitic and annealed steels of the identical chemical composition. Furthermore, the cavitation erosion behavior was elucidated through molecular dynamics (MD) simulations to provide atomic-scale insights. The experimental results demonstrated that nano-bainitic steel exhibited exceptional cavitation erosion resistance due to its unique combination of high strength and toughness. After 840 min of cavitation erosion, the mean depth of erosion (MDE) was approximately 2.20 μm, merely 1/15 and 1/2 that of annealed steel (600 min) and martensitic steel (840 min). The complexity of the eroded surface products of nano-bainitic steel after 840 min of cavitation erosion was significantly lower than that of martensitic steel (840 min) and annealed steel (600 min). MD simulations revealed that the nano-water hammer caused by the collapse of cavitation bubble could reach extreme transient conditions, including pressure up to 30 GPa and temperature up to 5000 K on the nano-bainitic model surface, accompanied by extremely high shear stresses. The combined effect of these conditions resulted in a partial transformation of the crystal structure on the surface of the nano-bainitic model. This transformation contributed to the enhanced cavitation erosion resistance of the nano-bainitic steel.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"582 ","pages":"Article 206340"},"PeriodicalIF":6.1,"publicationDate":"2025-09-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145046897","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}

引用次数: 0

FE analysis of the brake pad and brake disc wear with thermal-structure interaction 考虑热-结构相互作用的刹车片和制动盘磨损有限元分析

IF 6.1 1区工程技术

Wear Pub Date : 2025-09-10 DOI: 10.1016/j.wear.2025.206331

Piotr Grzes, Michal Kuciej

{"title":"FE analysis of the brake pad and brake disc wear with thermal-structure interaction","authors":"Piotr Grzes, Michal Kuciej","doi":"10.1016/j.wear.2025.206331","DOIUrl":"10.1016/j.wear.2025.206331","url":null,"abstract":"<div><div>Changes in the topography of the contacting surfaces of the friction pair components depend on the load, thermal expansion, wear, etc. In this article a FE model of a railway disc brake to evaluate distribution of the brake pad and brake disc wear depth has been proposed. The novel aspect of the 3D model of the brake assembly is the change in volume due to material loss of both sliding components with thermomechanical interactions. This comprehensive approach allows identifying an effect of the properties of materials and geometric features of the brake such as shape of the brake pads on the ventilated brake disc wear distribution. Computer simulations were performed for the parameters of single braking of a railway vehicle from initial velocity of 120 km/h to stop. In order to determine the brake pad wear according to Archard equation, a concise analytical formulation for the specific wear rate was derived based on the experimental data of bedding-in from full-scale dynamometer bench tests. The brake disc wear rate was found from the ratio of the average wear depth of brake pad to the brake disc. The model was verified by temperature evolutions of the brake disc measured using thermocouples. It was found that reducing thermal expansion coefficient of the brake pad equalized the distribution of temperature, contact pressure and wear depth of the brake pad and brake disc. However in both analyzed variants two circular bands with increased wear were visible on the brake disc working surface.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"582 ","pages":"Article 206331"},"PeriodicalIF":6.1,"publicationDate":"2025-09-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145046898","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}

引用次数: 0

Enhancement of tribological properties by reinforcing 316L stainless steel with nano ceramics fabricated by laser powder bed fusion 激光粉末床熔敷纳米陶瓷增强316L不锈钢的摩擦学性能

IF 6.1 1区工程技术

Wear Pub Date : 2025-09-10 DOI: 10.1016/j.wear.2025.206334

Baibhav Karan , Qiyang Tan , Kiomars Moheimani , Fanshuo Wang , Ayan Bhowmik , Mingxing Zhang

{"title":"Enhancement of tribological properties by reinforcing 316L stainless steel with nano ceramics fabricated by laser powder bed fusion","authors":"Baibhav Karan , Qiyang Tan , Kiomars Moheimani , Fanshuo Wang , Ayan Bhowmik , Mingxing Zhang","doi":"10.1016/j.wear.2025.206334","DOIUrl":"10.1016/j.wear.2025.206334","url":null,"abstract":"<div><div>Stainless steel 316 L (SS316L) is extensively employed in engineering applications owing to its excellent corrosion resistance, ductility, and workability. However, its relatively low yield strength and limited wear resistance hinder its suitability for environments of wear. The incorporation of ceramic nanoparticles as reinforcement within the SS316L matrix has emerged as a promising strategy to enhance its performance by leveraging the synergistic effects between the metallic matrix and the ceramic phase. In this study, SS316L based nanocomposites were fabricated via laser powder bed fusion (LPBF) by incorporating small amounts of tungsten carbide (WC) and titanium nitride (TiN) nanoparticles. The addition of WC nanoparticles not only resulted in enhanced mechanical strength, as confirmed previously, but also led to a significant reduction in wear rate without a reduction in the corrosion-resistant performance of SS316L. The incorporation of TiN nanoparticles further improved mechanical performance through grain refinement. Microstructural analysis confirmed a uniform dispersion of nanoparticles both within grain interiors and along grain boundaries, maintaining a high interfacial strength with the matrix. This corresponds to substantially lower wear rates, dominated by abrasive wear. These findings highlight the potential of nanoparticle reinforcement in enhancing the mechanical and tribological performance of LPBF-fabricated SS316L components for advanced structural applications.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"582 ","pages":"Article 206334"},"PeriodicalIF":6.1,"publicationDate":"2025-09-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145097247","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}

引用次数: 0

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