IF 6.1 1区工程技术

Wear Pub Date : 2025-10-08 DOI: 10.1016/j.wear.2025.206350

Minh Ngoc Le , Anke Dalke , Horst Biermann

{"title":"Microstructure and unlubricated sliding wear behavior of active screen plasma nitrided FeAl40 alloy against WC-6Co under ambient conditions","authors":"Minh Ngoc Le , Anke Dalke , Horst Biermann","doi":"10.1016/j.wear.2025.206350","DOIUrl":"10.1016/j.wear.2025.206350","url":null,"abstract":"<div><div>This study examines the microstructure of the nitride layer formed on FeAl40 alloy during active screen plasma nitriding (ASPN) at 575 °C for 4 h in a nitrogen-hydrogen mixture (30 vol% nitrogen) and its effect on the tribological behavior under severe wear conditions. The resulting tribological properties are evaluated using unlubricated linear-reciprocating sliding ball-on-disc wear tests against WC-6Co ball-counterbodies (ϕ6 mm) applying various normal loads <em>F</em><sub>N</sub> (10 N, 30 N, 50 N) and sliding distances <em>s</em> (100 m, 1000 m) under ambient conditions. During ASPN a complex-structured nitride layer forms, consisting of a compound bilayer and a diffusion layer. Notably, the microstructure of the compound bilayer consists of an outer sublayer with mainly iron nitrides and an inner sublayer with additional aluminum nitride, which differs significantly from the “white” compound layer formed by gas nitriding or conventional plasma nitriding, respectively, on FeAl40 alloy. The diffusion layer contains a very high nitrogen content up to 38 at.% nitrogen forming nitride phases of Fe and Al within the layer, resulting in an increase in surface hardness up to 1550 HV0.05. The presence of the nitride layer causes a change in the wear mechanism of the FeAl40 alloy, where the two-body abrasive wear is dominant. As a result, the nitrided samples exhibit excellent wear resistance with a reduction of the specific wear coefficient (<em>k</em>) with increasing <em>F</em><sub>N</sub>, in contrast to the base material.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"584 ","pages":"Article 206350"},"PeriodicalIF":6.1,"publicationDate":"2025-10-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145334314","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

Post-processing of material extrusion additively manufactured 17-4 PH stainless steel via aging and multi-step shot peening: surface integrity and wear response 17-4 PH不锈钢经时效和多步喷丸强化后的材料后处理：表面完整性和磨损响应

IF 6.1 1区工程技术

Wear Pub Date : 2025-10-08 DOI: 10.1016/j.wear.2025.206383

Aphichat Sakkaeo , Chanun Suwanpreecha , Prathompoom Newyawong , Visittapong Yordsri , Sukrit Songkuea , Tuksadon Wutikhun , Anchalee Manonukul

{"title":"Post-processing of material extrusion additively manufactured 17-4 PH stainless steel via aging and multi-step shot peening: surface integrity and wear response","authors":"Aphichat Sakkaeo , Chanun Suwanpreecha , Prathompoom Newyawong , Visittapong Yordsri , Sukrit Songkuea , Tuksadon Wutikhun , Anchalee Manonukul","doi":"10.1016/j.wear.2025.206383","DOIUrl":"10.1016/j.wear.2025.206383","url":null,"abstract":"<div><div>This study investigates the influence of aging, single and double shot peening treatments on 17-4 PH stainless steel fabricated via material extrusion additive manufacturing (MEX). The focus is on improving surface integrities—specifically mitigating surface imperfections inherent to MEX parts, such as printing-related strip patterns and sintering-induced roughness—and enhancing linear reciprocating wear performance using a WC-Co counterpart. The results show that both single and double shot peening treatments significantly reduce surface imperfections, leading to a notable decrease in the coefficient of friction (COF). Aging also contributes to COF reduction. Surface grain refinement is observed after shot peening, with nanocrystalline structures (grain size <100 nm) forming in the as-sintered specimen subjected to double shot peening, while other specimens exhibit larger grains or earlier stages of grain refinement. Aging enhances overall hardness, while the single and double shot peening further increases surface hardness, which gradually diminishes at depths beyond 80 μm from the surface. In addition, the wear rate decreases progressively with the application of aging and subsequent shot peening treatments. These improvements are attributed to a combination of surface grain refinement, the formation of a work-hardened layer, compressive residual stress from shot peening, and precipitation hardening from aging. As a result, the dominant wear mechanisms shift from oxidation-induced delamination and low cycle fatigue—most severe in untreated, as-sintered specimen—to predominantly abrasive wear in aged and peened condition. Overall, the synergistic effects of aging and double shot peening markedly enhance the wear resistance and surface integrity of MEX-fabricated 17-4 PH stainless steel components.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"584 ","pages":"Article 206383"},"PeriodicalIF":6.1,"publicationDate":"2025-10-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145334284","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

Wear and contact conductivity of multicomponent copper/stainless steel additively manufactured alloys in unlubricated sliding with passing electric current 多组分铜/不锈钢增材制造合金在无润滑滑动下的接触电导率和磨损

IF 6.1 1区工程技术

Wear Pub Date : 2025-10-08 DOI: 10.1016/j.wear.2025.206372

K.S. Osipovich, V.V. Fadin, N.L. Savchenko, A.V. Chumaevskii, A.O. Panfilov, E.N. Moskvichev, D.A. Gurianov, E.A. Kolubaev, S. Yu Tarasov

{"title":"Wear and contact conductivity of multicomponent copper/stainless steel additively manufactured alloys in unlubricated sliding with passing electric current","authors":"K.S. Osipovich, V.V. Fadin, N.L. Savchenko, A.V. Chumaevskii, A.O. Panfilov, E.N. Moskvichev, D.A. Gurianov, E.A. Kolubaev, S. Yu Tarasov","doi":"10.1016/j.wear.2025.206372","DOIUrl":"10.1016/j.wear.2025.206372","url":null,"abstract":"<div><div>Multicomponent stainless steel/copper alloys were produced using dual-wire and electron beam additive manufacturing (WEBAM) with addition of 10 vol%, 25 vol% 36 vol% and 50 vol% of stainless steel. Tribological testing was carried out with and without passing electric current on samples oriented with their layers parallel and perpendicular to the worn surfaces. The ascending dependencies of wear and descending dependencies of coefficient of friction from electric current density have been obtained along with the voltage current ones to characterize the sliding contact performance. At low current levels, sliding behavior was similar to that in dry sliding conditions, characterized by adhesive wear and the formation of tribological transfer layers formed on the worn surfaces. Passing higher currents led to the formation of smooth tribological layers containing the in-situ formed spinels with the wear mechanism transition to flow wear. The wear dependencies did not allow observing the differences that related to the sample orientation with respect to worn surface because of generation of mechanically mixed layers.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"584 ","pages":"Article 206372"},"PeriodicalIF":6.1,"publicationDate":"2025-10-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145270945","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

Tool wear prediction for coated cutting inserts during milling of Ti-6Al-4V using a grey box model 基于灰盒模型的Ti-6Al-4V涂层切削齿铣削过程刀具磨损预测

IF 6.1 1区工程技术

Wear Pub Date : 2025-10-06 DOI: 10.1016/j.wear.2025.206352

Laura Zinnel , Moritz Goeldner , Daniel Piendl , Yair Shneor , Michael F. Zaeh

{"title":"Tool wear prediction for coated cutting inserts during milling of Ti-6Al-4V using a grey box model","authors":"Laura Zinnel , Moritz Goeldner , Daniel Piendl , Yair Shneor , Michael F. Zaeh","doi":"10.1016/j.wear.2025.206352","DOIUrl":"10.1016/j.wear.2025.206352","url":null,"abstract":"<div><div>Titanium alloys are widely used in aerospace, medical, and automotive industries due to their high strength and corrosion resistance, as well as low density. However, the machining of titanium presents significant challenges, including high mechanical loads, excessive heat generation, and, thus, increased tool wear. This wear leads to a poor surface quality, dimensional inaccuracies, and increased production costs due to an unplanned downtime and frequent tool replacements. Traditional monitoring methods for predicting tool wear, such as periodic inspections and simple threshold analyses, are often inefficient and time consuming. Artificial Intelligence has emerged as a powerful tool for identifying complex wear patterns, enabling accurate predictions of tool life and optimal replacement timing. However, Artificial Intelligence models are often used as black box models and therefore lack interpretability. In contrast, white box models, which are based only on physical principles, often fail to capture complex wear dynamics. Grey box models combine both approaches, integrating domain knowledge with machine learning algorithms to enhance prediction accuracy and reliability. A particular strength of the present study is that the dataset covers the complete wear curve, including the progressive wear phase, and not only up to the commonly used wear limit of 0.3 mm. This allows the model to be trained and evaluated across all stages of tool wear. In this article, a Long Short-Term Memory Neural Network with domain knowledge of the physical behaviour of tool wear as a cubic function and a loss function that enforces monotonic tool wear behaviour is presented. The performance of the model achieved a mean absolute error in the tool wear prediction of 0.0447 mm, which is good. However, it could not be compared to state-of-the-art approaches for predicting tool wear because the entire data curve is not usually determined.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"584 ","pages":"Article 206352"},"PeriodicalIF":6.1,"publicationDate":"2025-10-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145334283","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

Performance evaluation of Cu-based contact material reinforced by the CuCrNiCoFe high entropy particles CuCrNiCoFe高熵粒子增强cu基接触材料的性能评价

IF 6.1 1区工程技术

Wear Pub Date : 2025-10-06 DOI: 10.1016/j.wear.2025.206373

Jiacheng Tong , Jun Wang , Huimin Zhang , Haoran Liu , Youchang Sun , Zhiguo Li , Wenyi Zhang , Zhe Wang , Yanli Chang , Zhao Yuan , Henry Hu

{"title":"Performance evaluation of Cu-based contact material reinforced by the CuCrNiCoFe high entropy particles","authors":"Jiacheng Tong , Jun Wang , Huimin Zhang , Haoran Liu , Youchang Sun , Zhiguo Li , Wenyi Zhang , Zhe Wang , Yanli Chang , Zhao Yuan , Henry Hu","doi":"10.1016/j.wear.2025.206373","DOIUrl":"10.1016/j.wear.2025.206373","url":null,"abstract":"<div><div>In this study, Cu-based contact materials reinforced with 20 wt% high-entropy alloy particles of CuCrNiCoFe were successfully prepared by combining ball milling and spark plasma sintering (SPS) technology. The microstructure and fundamental physical properties of the novel Cu-20HEAs samples were investigated, and their arc erosion behavior was systematically evaluated. The results demonstrate that after low-speed ball milling for 3 h, the high entropy alloys (HEAs) particles achieved uniform distribution within the Cu matrix. Following SPS, the material exhibited excellent overall performance, with an electrical conductivity of 25.5 %IACS, a Vickers hardness of 90.1 HV, and a density of 8.77 g/cm<sup>3</sup>. The Cu-20HEAs samples displayed favorable resistance to arc erosion during vacuum arc breakdown testing. During arcing, a larger arc diffusion area facilitated rapid dispersion of arc energy, effectively suppressing splashing of the Cu matrix and minimizing mass loss. In 50 arc erosion tests, the dielectric strength of the sample exhibited minimal fluctuation, demonstrating excellent operational stability and a prolonged service life.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"584 ","pages":"Article 206373"},"PeriodicalIF":6.1,"publicationDate":"2025-10-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145334310","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

Thermal crack propagation analysis of railway brake discs considering wear effects via a full thermo-mechanical coupling approach 考虑磨损影响的铁路制动盘热裂纹扩展分析

IF 6.1 1区工程技术

Wear Pub Date : 2025-10-05 DOI: 10.1016/j.wear.2025.206371

Wei Chen , Jiliang Mo , Xiaocui Wang , Qixiang Zhang , Wenwei Jin , Chunguang Zhao

引用次数: 0

Study on the tribocorrosion behavior of the cylinder liner in the ammonia solution 汽缸套在氨溶液中的摩擦腐蚀行为研究

IF 6.1 1区工程技术

Wear Pub Date : 2025-10-04 DOI: 10.1016/j.wear.2025.206367

Xing Xu , Chang Ge , Baofeng Zhang , Hang Li , Xuan Ma , Zhancheng Dou , Xiqun Lu

引用次数: 0

Numerical study on erosion wear and aerodynamic characteristics of coaxial contra-rotating propellers 同轴对旋螺旋桨冲蚀磨损及气动特性数值研究

IF 6.1 1区工程技术

Wear Pub Date : 2025-10-03 DOI: 10.1016/j.wear.2025.206370

Yunan Zhu, Xiangying Guo, Fujin Zang, Dongxing Cao

{"title":"Numerical study on erosion wear and aerodynamic characteristics of coaxial contra-rotating propellers","authors":"Yunan Zhu, Xiangying Guo, Fujin Zang, Dongxing Cao","doi":"10.1016/j.wear.2025.206370","DOIUrl":"10.1016/j.wear.2025.206370","url":null,"abstract":"<div><div>This study examines the erosion and wear behavior of coaxial contra-rotating propeller (CRP) blades operating in extreme wind-sand environments, such as desert plateaus, and evaluates the subsequent effects of airborne sand and dust particles on the blades' aerodynamic performance. First, the configured CRP is compared with open-rotor wind-tunnel datasets (NASA ORPR and AI-PX7/S1MA) under clean-surface conditions (no particle erosion) to verify the accuracy and reliability of the simulation settings. Then, the influence of key operational parameters is investigated, including rotational speed and blade spacing, on the erosion and wear characteristics of the propeller blades. Through a detailed analysis of wear patterns on the blade surface under varying operational conditions, the relationship between these parameters and the extent of blade degradation is elucidated. Next, the regions on the blade surface are identified and classified with varying degrees of erosion. The effects of surface roughness in these damaged regions on the aerodynamic performance of the CRP are thoroughly explored. Particular attention is given to the impact of different levels of surface roughness on aerodynamic efficiency, thrust, and power consumption, with a focus on influence of different roughness on propeller performance. The findings provide theoretical insights that contribute to the design and optimization of propeller blades for operation in harsh wind-sand environments, enhancing both blade durability and aerodynamic efficiency.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"582 ","pages":"Article 206370"},"PeriodicalIF":6.1,"publicationDate":"2025-10-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145268448","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

Lantern-inspired integrated multi-biomimetic microstructure for efficiently improving tribological performance of cemented carbide under green lubrication 绿色润滑下高效提高硬质合金摩擦学性能的lantern型集成多仿生微观结构

IF 6.1 1区工程技术

Wear Pub Date : 2025-10-02 DOI: 10.1016/j.wear.2025.206368

Yunpeng Ma, Xiaobin Cui, Ying Niu, Daohui Xiang, Feng Jiao, Pingmei Ming

{"title":"Lantern-inspired integrated multi-biomimetic microstructure for efficiently improving tribological performance of cemented carbide under green lubrication","authors":"Yunpeng Ma, Xiaobin Cui, Ying Niu, Daohui Xiang, Feng Jiao, Pingmei Ming","doi":"10.1016/j.wear.2025.206368","DOIUrl":"10.1016/j.wear.2025.206368","url":null,"abstract":"<div><div>Vegetable oil-based minimum quantity lubrication (VMQL) is a green lubrication method limited in improving lubrication at friction interfaces. The introduction of integrated multi-biomimetic microstructure (IMM) on cemented carbide surface is expected to efficiently improve tribological performance under VMQL conditions. Inspired by lanterns' layered integration, we integrated four biomimetic microstructures vertically and horizontally using a wear-resistant biomimetic microstructure as the basic frame. Four IMM with different wettability were obtained: superlipophilic IMM (IMM-L), superoleophobic IMM (IMM-O), IMM with superlipophilic upper and superoleophobic lower surface (IMM-LO), and IMM with superoleophobic upper and superlipophilic lower surface (IMM-OL). We investigated the morphology and wettability behavior of the IMM. Influences of load, sliding speed, and lubricant flow rate on the average coefficient of friction (COF) and wear rate of cemented carbide with and without IMM were analyzed. The integration methods' effects on tribological performance were analyzed, and the optimal area ratio (defined as the upper-to-lower surface area ratio) for the best IMM was investigated. We revealed the influencing mechanism of the integration methods on the tribological performance improvement. IMM incorporated features of various biomimetic microstructures. The integration method significantly affected surface energy distribution, causing differences in surface superwettability. Surfaces with IMM showed much better tribological performance compared to conventional surfaces. The average COF decreased by 18.2 %–54.5 %, while wear rate reduction ranged from 31.7 % to 60.9 %. IMM-LO offered the largest reduction, with optimal tribological performance achieved at an area ratio of 1.2, owing to its unique superwettability distribution enhancing hydrodynamic pressure effect and lubricant-transport efficiency.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"584 ","pages":"Article 206368"},"PeriodicalIF":6.1,"publicationDate":"2025-10-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145227843","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

Evolution of electrical contact status and wear pattern under various loading conditions for copper-beryllium alloy 不同载荷条件下铜铍合金电接触状态及磨损规律的演化

IF 6.1 1区工程技术

Wear Pub Date : 2025-10-01 DOI: 10.1016/j.wear.2025.206366

Chun-Zheng Zhang , Fei Shen , Xin Feng , Liao-Liang Ke

引用次数: 0

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