IF 6.1 1区工程技术

Wear Pub Date : 2026-03-15 Epub Date: 2026-01-10 DOI: 10.1016/j.wear.2025.206494

Righdan M. Namus , W Mark Rainforth

{"title":"Using electrochemical noise EN to investigate the tribocorrosion behaviour of Ti27.78Zr27.78Hf27.78Nb8.33Ta8.33 at% HEA","authors":"Righdan M. Namus , W Mark Rainforth","doi":"10.1016/j.wear.2025.206494","DOIUrl":"10.1016/j.wear.2025.206494","url":null,"abstract":"<div><div>Commonly used metallic biomaterials exhibit significant disadvantages, including releasing toxic metallic ions from CoCrMo alloy and the insufficient wear resistance of Ti-based alloys. This underscores the need for enhanced metallic materials for orthopedic applications. The optimal material must exhibit superior mechanical properties, high corrosion resistance, biocompatibility, and, crucially, exceptional tribocorrosion resistance. High Entropy Alloys (HEAs) are promising for fulfilling these requirements due to their remarkable combination of features that may be customised for individual purposes. The Ti<sub>27.78</sub>Zr<sub>27.78</sub>Hf<sub>27.78</sub>Nb<sub>8.33</sub>Ta<sub>8.33</sub> at% HEA has garnered interest as a promising candidate for orthopedic applications. This alloy demonstrates outstanding electrochemical performance. However, a comprehensive investigation into its tribocorrosion behaviour has yet to be conducted. The current study employed the Electrochemical Noise (EN) technique to analyze the tribocorrosion behaviour of the alloy in simulated body fluid at 37 °C. The findings indicate that the alloy demonstrates similar tribocorrosion performance when compared to its competitors. Additionally, the examination of the surface status after performing the tribocorrosion tests revealed a marked decrease in corrosion resistance.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"589 ","pages":"Article 206494"},"PeriodicalIF":6.1,"publicationDate":"2026-03-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145981701","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

Chemical wear of cemented carbide tools in contact with Cu-Zn alloy – investigated using thermodynamic calculations 用热力学计算方法研究了与Cu-Zn合金接触的硬质合金刀具的化学磨损

IF 6.1 1区工程技术

Wear Pub Date : 2026-03-15 Epub Date: 2026-01-09 DOI: 10.1016/j.wear.2026.206530

F. Ekholm, J. Heinrichs Lindgren, S. Jacobson

{"title":"Chemical wear of cemented carbide tools in contact with Cu-Zn alloy – investigated using thermodynamic calculations","authors":"F. Ekholm, J. Heinrichs Lindgren, S. Jacobson","doi":"10.1016/j.wear.2026.206530","DOIUrl":"10.1016/j.wear.2026.206530","url":null,"abstract":"<div><div>Cemented carbide (WC-Co) tools are worn at a very slow rate when shearing Cu-Zn alloy wire into zipper elements. Despite this, the wear is the limiting factor in the operation. Analysis of worn WC-Co from both the zipper production and tribological tests, mimicking the wear caused by the shearing action, indicate that WC grains and Co binder are worn through oxidative mechanisms. The Zn in the alloy is believed to preferentially react with oxygen in the contact. The wear mechanisms are still not fully understood since the wear occurs at a very fine scale, and consequently leaves diminutive damage. In the present study, CALPHAD based thermodynamic calculations, proven successful for studying chemical wear of tool materials in other machining operations, are performed to further investigate the chemical wear of WC-Co against Cu-Zn alloy. Equilibrium conditions are set to represent the tribological contact. This enables the stable phases and their compositions, as well as their driving forces in the contact, to be calculated and coupled, to study possible chemical wear mechanisms.</div><div>The calculations indicate that wear of WC-Co is governed by oxidative mechanisms. Zn in the alloy can preferentially react with oxygen and this reduces its availability, so that both WC and Co become thermodynamically stable and thus not oxidise. This calculated effect of Zn becomes stronger with increasing Zn content and is therefore in line with the results from experimental work. This shows that CALPHAD is a suitable approach for investigating fine scale chemical wear of cemented carbides.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"589 ","pages":"Article 206530"},"PeriodicalIF":6.1,"publicationDate":"2026-03-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145981700","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

Cold sintering process on the tribological properties of h-BN@SiO2/PEEK composite 冷烧结工艺对h-BN@SiO2/PEEK复合材料摩擦学性能的影响

IF 6.1 1区工程技术

Wear Pub Date : 2026-03-15 Epub Date: 2026-01-19 DOI: 10.1016/j.wear.2026.206549

Dapeng Gu , Hao Xu , Ke Liu , Chenxi Suo , Junqi Ge , Suwen Chen

{"title":"Cold sintering process on the tribological properties of h-BN@SiO2/PEEK composite","authors":"Dapeng Gu , Hao Xu , Ke Liu , Chenxi Suo , Junqi Ge , Suwen Chen","doi":"10.1016/j.wear.2026.206549","DOIUrl":"10.1016/j.wear.2026.206549","url":null,"abstract":"<div><div>To achieve the low-temperature combination of ceramics and polymers, the core-shell structure and cold sintering method are employed to prepare ceramic/polymer composites. An easy-bonding Silica (SiO<sub>2</sub>) shell was introduced onto the surface of the hard-bonding Hexagonal boron nitride (h-BN) core by a sol-gel method to fabricate a core-shell structured h-BN@SiO<sub>2</sub> composite. Polyether ether ketone (PEEK) was subsequently filled into h-BN@SiO<sub>2</sub> to prepare h-BN@SiO<sub>2</sub>/PEEK ceramic composite by a cold sintering method. The effects of PEEK content (20 vol%, 35 vol%, and 50 vol%), sintering temperature (205 °C, 245 °C, 285 °C, and 325 °C), and molding pressure (350 MPa, 450 MPa, and 550 MPa) on the dry tribological properties of h-BN@SiO<sub>2</sub>/PEEK ceramic composites against GCr15 bearing steel were investigated using a ball-on-disc contact configuration. Field emission transmission electron microscopy (TEM), Energy dispersive spectrometer (EDS), Field emission scanning electron microscopy (SEM), X-ray diffraction (XRD), and Fourier transform infrared spectrometer (FTIR) were used to characterize and analyze h-BN@SiO<sub>2</sub> or h-BN@SiO<sub>2</sub>/PEEK ceramic composites. The results indicate that h-BN@SiO<sub>2</sub>/PEEK composite exhibits better tribological performance when fabricated with a PEEK content of 35 vol%, a sintering temperature of 285 °C, and a molding pressure of 450 MPa under the investigated conditions. The formation of a stable and continuous mixed lubrication layer composed of h-BN, PEEK, and SiO<sub>2</sub> is identified as the primary factor contributing to the enhanced friction reduction and wear resistance. Under the investigated conditions, the main wear mechanisms observed in h-BN@SiO<sub>2</sub>/PEEK composites are adhesive wear, fatigue wear, and slight abrasive wear.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"589 ","pages":"Article 206549"},"PeriodicalIF":6.1,"publicationDate":"2026-03-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146024659","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

Friction and wear prediction of copper-free resin-based brake materials: A hybrid PSO-FPA-BP neural network approach 无铜树脂基制动材料的摩擦磨损预测：混合PSO-FPA-BP神经网络方法

IF 6.1 1区工程技术

Wear Pub Date : 2026-03-15 Epub Date: 2026-01-12 DOI: 10.1016/j.wear.2026.206536

Kaikui Zheng , Qing Le , Ling Pan , Jianmeng Huang

{"title":"Friction and wear prediction of copper-free resin-based brake materials: A hybrid PSO-FPA-BP neural network approach","authors":"Kaikui Zheng , Qing Le , Ling Pan , Jianmeng Huang","doi":"10.1016/j.wear.2026.206536","DOIUrl":"10.1016/j.wear.2026.206536","url":null,"abstract":"<div><div>Copper-free resin-based brake materials are multicomponent composites comprising both organic and inorganic constituents. Their friction and wear behavior is governed by complex nonlinear interactions among various components and temperature, making accurate prediction through conventional approaches difficult. To overcome this challenge, the present study investigates a novel copper-free resin-based brake material reinforced with foundry waste sand, and proposes a back-propagation (BP) neural network model optimized by a hybrid Particle Swarm Optimization–Flower Pollination Algorithm (PSO-FPA), referred to as PSO-FPA-BP, for precise prediction of the material's friction and wear properties. Orthogonal analysis of variance (ANOVA) was employed to examine the correlations between the friction coefficient, wear rate, and raw material composition, with the optimal formulation determined through range analysis. The data derived from orthogonal experiments served as the training set for model development. Using the principal material components and temperature as input variables, and the friction coefficient and wear rate as outputs, the PSO-FPA-BP prediction model was constructed. Comparative evaluations against BP neural networks optimized solely by the Flower Pollination Algorithm (FPA-BP) or the Particle Swarm Optimization algorithm (PSO-BP) revealed that the PSO-FPA-BP model achieved superior predictive accuracy, with coefficients of determination (R<sup>2</sup>) of 0.879 for the friction coefficient and 0.979 for the wear rate. Furthermore, friction and wear tests were conducted using the optimized formulation to generate validation data. The results indicated that the prediction accuracy of the PSO-FPA-BP model reached 95.005 % for the friction coefficient and 88.021 % for the wear rate on the validation samples, confirming the model's strong robustness and generalization capability.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"589 ","pages":"Article 206536"},"PeriodicalIF":6.1,"publicationDate":"2026-03-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145950268","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

Mechanical and tribological properties of Al-20Si-5Fe-2Ni composites reinforced by Cu-coated Mo2BC ceramic cu包覆Mo2BC陶瓷增强Al-20Si-5Fe-2Ni复合材料的力学和摩擦学性能

IF 6.1 1区工程技术

Wear Pub Date : 2026-03-15 Epub Date: 2026-01-19 DOI: 10.1016/j.wear.2026.206551

Shuai Wang , Zhiyuan Zhang , Yu Cai , Xianjuan Pang , Long You , Chenfei Song , Sanming Du , Yongzhen Zhang

{"title":"Mechanical and tribological properties of Al-20Si-5Fe-2Ni composites reinforced by Cu-coated Mo2BC ceramic","authors":"Shuai Wang , Zhiyuan Zhang , Yu Cai , Xianjuan Pang , Long You , Chenfei Song , Sanming Du , Yongzhen Zhang","doi":"10.1016/j.wear.2026.206551","DOIUrl":"10.1016/j.wear.2026.206551","url":null,"abstract":"<div><div>In this paper, Al-20Si-5Fe-2Ni composites reinforced with varying contents of Mo<sub>2</sub>BC and Cu-coated Mo<sub>2</sub>BC were fabricated via vacuum hot-press sintering. The influence of Cu-coated Mo<sub>2</sub>BC content on the mechanical and tribological properties of the composites was systematically examined. Results revealed that the Cu coating on Mo<sub>2</sub>BC ceramic particles reacted with the aluminum alloy matrix during sintering, leading to the formation of Al<sub>2</sub>Cu interfacial bridges. The incorporation of Cu-coated Mo<sub>2</sub>BC significantly enhanced the overall mechanical properties of the composites, which was attributed to the synergistic effects of interfacial bridging strengthening and the pinning effect provided by the Mo<sub>2</sub>BC ceramic particles. Moreover, the tribological performance of the Al-20Si-5Fe-2Ni composites was markedly improved. When sliding against GCr15 bearing steel, the primary wear mechanisms of the unreinforced alloy included adhesive, fatigue, and abrasive wear. With the addition of up to 20 wt% Cu-coated Mo<sub>2</sub>BC, a smooth and continuous oxide film formed on the worn surface, which exerted a lubricating effect and reduced wear. However, as the content of Cu-coated Mo<sub>2</sub>BC further increased to 30 wt%, agglomeration of Mo<sub>2</sub>BC particles became evident. Under applied shear stresses during sliding, these agglomerated particles were prone to fracture and disperse within the wear track, ultimately resulting in an increased friction coefficient and higher wear rate.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"589 ","pages":"Article 206551"},"PeriodicalIF":6.1,"publicationDate":"2026-03-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146024658","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

Improving the tribological and anti-corrosion performance of LPBF-processed GH3230 superalloy by post-treatment 通过后处理提高lpbf加工的GH3230高温合金的摩擦学和防腐性能

IF 6.1 1区工程技术

Wear Pub Date : 2026-03-15 Epub Date: 2026-01-21 DOI: 10.1016/j.wear.2026.206560

Xiaohang Liu , Xueping Guo , Qilin Zhang , Shengbin Dai , Jiangqi Zhu , Bingwen Lu , Changri Xiong , Hao Qiu , Ting Yu , Xingchen Yan

{"title":"Improving the tribological and anti-corrosion performance of LPBF-processed GH3230 superalloy by post-treatment","authors":"Xiaohang Liu , Xueping Guo , Qilin Zhang , Shengbin Dai , Jiangqi Zhu , Bingwen Lu , Changri Xiong , Hao Qiu , Ting Yu , Xingchen Yan","doi":"10.1016/j.wear.2026.206560","DOIUrl":"10.1016/j.wear.2026.206560","url":null,"abstract":"<div><div>The poor tribological performance and susceptibility to corrosion of as-printed nickel-based superalloys produced by laser powder bed fusion (LPBF) limit their application in demanding environments, such as the unlubricated, high-temperature components of aerospace engines. To address this challenge, this study aims to enhance the wear and corrosion resistance of LPBF-fabricated GH3230 superalloy through tailored post-processing. Specimens were subjected to solution treatment (ST) and hot isostatic pressing (HIP), and their microstructure, dry sliding wear behavior against a Si<sub>3</sub>N<sub>4</sub> counter body, and electrochemical corrosion performance were systematically investigated. Results indicate that both ST and HIP promoted recrystallization and the formation of coarse carbides, completely transforming the initial molten pool structure. The HIP-treated alloy exhibited the lowest friction coefficient (0.69) and wear rate (3.23 × 10<sup>−5</sup> mm<sup>3</sup>/(N·m)), which is attributed to the synergistic effect of coarse carbides and high-density dislocations that facilitated the formation of a work-hardened layer, thereby reducing the actual contact area. Furthermore, the HIP treatment enabled the formation of a more stable and protective passive film, resulting in superior corrosion resistance. This work demonstrates that HIP is an effective post-processing strategy for achieving a synergistic improvement in tribological and anti-corrosion properties, providing critical insights for the performance optimization of additively manufactured superalloys in severe service conditions.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"589 ","pages":"Article 206560"},"PeriodicalIF":6.1,"publicationDate":"2026-03-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146079451","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

Tribological compatibility investigation of multiwall carbon nanotubes/nickel coatings sliding against silicon nitride under dry friction and oil lubrication 干摩擦和油润滑条件下多壁碳纳米管/镍涂层与氮化硅的摩擦学相容性研究

IF 6.1 1区工程技术

Wear Pub Date : 2026-03-15 Epub Date: 2026-01-26 DOI: 10.1016/j.wear.2026.206564

Lupeng Wu , Haifeng Xue , Ke Zhang , Tianxiang Li , Wei Gao , Le Gu , Yongtao Zhang

{"title":"Tribological compatibility investigation of multiwall carbon nanotubes/nickel coatings sliding against silicon nitride under dry friction and oil lubrication","authors":"Lupeng Wu , Haifeng Xue , Ke Zhang , Tianxiang Li , Wei Gao , Le Gu , Yongtao Zhang","doi":"10.1016/j.wear.2026.206564","DOIUrl":"10.1016/j.wear.2026.206564","url":null,"abstract":"<div><div>Multiwall carbon nanotubes reinforced nickle (MWCNTs/Ni) coatings were electrodeposited in electrolyte solution containing carboxylated MWCNTs with dimensions of 285–427 nm. Surface morphology and hardness analysis determined 3 g/L MWCNTs as the optical addition concentration under low current density of 1 Adm<sup>−2</sup>. Based on friction and wear behaviors, the tribological compatibility of Ni coating sliding against silicon nitride was improved by using MWCNTs as lubrication reinforcements. 50.6 and 44.4 % of friction and wear reduction was achieved under dry friction at 1214 MPa and 0.089 m/s while 35.8 % and 24.2 % of that was accomplished under oil lubrication. Micro-protrudes containing MWCNTs were crushed because of the high contact stress caused by coarse surface during sliding and hereby MWCNTs were released into oil. The improved tribological properties were attributed to the synergistic mechanism of MWCNTs serve as solid lubricants inside coatings and lubrication additives in oil.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"589 ","pages":"Article 206564"},"PeriodicalIF":6.1,"publicationDate":"2026-03-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146079456","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

Tribological properties of gradient-structured TiAlSiN coatings: A comparative study with homogeneous coatings under a wide range of load-speed conditions 梯度结构TiAlSiN涂层的摩擦学性能：与均匀涂层在大范围载荷-速度条件下的比较研究

IF 6.1 1区工程技术

Wear Pub Date : 2026-03-15 Epub Date: 2026-01-21 DOI: 10.1016/j.wear.2026.206559

Lianggang Ji , Hanlian Liu , Chuanzhen Huang , Guanqun Wang , Xuefei Liu , Jinfu Zhao , Longhua Xu

{"title":"Tribological properties of gradient-structured TiAlSiN coatings: A comparative study with homogeneous coatings under a wide range of load-speed conditions","authors":"Lianggang Ji , Hanlian Liu , Chuanzhen Huang , Guanqun Wang , Xuefei Liu , Jinfu Zhao , Longhua Xu","doi":"10.1016/j.wear.2026.206559","DOIUrl":"10.1016/j.wear.2026.206559","url":null,"abstract":"<div><div>To investigate the influence of gradient structure on the tribological properties of coatings, this study compares the dry sliding behavior of gradient TiAlSiN, homogeneous TiAlSiN, and TiAlN coatings against GCr15 steel balls under loads of 10–40 N and sliding speeds of 10–40 m/min. The wear mechanisms were revealed through multi-scale characterization. Results show that the wear rates of all three coatings increase with increasing load and speed, while the gradient coating exhibits a more stable friction coefficient and a gentler increase in wear rate. Under conditions of a 40 N load and a 20 m/min sliding speed, its wear rate is reduced by 17.2 % and 41.3 % compared to homogeneous TiAlSiN and TiAlN coatings, respectively. In terms of failure modes, homogeneous TiAlSiN exhibits brittle spalling, while TiAlN suffers from poor wear resistance due to low hardness. The superior performance of the gradient coating originates from its gradual microstructural and mechanical transitions. Finite element modeling (FEM) confirms that this design effectively mitigates stress concentrations, leading to enhanced load-bearing capacity and a reduced risk of interfacial delamination. Abrasive wear is the dominant mechanism for all coatings under low load and speed, while the synergistic effect of adhesive wear and oxidative wear becomes predominant under high load and speed. This study confirms that gradient structure design can significantly enhance wear resistance of coating, providing theoretical support for coating development under extreme operating conditions.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"589 ","pages":"Article 206559"},"PeriodicalIF":6.1,"publicationDate":"2026-03-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146079453","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

Addition of Al anodizing waste in a commercial friction material in an industrial symbiosis perspective 工业共生视角下铝阳极氧化废料在工业摩擦材料中的添加

IF 6.1 1区工程技术

Wear Pub Date : 2026-03-15 Epub Date: 2026-01-24 DOI: 10.1016/j.wear.2026.206553

G.S. Gehlen , F. Valentini , A.P. Nogueira , R. Masciocchi , A. Barbieri , G. Straffelini

{"title":"Addition of Al anodizing waste in a commercial friction material in an industrial symbiosis perspective","authors":"G.S. Gehlen , F. Valentini , A.P. Nogueira , R. Masciocchi , A. Barbieri , G. Straffelini","doi":"10.1016/j.wear.2026.206553","DOIUrl":"10.1016/j.wear.2026.206553","url":null,"abstract":"<div><div>This study investigates the incorporation of anodizing aluminum waste (AAW), primarily aluminum hydroxide, into commercial brake pad friction materials. Four formulations were evaluated: a reference benchmark, one with 12 % unsieved AAW, and two with 6 % and 12 % sieved AAW. Samples were produced by hot pressing and characterized in terms of wear, friction behavior, and particulate matter (PM) emissions using a sub-scale dynamometer and a 168-cycle braking protocol based on the AK Master standard. To assess the environmental implications of AAW addition and the associated drying step, a life cycle assessment (LCA) was also conducted. The results revealed that increasing AAW content led to larger friction coefficient fluctuations and higher sensitivity to pressure and sliding speed, with the 12 % AAW formulations showing the greatest instability. The mean coefficient of friction under mild braking conditions decreased with AAW incorporation. In terms of wear, the 6 % AAW formulation achieved performance comparable to the reference, whereas 12 % AAW increased pad wear; disc wear remained unaffected across all compositions. Importantly, PM emissions from AAW-containing materials were similar to or lower than those of the reference, regardless of AAW content or sieving. LCA demonstrated that replacing alumina with AAW consistently reduced environmental impacts across all categories. Overall, among the tested compositions, the 6 % AAW formulation provided the best compromise between tribological stability and environmental benefits, supporting both the technical feasibility and the sustainability potential of incorporating AAW into friction material manufacturing within an industrial symbiosis framework.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"589 ","pages":"Article 206553"},"PeriodicalIF":6.1,"publicationDate":"2026-03-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146079448","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 stage evolution and failure mechanism of hard chromium-coated calender rolls during continuous lithium-ion battery electrode calendering 锂离子电池电极连续压延过程中硬铬压延辊磨损阶段演变及失效机理

IF 6.1 1区工程技术

Wear Pub Date : 2026-03-15 Epub Date: 2026-01-14 DOI: 10.1016/j.wear.2026.206537

Jingyu Fan , Xipeng Xin , Qingdong Liu , Yifeng Xu , Yiqiu Zhu , Hu Chen , Wei Chen , Xiaofeng Zhao , Xuefeng Song

{"title":"Wear stage evolution and failure mechanism of hard chromium-coated calender rolls during continuous lithium-ion battery electrode calendering","authors":"Jingyu Fan , Xipeng Xin , Qingdong Liu , Yifeng Xu , Yiqiu Zhu , Hu Chen , Wei Chen , Xiaofeng Zhao , Xuefeng Song","doi":"10.1016/j.wear.2026.206537","DOIUrl":"10.1016/j.wear.2026.206537","url":null,"abstract":"<div><div>The wear mechanisms and life cycle evolution of hard chromium-coated rolls during lithium-ion battery electrode calendering remain underexplored. In this study, a modified ball-on-disk configuration was employed to simulate the long-term sliding contact (360 h) between hard chromium coatings and LiFePO<sub>4</sub> (LFP) electrode sheets. A non-linear, four-stage wear evolution law was identified: (1) Running-in (0–120 h), characterized by mild abrasion protected by the native oxide film; (2) Stable wear (120–170 h), marked by oxide breakdown and substrate exposure; (3) Severe wear (170–270 h), driven by matrix-mediated adhesion, where carbon-rich binder accumulation formed protrusions that induced fatigue shear fracture and deep pitting; and (4) Secondary stable wear (270–360 h), featuring a cyclic competition between tribo-oxidative regeneration and fatigue spallation. The failure mechanism is attributed to the synergy between binder-driven adhesion and third-body abrasion caused by hard oxide debris. These findings highlight that maintaining the integrity of the surface Cr<sub>2</sub>O<sub>3</sub> layer is critical for suppressing adhesive wear and optimizing roll durability in battery manufacturing.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"589 ","pages":"Article 206537"},"PeriodicalIF":6.1,"publicationDate":"2026-03-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145981554","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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