IF 6.1 1区工程技术

Wear Pub Date : 2025-09-22 DOI: 10.1016/j.wear.2025.206357

Junyan Wang, Jianxin Deng, Zhihui Zhang, Yichen Bao, Kexin Ma

{"title":"Al2O3 fiber reinforced epoxy / WS2 - PEG composite coatings for wear resistance enhancement by electrohydrodynamic atomization","authors":"Junyan Wang, Jianxin Deng, Zhihui Zhang, Yichen Bao, Kexin Ma","doi":"10.1016/j.wear.2025.206357","DOIUrl":"10.1016/j.wear.2025.206357","url":null,"abstract":"<div><div>Incorporating reinforcing and lubricating fillers is an efficient approach to improve the mechanical and tribological properties of epoxy-based coatings. In this study, two types of fiber reinforced epoxy/tungsten disulfide and polyethylene glycol (WS<sub>2</sub>-PEG) composite coatings with good wear resistance were successfully synthesized by electrohydrodynamic atomization (EHDA) method. One is constructed by the in-situ synthesized epoxy resin (EP), Al<sub>2</sub>O<sub>3</sub> fibers and WS<sub>2</sub>-PEG nanoflakes hybrids (EP + Al + WS<sub>2</sub>). Another comprises a WS<sub>2</sub>-PEG nanoflakes top layer and an epoxy encapsulated Al<sub>2</sub>O<sub>3</sub> fibers layer at the bottom (EP + Al/WS<sub>2</sub>). The coatings were systematically evaluated for their microstructure, thermal, mechanical, and tribological properties. Results showed that the plasticity index and heat distortion temperature of the composite coatings all improved. Furthermore, The EP + Al/WS<sub>2</sub> exhibited superior good tribology property under dry friction condition, with a 67.2 % and 67.4 % reduction on friction coefficient and wear rate compared with pristine epoxy. EP + Al + WS<sub>2</sub> coatings exhibited great anti-wear performance under water lubrication condition, showing an order of magnitude reduction of wear rate than in dry friction condition. Therefore, fiber reinforced composite coatings hold promising potential in anti-wear coatings field.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"582 ","pages":"Article 206357"},"PeriodicalIF":6.1,"publicationDate":"2025-09-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145158981","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

Influence of surfactants on the tribological characteristics of copper oxide nanoparticles as lubricant oil additives 表面活性剂对氧化铜纳米颗粒润滑油摩擦学特性的影响

IF 6.1 1区工程技术

Wear Pub Date : 2025-09-20 DOI: 10.1016/j.wear.2025.206353

Alper Uğur , Emel Ermiş , İlker Avan

引用次数: 0

Abrasive and oxidative wear mechanisms on additively manufactured Ti-6Al-4V alloy against Al2O3: effect of microstructures and hardness Ti-6Al-4V合金抗Al2O3磨料和氧化磨损机理：显微组织和硬度的影响

IF 6.1 1区工程技术

Wear Pub Date : 2025-09-20 DOI: 10.1016/j.wear.2025.206356

Guilherme Arthur Longhitano , Ignacio Manuel García , Elif Nihal Eren , María Angeles Arenas , Juan José de Damborenea , Rubens Maciel Filho , Ana Conde

{"title":"Abrasive and oxidative wear mechanisms on additively manufactured Ti-6Al-4V alloy against Al2O3: effect of microstructures and hardness","authors":"Guilherme Arthur Longhitano , Ignacio Manuel García , Elif Nihal Eren , María Angeles Arenas , Juan José de Damborenea , Rubens Maciel Filho , Ana Conde","doi":"10.1016/j.wear.2025.206356","DOIUrl":"10.1016/j.wear.2025.206356","url":null,"abstract":"<div><div>The increasing adoption of additive manufacturing (AM) in biomedical applications demands a deeper understanding of the wear behavior of AM Ti-6Al-4V alloy. The microstructures obtained from AM processes often require further tailoring through heat treatments to meet application demands. In this regard, this study investigates the dry sliding wear behavior of Ti-6Al-4V alloy produced by laser and electron beam powder bed fusion. Various microstructures were obtained through different heat treatments performed below and above the alloy β transus temperature. The microstructures were characterized by optical microscopy, scanning electron microscopy, and Vickers hardness testing. Wear tests were conducted under reciprocating sliding using an Al<sub>2</sub>O<sub>3</sub> counter-body with different normal loads (1–5 N), and specific wear rates and coefficients of friction were analyzed. Results revealed different hardness values between 356.6 ± 8.5 and 284.1 ± 11.0 HV, associated with different microstructures, varying from a fully martensitic α′ structure to lamellar α+β structures with increasing heat treatment temperature. The wear mechanisms were a combination of abrasive and oxidative, with oxide debris contributing to tribolayer formation. Higher normal loads favored tribolayer formation, reducing the coefficient of friction from 0.664 ± 0.021 to 0.544 ± 0.004 and from 0.680 ± 0.017 to 0.581 ± 0.015 for the highest and lowest hardness conditions, respectively, and specific wear rate. The findings highlight that both hardness and tribolayer formation govern wear resistance, necessitating further studies on load effects in AM Ti-6Al-4V alloys.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"582 ","pages":"Article 206356"},"PeriodicalIF":6.1,"publicationDate":"2025-09-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145221177","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

The influence of different grease lubrications on the current-carrying wear performance of carbon skateboards/contact wires 不同润滑脂润滑对碳滑板/接触导线载流磨损性能的影响

IF 6.1 1区工程技术

Wear Pub Date : 2025-09-18 DOI: 10.1016/j.wear.2025.206351

Ming-sheng Gao, Xin-long Liu, Ming-xue Shen, Ting Peng, Yi-ting Zheng, Wen-bin Yang, Dan Zhang, Hai-yang Cao, Ze Wang

引用次数: 0

Tribological characteristics of contaminated lubricating oil in the ammonia engine 氨发动机污染润滑油的摩擦学特性

IF 6.1 1区工程技术

Wear Pub Date : 2025-09-17 DOI: 10.1016/j.wear.2025.206347

Xing Xu , Zetong Wang , Kun Zou , Yuxuan Sheng , Chang Ge , Baofeng Zhang , Xuan Ma , Xiqun Lu

{"title":"Tribological characteristics of contaminated lubricating oil in the ammonia engine","authors":"Xing Xu , Zetong Wang , Kun Zou , Yuxuan Sheng , Chang Ge , Baofeng Zhang , Xuan Ma , Xiqun Lu","doi":"10.1016/j.wear.2025.206347","DOIUrl":"10.1016/j.wear.2025.206347","url":null,"abstract":"<div><div>As an alternative fuel with zero carbon emissions, ammonia has great potential for development in the shipping industry. Several initiatives and studies are underway to bring ammonia engines to the market soon. In this study, the tribological characteristics of lubricant used in ammonia fuel engines after contamination were investigated. The piston ring and cylinder liner were used as friction pairs, with cast iron as the base material and the piston rings coated with a chromium-based ceramic composite. The effect of ammonia was considered by introducing the combustion products of ammonia in an artificial engine oil modification process and employing these lubricants during the tribotests. The results show that the artificially altered oil will not only cause corrosion wear on the surface, but also destroy the anti-wear performance of the lubricant additives, resulting in increased surface wear. The outcomes of the work are anticipated to offer beneficial insights of lubricating oil uses in ammonia engines, particularly in scenarios where ammonia contamination poses a concern.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"582 ","pages":"Article 206347"},"PeriodicalIF":6.1,"publicationDate":"2025-09-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145097287","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 novel data concept for cutting processes through comprehensive experimental setup enabling grey-box models 一个新颖的数据概念，切割过程通过全面的实验设置，使灰盒模型

IF 6.1 1区工程技术

Wear Pub Date : 2025-09-17 DOI: 10.1016/j.wear.2025.206348

Sebastian Schibsdat , Ya-Jing Wu , Martin Keunecke , Sarah Baron , Daniel Höche , Jens-Peter Zemke , Sebastian Götschel , Christoph Herrmann , Jan Hendrik Dege

{"title":"A novel data concept for cutting processes through comprehensive experimental setup enabling grey-box models","authors":"Sebastian Schibsdat , Ya-Jing Wu , Martin Keunecke , Sarah Baron , Daniel Höche , Jens-Peter Zemke , Sebastian Götschel , Christoph Herrmann , Jan Hendrik Dege","doi":"10.1016/j.wear.2025.206348","DOIUrl":"10.1016/j.wear.2025.206348","url":null,"abstract":"<div><div>This paper presents a novel experimental setup for recording the cutting process of external longitudinal turning in situ, capturing data such as cutting force, vibration, acoustic emission (AE), rake face temperature, surface quality, and tool wear. The primary objective of this setup is to generate reliable, repeatable data for developing a comprehensive grey-box model. To achieve this, the measurements were partly automated. Additionally, a complete post-processing pipeline has been introduced to combine all relevant data. To validate the setup, external longitudinal turning experiments were conducted and two of these were analysed for sensitivity to tool wear. This was achieved by analysing the mean and variance of the resultant force F<sub>Z</sub>, resultant vibrations a<sub>Z</sub> and AE signal, in order to demonstrate the impact of tool wear on the measurement. The experiments were also used to train an autoencoder to analyse the process data.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"582 ","pages":"Article 206348"},"PeriodicalIF":6.1,"publicationDate":"2025-09-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145221172","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 resistance enhancement in PTFE composites by the additive of Si3N4 nanoparticles 掺加氮化硅纳米颗粒增强PTFE复合材料耐磨性

IF 6.1 1区工程技术

Wear Pub Date : 2025-09-16 DOI: 10.1016/j.wear.2025.206345

Jinrui Xiao , Zibo Qin , Mingyue Cai , Yanhui Liu , Fulin Zhou

{"title":"Wear resistance enhancement in PTFE composites by the additive of Si3N4 nanoparticles","authors":"Jinrui Xiao , Zibo Qin , Mingyue Cai , Yanhui Liu , Fulin Zhou","doi":"10.1016/j.wear.2025.206345","DOIUrl":"10.1016/j.wear.2025.206345","url":null,"abstract":"<div><div>Polymer friction materials play a vital role in friction pendulum bearings (FPBs) but often experience premature failure due to high wear rates, significantly limiting their service life. This study developed a composite containing nanoscale silicon nitride (Si<sub>3</sub>N<sub>4</sub>) particles and microscale polytetrafluoroethylene (PTFE) powder. The tribological properties of the composite against an AISI 304 stainless steel (AISI 304 SS) counterpart were characterized using a pin-on-disc sliding tribometer. Experimental results revealed that the composite containing 5 % Si<sub>3</sub>N<sub>4</sub> exhibited a lower friction coefficient and an ultra-low wear rate compared to pure PTFE. At a sliding velocity of 0.15 m/s and a normal load of 150 N, the wear rate of the 5 % Si<sub>3</sub>N<sub>4</sub> composite was reduced by 95 % relative to pure PTFE. This enhancement was primarily attributed to the dispersion strengthening and load-bearing effects of Si<sub>3</sub>N<sub>4</sub> nanoparticles, along with the formation of a more stable transfer film at the friction interface. These results underscore the potential of Si<sub>3</sub>N<sub>4</sub> nanoparticles to significantly improve the durability of polymer friction materials in FPBs applications.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"582 ","pages":"Article 206345"},"PeriodicalIF":6.1,"publicationDate":"2025-09-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145097281","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

Characterization of AlCrVY(O)N coating properties and thermo-mechanical load profiles in machining AISI 304 stainless steel using black box modelling approaches 用黑箱建模方法表征AlCrVY(O)N涂层性能和加工AISI 304不锈钢时的热机械负荷分布

IF 6.1 1区工程技术

Wear Pub Date : 2025-09-16 DOI: 10.1016/j.wear.2025.206346

Justin Kopp , Finn Rümenapf , Kai Donnerbauer , Jannis Saelzer , Nelson Filipe Lopes Dias , Erik Krumme , Pascal Volke , Andreas Zabel , Wolfgang Tillmann , Frank Walther

{"title":"Characterization of AlCrVY(O)N coating properties and thermo-mechanical load profiles in machining AISI 304 stainless steel using black box modelling approaches","authors":"Justin Kopp , Finn Rümenapf , Kai Donnerbauer , Jannis Saelzer , Nelson Filipe Lopes Dias , Erik Krumme , Pascal Volke , Andreas Zabel , Wolfgang Tillmann , Frank Walther","doi":"10.1016/j.wear.2025.206346","DOIUrl":"10.1016/j.wear.2025.206346","url":null,"abstract":"<div><div>The thermo-mechanical load collective prevailing during machining significantly influences the wear behavior of coated carbide tools and thereby impacts the productivity and sustainability of many industrial value chains. AlCrVY(O)N coatings show a significant potential for reducing tool wear due to their lower friction and enhanced thermal stability at elevated temperatures compared to conventional coatings. However, due to the complex interplay between friction, temperature, and wear mechanisms, further development of such coating systems remains essential. Additionally, detecting tool wear using black box approaches based on process data provides valuable insights into the wear process and coating behavior during machining operations. In this study, AlCrVY(O)N coatings were benchmarked against TiAlN coatings under varying cutting parameters to evaluate their performance. The variation in cutting parameters allowed for an investigation of coatings under different load levels. Sensor data collected during machining was used to train a long short-term memory autoencoder (LSTM) for analyzing the tool wear. Fundamental investigations revealed that the applied coatings exhibit a homogeneous chemical composition and high hardness values around 35 GPa. However, cutting tests showed that the temperatures on the rake face were not significantly reduced when using AlCrVY(O)N coatings compared to TiAlN coatings. The developed LSTM-autoencoder successfully identified tool wear by analyzing differences in the reconstruction error and latent space representations caused by variations in coating properties.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"582 ","pages":"Article 206346"},"PeriodicalIF":6.1,"publicationDate":"2025-09-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145159069","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

Improvement of strength and wear resistance of stir cast SiCp/Al brake disc through friction stir processing 通过搅拌摩擦工艺提高搅拌铸造SiCp/Al刹车盘的强度和耐磨性

IF 6.1 1区工程技术

Wear Pub Date : 2025-09-16 DOI: 10.1016/j.wear.2025.206343

Kangxi Fu, Shiqi Zhang, Dong Tan, Jianyun Zhang, Hongmei Gao, Baowang Wang, Xiangping Li, Shaohua Xia

{"title":"Improvement of strength and wear resistance of stir cast SiCp/Al brake disc through friction stir processing","authors":"Kangxi Fu, Shiqi Zhang, Dong Tan, Jianyun Zhang, Hongmei Gao, Baowang Wang, Xiangping Li, Shaohua Xia","doi":"10.1016/j.wear.2025.206343","DOIUrl":"10.1016/j.wear.2025.206343","url":null,"abstract":"<div><div>This study presents a hybrid manufacturing approach combining stir casting (SC) with friction stir processing (FSP) to produce high-performance SiCp/Al brake discs for high-speed commuter trains. This work is the first to apply FSP to full-size brake disc components and evaluate their tribological performance under simulated service conditions. The 20 vol% SiC-reinforced A356 alloy, initially fabricated by vacuum-assisted stir casting, exhibited typical casting defects such as porosity and particle agglomeration. These were effectively eliminated by surface FSP, which resulted in homogeneous SiC dispersion, refined microstructure, and improved interfacial bonding. Compared to SC discs, FSP discs demonstrate a significant increase in yield strength (196.8 MPa), ultimate tensile strength (219.6 MPa), and elongation (4.76 %), along with a 33 % reduction in wear loss. Moreover, the average friction coefficient of the FSP disc remains more stable across a range of braking speeds and pressures. These findings validate the feasibility of the proposed SC + FSP process as a scalable, lightweight, and durable solution for next-generation rail braking systems.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"582 ","pages":"Article 206343"},"PeriodicalIF":6.1,"publicationDate":"2025-09-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145097282","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

Correlation between shaft voltage characteristics, electrical discharge behavior and surface damage of motor bearing in EV bench tests 电动汽车台架试验中轴电压特性、放电行为与电机轴承表面损伤的相关性

IF 6.1 1区工程技术

Wear Pub Date : 2025-09-16 DOI: 10.1016/j.wear.2025.206344

Shutian Liu , Juncheng Lv , Shaoli Jiang , Long Kuang , Leidi Zhao , Chuanbo Liu

{"title":"Correlation between shaft voltage characteristics, electrical discharge behavior and surface damage of motor bearing in EV bench tests","authors":"Shutian Liu , Juncheng Lv , Shaoli Jiang , Long Kuang , Leidi Zhao , Chuanbo Liu","doi":"10.1016/j.wear.2025.206344","DOIUrl":"10.1016/j.wear.2025.206344","url":null,"abstract":"<div><div>The electric discharge damage had emerged as the primary failure mode of bearing in electrical vehicle's (EV) driving motor, with the fundamental cause being the shaft voltage produced during motor operation. However, the shaft voltage would exhibit different characteristics depending on the bearing's operating state. Here, this paper examined a dedicated hybrid transmission (DHT) detached from a real EV to investigate the connection between shaft voltage characteristics, electrical discharge behaviors and electrical damage within the driving motor bearing. The results demonstrated that different patterns of shaft voltage were characterized, which was associated with lubricating status inside the bearing. The establishment of lubricating oil film led the bearing to undergo resistive, mixed and capacitive voltage states in sequence, with the electrical discharge behavior in the capacitive state resulting in electrical damage. The decrease in viscosity of lubricating oil caused bearing damage to change from fluting damage to frosting damage, resulting from a shift in electrical discharge mode to high discharge frequency and low voltage value. Notably, the presence of conductive ring eliminated electrical discharge behavior within the bearing by creating a low-resistance charge flow pathway, therefore preventing the bearing electrical damage. The knowledge gained herein provided a theoretical foundation for the structural design and lubricant selection of EV's DHT system.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"582 ","pages":"Article 206344"},"PeriodicalIF":6.1,"publicationDate":"2025-09-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145097285","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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