Wear最新文献

{"title":"Sensorless prediction of notch wear in Ti–6Al–4V ball-end milling based on cutting edge geometry and thermo-mechanical coupling","authors":"Peishuo Zhang ,&nbsp;Hongjun Wang ,&nbsp;Yubin Yue","doi":"10.1016/j.wear.2025.206485","DOIUrl":"10.1016/j.wear.2025.206485","url":null,"abstract":"<div><div>The poor machinability of Ti–6Al–4V poses challenges to notch wear prediction during ball-end milling, including complex mechanism modeling and heavy reliance on sensors. Existing data-driven approaches often suffer from limited interpretability and high monitoring costs. To address these issues, this study proposes a hybrid mechanism and data-driven method for predicting notch wear. A geometric model of the ball-end cutting edge was constructed, and the cutting edge micro-element force feature (CFF) and the effective cutting edge length feature (ECEF) were derived using polar coordinate projection and interpolation algorithms. These two features were identified as core drivers of notch wear, with clear mechanistic links. The derived features were then used to train predictive models based on ensemble learning, kernel methods, and artificial neural networks. All predictive models achieved a coefficient of determination (<span><math><msup><mrow><mi>R</mi></mrow><mrow><mn>2</mn></mrow></msup></math></span>) consistently exceeding 0.97, demonstrating robust generalization across multiple modeling paradigms, the Random Forest (RF) model stood out with optimal performance (<span><math><msup><mrow><mi>R</mi></mrow><mrow><mn>2</mn></mrow></msup></math></span> = 0.998). Further integrating the random forest algorithm with recursive feature elimination, feature optimization achieved a 50.2% improvement in computational efficiency while retaining 99.84% of the original model’s predictive capability. Finally, based on wear mechanism decoupling and ablation experiments, a cross-scale framework combining geometry, mechanics, and data was established. The results indicated that force-induced thermal cyclic load plays a dominant role in the notch wear process, while abrasive wear acts as an auxiliary factor, and the contribution of the former is 3.6 times that of the latter. This framework offers a new paradigm for wear prediction that is both mechanistically interpretable and practically applicable, with significant potential for high-end manufacturing sectors such as aerospace.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"587 ","pages":"Article 206485"},"PeriodicalIF":6.1,"publicationDate":"2026-02-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145842287","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Microstructure-dependent tribocorrosion mechanisms of low-carbon martensitic stainless steel","authors":"Liangying Yin ,&nbsp;Tingyu Zhang ,&nbsp;Feiteng Xv ,&nbsp;Yang Yu ,&nbsp;Shenghua Zhang ,&nbsp;Yanli Wang","doi":"10.1016/j.wear.2025.206480","DOIUrl":"10.1016/j.wear.2025.206480","url":null,"abstract":"<div><div>The selection of materials for hydraulic turbine blades, which suffer from premature failure due to the synergistic interplay of mechanical wear and electrochemical corrosion in sediment-laden water, remains a significant challenge. This study focuses on 11Cr4NiMo low-carbon martensitic stainless steel and aims to elucidate the role of heat-treatment-induced microstructure, particularly reversed austenite, in governing the tribocorrosion mechanisms of low-carbon martensitic stainless steels under a custom triboelectrochemical setup with a silicon nitride (Si₃N₄) counterpart in a 3.5 wt% NaCl solution. The results demonstrate that the microstructure, containing 6.54 % reverted austenite, provides optimal performance, reducing wear volume and corrosion current density by approximately 31 % compared to tempered martensite. This superior resistance is attributed to a novel dual mechanism: reversed austenite facilitates the rapid regeneration of a continuous, Cr-rich passive film, maintaining a “repassivation rate &gt; wear rate” balance to impede Cl⁻ attack; and (2) It coordinates plastic deformation to alleviate stress concentration, maintaining passivation film integrity, ultimately resulting in mild abrasive wear. In contrast, martensitic structures, due to strain localization and slow regeneration of passivation films post-rupture, are prone to delamination, leading to layered-oxidative composite wear. This work establishes that microstructural engineering for synergistic passivation and deformation capacity, rather than pursuing high hardness alone, is the key to enhancing tribocorrosion resistance in demanding aqueous environments.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"587 ","pages":"Article 206480"},"PeriodicalIF":6.1,"publicationDate":"2026-02-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145808361","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Enhanced ultrasonic cavitation resistance of photopolymerizable acrylate resins through increased proportion of polyurethane acrylate in the blend","authors":"Mohammed Bendimerad ,&nbsp;Sylvain Giljean ,&nbsp;Marie-José Pac ,&nbsp;Cyril Marsiquet ,&nbsp;Gautier Schrodj ,&nbsp;Loïc Vidal ,&nbsp;Dominique Zwingelstein ,&nbsp;Jacques Lalevée ,&nbsp;Laurent Vonna","doi":"10.1016/j.wear.2025.206492","DOIUrl":"10.1016/j.wear.2025.206492","url":null,"abstract":"<div><div>This study investigates the influence of polyurethane acrylate (PUA) content on the cavitation resistance of UV-cured epoxy acrylate (EPA)-PUA polymer networks. Four blends containing 0, 15, 30, and 45 wt% PUA were prepared and characterized to understand the relationship between mechanical properties and cavitation resistance. Thermogravimetric analysis (TGA), dynamic mechanical analysis (DMA), and nanoindentation were used to confirm that increasing PUA content in the epoxy matrix enhanced material deformability. Cavitation tests performed according to ASTM <span><span>G32</span><svg><path></path></svg></span> revealed that increasing PUA content improved cavitation resistance, as evidenced by longer incubation periods before surface damage and fewer pits and cracks. Notably, nanoindentation conducted on cavitated surfaces showed a hardening effect during the incubation phase, particularly in the 45 % PUA blend, which was attributed to plastic deformation induced by cavitation. These findings highlight the role of material deformability in absorbing energy from collapsing bubble, making UV-cured EPA-PUA blends promising candidates for applications requiring polymeric coatings resistant to cavitation erosion.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"587 ","pages":"Article 206492"},"PeriodicalIF":6.1,"publicationDate":"2026-02-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145842284","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"TEA-net: A multimodal deep learning framework for tool wear classification in biomedical machining","authors":"Phanindra Addepalli ,&nbsp;Lavanya Addepalli ,&nbsp;Vidya Sagar S.D ,&nbsp;Worapong Sawangsri ,&nbsp;Saiful Anwar Che Ghani ,&nbsp;Jaime Lloret","doi":"10.1016/j.wear.2025.206484","DOIUrl":"10.1016/j.wear.2025.206484","url":null,"abstract":"<div><div>In biomedical machining, proper tool wear monitoring is required as surface integrity and dimensional accuracy have a direct impact on the way of the implants to work and the safety of patients. Traditional monitoring methods that are based on single-modality data do not usually identify the presence of the subtle wear development in a complex cutting environment. In this research, the authors introduce a deep-learning methodology based on multimodality as Thermo-Edge Attention Network (TEA-Net) consisting of the fusion of thermal images, line maps, and statistical wear detection to obtain accurate tool-wear separation. The model uses multi-head attention to focus on local wear areas and combines similarities of complementary cues of various data modalities using a common fusion point. Experimental analyses on Austenitic Stainless Steel 316L (SS316L) and Zirconia (ZrO₂) machining tools show that TEA-Net can be evaluated at 82.5 and 88.4 classification accuracy on direct comparison with conventional machine-learning models, and with standard convolutional networks, respectively, with 15-percent higher accuracy. This framework also has a high capability of discrimination whose Area Under the Receiver Operating Characteristic Curve (AUC) exceed 0.97 therefore showing the reliability in both ductile and brittle materials. The findings show that multimodal integration has a significant positive effect on interpretability and prediction stability despite the scanty data quantity. TEA-Net is therefore an effective and timely solution to intelligent tool-wear saving and predictive maintenance in biomedical manufacturing sector.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"587 ","pages":"Article 206484"},"PeriodicalIF":6.1,"publicationDate":"2026-02-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145808362","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"High-temperature wear behavior and mechanical properties of laser-clad AlCoCrFeNi HEA coatings on H13 steel co-strengthened by B4C/Y2O3","authors":"Yiwen Zhou ,&nbsp;Jiang Bi ,&nbsp;Dehua Liu ,&nbsp;Zhuoyun Yang ,&nbsp;Guojiang Dong ,&nbsp;Yuhang Li ,&nbsp;Xiangdong Jia","doi":"10.1016/j.wear.2025.206481","DOIUrl":"10.1016/j.wear.2025.206481","url":null,"abstract":"<div><div>H13 hot-work die steel is susceptible to oxidative spalling during high-temperature service, while conventional treatments struggle to balance strength and toughness. In this study, an AlCoCrFeNi high-entropy alloy coating was fabricated via laser cladding, with an innovative dual-phase strengthening system incorporating. The composite coating exhibits superior performance: average microhardness reaches 596.9 (±8.4) HV_0.2 (2.8 × higher than the substrate); at 600 °C, the wear rate ((3.86 ± 0.15) × 10⁻⁵ mm³ N⁻¹ m⁻¹) decreases by 70.2 % compared to H13 steel; corrosion current density (3.34 × 10⁻⁷ A/cm²) is 45 % lower than the base coating. The strengthening mechanisms originate from B₄C-derived dispersion hardening and Y₂O₃-enhanced oxidation resistance. This work proposes a multi-scale synergistic strategy for prolonging mold service life and establishes a theoretical foundation for coatings under extreme conditions.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"587 ","pages":"Article 206481"},"PeriodicalIF":6.1,"publicationDate":"2026-02-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145842283","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Influence of WCp addition (1:1 ratio) on the dry wear behavior of in-situ synthesized B4C-Ti DEDed hardfacing against Si3N4 counterbody","authors":"Huabing Gao ,&nbsp;Wenjun Zhu ,&nbsp;Chunhuan Guo ,&nbsp;Wei Chen ,&nbsp;Fengchun Jiang","doi":"10.1016/j.wear.2025.206479","DOIUrl":"10.1016/j.wear.2025.206479","url":null,"abstract":"<div><div>A dual ceramics (32.5 wt%B₄C-32.5 wt%WC)-T55 coating was fabricated via laser direction energy deposition on TC4, achieving α/β-Ti matrix with dispersed B₄C, WC, W₂C, TiB, and TiC phases, yielding ultrahigh hardness (1956.3 HV_0.2 vs. 412.6 HV_0.2 in 32.5 wt%B₄C-T55). Both coatings exhibited abrasive-surface fatigue-tribochemical hybrid wear with coefficient of friction 0.46–0.60. The dual-ceramic coating demonstrated lower wear rate (∼10⁻¹¹-10⁻¹² mm³/(N·m)) and counterbody damage (lg(W_DED) + lg(W_Ball) = -14.51) than single-ceramic (−10.39), attributed to WC-induced phase optimization. Wear mechanisms transitioned from coating spallation (B₄C-T55/Si₃N₄) to counterbody abrasion (B₄C-WC-T55/Si₃N₄). Results confirm dual-ceramic design enhances wear resistance via microstructure tailoring.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"587 ","pages":"Article 206479"},"PeriodicalIF":6.1,"publicationDate":"2026-02-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145842282","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Mechanical pitting mechanism of hydraulic cavitation erosion in a venturi: A coupled experimental-numerical investigation","authors":"Liang Fang ,&nbsp;Xiaogang Xu ,&nbsp;Anjun Li ,&nbsp;Zhenbo Wang ,&nbsp;Qiang Li","doi":"10.1016/j.wear.2025.206488","DOIUrl":"10.1016/j.wear.2025.206488","url":null,"abstract":"<div><div>Hydraulic cavitation erosion is a prevalent form of wear in fluid engineering, which primarily results from the mechanical effects of cavity collapse. However, a precise understanding of the dynamic pitting process has been lacking. Coupled synchronized cavitation-erosion experiments with high-fidelity compressible cavitation simulations in a Venturi, this study investigates the mechanical pitting mechanism. The results definitively demonstrate that pitting originates solely from detached cavity collapse, and is irrelevant to attached cavity development and movement. The collapse process is revealed to be progressive, evolving through three successive physical stages: the initial isolated cavity collapse stage, the core large cavity collapse stage where extreme pressure arises from the spatiotemporal superposition of collapse-induced shocks, and the subsequent rebound cavity collapse stage characterized by multiple pressure peaks. Specifically, quantitative analysis attributes differential pitting severity to these three stages: the large cavity collapse stage is the core pitting source, the rebound cavity collapse stage is a significant contributor, while the isolated cavity collapse stage presents only minor supplementary pitting. Moreover, the study clarifies that the potential pitting risk from cavity shedding is not direct but attributable to the collapse of shedding-induced isolated cavities; however, the actual damage is negligible due to low pressure amplitude and distribution density. Additionally, pitting severity worsens nonlinearly with cavitation aggravation, underscoring that preventing severe cavitation is paramount for mitigating damage.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"587 ","pages":"Article 206488"},"PeriodicalIF":6.1,"publicationDate":"2026-02-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145808363","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Bionic synergistic enhancement of erosive wear resistance with mechanical properties","authors":"Haiyue Yu ,&nbsp;Kaixin Sun ,&nbsp;Jianfeng Song ,&nbsp;Junqiu Zhang ,&nbsp;Zhiwu Han","doi":"10.1016/j.wear.2025.206490","DOIUrl":"10.1016/j.wear.2025.206490","url":null,"abstract":"<div><div>Erosion wear impairs the mechanical strength of flow components, severely restricting machinery, energy, and related industrial development. Bionics offers new solutions to the problem of wear. Drawing inspiration from <em>Mammillaria hahniana</em> cactus petals, this study proposes a new bionic model: a symmetrical biconical structure. Multiple bionic petal models were fabricated using fused deposition modelling (FDM) technology. Gas-solid erosion tests were conducted using gravel particles of different sizes at various angles of erosion. Tests have shown that the biconical structure exhibits superior erosion resistance at high angles (≥60°), achieving a maximum erosion wear rate reduction of 45.9 % compared to other samples. Computational fluid dynamics (CFD) analysis was used to study the flow patterns and the way the particles moved. The biconical structure's unique streamlined shape prevents the boundary layer from separating, guiding the particles to slip directionally along the cone surface. This reduces the normal impact and sliding friction between the particles and the sample surface. Meanwhile, tensile and compression tests showed that the front and back ends of the biconical structure could support each other, enabling the structure to resist plastic deformation during erosion. Additionally, the overall structural strength of the biconical samples increased, particularly with regard to compressive loads. This study overcomes the shortcomings of conventional erosion-resistant structures, which are limited to a single function. The synergistic effect of erosion and deformation resistance is achieved through ‘flow field regulation - particle motion guidance - stress dispersion’, which enriches the theoretical system in the field of bionic wear resistance.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"587 ","pages":"Article 206490"},"PeriodicalIF":6.1,"publicationDate":"2026-02-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145842279","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Tribocorrosion of additively manufactured and wrought Ti6Al4V in a saline environment","authors":"Saman Nikpour ,&nbsp;René Daniel Pütz ,&nbsp;Ayush Khurana ,&nbsp;Sina Matin ,&nbsp;Anna Neus Igual Munoz ,&nbsp;Stefano Mischler ,&nbsp;Yolanda S. Hedberg","doi":"10.1016/j.wear.2025.206440","DOIUrl":"10.1016/j.wear.2025.206440","url":null,"abstract":"<div><div>Laser powder bed fusion (LPBF) and wrought Ti6Al4V were compared from a tribocorrosion perspective in 0.9 % NaCl, distinguishing between mechanical and chemical (oxidative) wear through potential-controlled measurements. The aim was to elucidate the manufacturing- and potential-dependent tribocorrosion mechanisms in a saline environment. While both manufacturing methods resulted in excellent corrosion resistance, the LPBF titanium alloy exhibited a finer, distinct microstructure, higher microhardness, and greater tribocorrosion resistance under applied cathodic and anodic potentials in saline than the wrought alloy. More available slip systems, lower grain boundary density, easier crack formation and propagation at the oxide-subsurface interface, and more oxidized third-body particles were responsible for the higher mechanical and chemical volume loss of wrought samples. These features were related to the microstructural differences; the wrought titanium alloy consisted of a β phase, along with α phase, and a lower grain boundary density, whereas the LPBF alloy possessed α/α′ phases and a higher grain boundary density.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"586 ","pages":"Article 206440"},"PeriodicalIF":6.1,"publicationDate":"2026-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145658704","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Material removal mechanism and micro evolution of ultrasonic elliptical vibration cutting of tungsten alloys based on polycrystalline diamond and single crystal diamond tools","authors":"Jinbo Liu ,&nbsp;Zhigang Dong ,&nbsp;Yan Bao ,&nbsp;Renke Kang ,&nbsp;Yintian Xing ,&nbsp;Sen Yin","doi":"10.1016/j.wear.2025.206468","DOIUrl":"10.1016/j.wear.2025.206468","url":null,"abstract":"<div><div>Tungsten alloys have two-phase structure, high heterogeneity and hard and brittle characteristics, and the combination of single crystal diamond (SCD) tool and ultrasonic elliptical vibration cutting (UEVC) has become critical for UPM of tungsten alloys. However, SCD tool costs and severe UEVC speed limitations constrain mass production. Therefore, UEVC with polycrystalline diamond (PCD) tools was proposed for efficient precision machining. UEVC experiments establish distinct wear mechanisms: PCD tools exhibit gradual wear through grain detachment, yielding a characteristic “honeycomb” morphology, whereas SCD tools undergo abrupt failure via edge chipping. Critically, PCD tools demonstrate superior cutting performance stability at elevated cutting speeds. Furthermore, while the surface roughness values are comparable (PCD: Sa≈65 nm, SCD: Sa≈26 nm), the evolution mechanism of surface morphology and subsurface microstructure differ significantly: PCD tools generate a 1.5 μm thick subsurface layer characterized by fine grains and extensive dislocation entanglements, forming a fine-grain reinforced zone. Conversely, SCD tools generate a fragmented-grain zone of similar thickness but containing localized banded dislocations. The refined microstructure induced by PCD tools is potentially more advantageous for enhancing the irradiation resistance of tungsten alloys. This work validates the feasibility of substituting PCD for SCD tools in UEVC of tungsten alloys, which approach offers a promising route towards the high-efficiency, low-cost and UPM for tungsten alloy components, significantly advancing the potential for industrial adoption of UEVC technology.</div></div>","PeriodicalId":23970,"journal":{"name":"Wear","volume":"586 ","pages":"Article 206468"},"PeriodicalIF":6.1,"publicationDate":"2026-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145798148","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}