Wear and corrosion resistance of pack chromised carbon steel

Pack chromising treatment is an environmentally friendly alternative to hard chromium to form wear and corrosion resistant surface layers. In this work, samples of AISI 1060 steel were pack chromised for 6 and 9 h at 1000 and 1050 degrees C using different activator concentrations. Wear tests were performed in dry conditions and corrosion tests in natural sea water for the pack chromised samples and hard chromium. Pack chromising yielded the formation of layers with high chromium concentrations, high hardness and wear resistance. Increasing activator concentration causes no significant change on the morphology and thickness of the layers. The layers produced at 1050 degrees C yielded only a (Cr,Fe)(2)N1-x phase, and those obtained at 1000 degrees C are composed of a carbide mixture with (Cr,Fe)(2)N1-x. The sample treated at 1050 degrees C for 9 h resulted in an optimum condition by means of better wear resistance and corrosion properties, which were close to that exhibited by the hard chrome, indicating that pack chromising is a promising alternative.

Wear of high aluminium zinc-based alloys in plain bearing applications

Two zinc-based alloys of high aluminium content, Super Cosmal alloy containing 60% Al, 6% Si, 1% Cu, 0.3% Mn and HAZCA alloy containing 60% Al, 8% Si, 2% Cu, 0.06% Mg were produced by sand casting. Foundry characteristics in particular, fluidity, mode of solidification and feeding ability were examined. Metallographic analysis of structures was carried out using optical and scanning electron microscopy and their mechanical properties were determined using standard techniques. Dry wear characteristics were determined using a pin-on-disc test, and boundary-lubricated wear was studied using full bearing tests. Results from casting experiments were evaluated and compared with the behaviour of a standard ZA-27 alloy and those from tribological tests with both ZA-27 alloy and a leaded tin-bronze (SAE660) under the same testing conditions. The presence of silicon was beneficial, reducing the temperature range of solidification, improving feeding efficiency and reducing gravity segregation of phases. Use of chills and melt degassing was found necessary to achieve soundness and enhanced mechanical properties. Dry wear tests were performed against a steel counterface for sliding speeds of 0.25, 0.5, 1.0 and 2 m/s and for a range of loads up to 15 kgf. The high aluminium alloys showed wear rates as low as those of ZA-27 at speeds of 0.25 and 0.5 m/s for the whole range of applied loads. ZA-27 performed better at higher speeds. The build up of a surface film on the wearing surface of the test pins was found to be responsible for the mild type of wear of the zinc based alloys. The constitution of the surface film was determined as a complex mixture of aluminium, zinc and iron oxides and metallic elements derived from both sliding materials. For full bearing tests, bushes were machined from sand cast bars and were tested against a steel shaft in the presence of a light spindle oil as the lubricant. Results showed that all zinc based alloys run-in more rapidly than bronze, and that wear in Super Cosmal and HAZCA alloys after prolonged running were similar to those in ZA-27 bearings and significantly smaller than those of the bronze.

A rolling-gliding wear simulator for the investigation of tribological material pairings for application in total knee arthroplasty

Background: Material wear testing is an important technique in the development and evaluation of materials for use in implant for total knee arthroplasty. Since a knee joint induces a complex rolling-gliding movement, standardised material wear testing devices such as Pin-on-Disc or Ring-on-Disc testers are suitable to only a limited extent because they generate pure gliding motion only.Methods: A rolling-gliding wear simulator was thus designed, constructed and implemented, which simulates and reproduces the rolling-gliding movement and loading of the knee joint on specimens of simplified geometry. The technical concept was to run a base-plate, representing the tibia plateau, against a pivoted cylindrical counter-body, representing one femur condyle under an axial load. A rolling movement occurs as a result of the friction and pure gliding is induced by limiting the rotation of the cylindrical counter-body. The set up also enables simplified specimens handling and removal for gravimetrical wear measurements. Long-term wear tests and gravimetrical wear measurements were carried out on the well known material pairings: cobalt chrome-polyethylene, ceramic-polyethylene and ceramic-ceramic, over three million motion cycles to allow material comparisons to be made.Results: The observed differences in wear rates between cobalt-chrome on polyethylene and ceramic on polyethylene pairings were similar to the differences of published data for existing material-pairings. Test results on ceramic-ceramic pairings of different frontal-plane geometry and surface roughness displayed low wear rates and no fracture failures.Conclusions: The presented set up is able to simulate the rolling-gliding movement of the knee joint, is easy to use, and requires a minimum of user intervention or monitoring. It is suitable for long-term testing, and therefore a useful tool for the investigation of new and promising materials which are of interest for application in knee joint replacement implants. © 2010 Richter et al; licensee BioMed Central Ltd.

Particle size effect on abrasion resistance of mottled cast iron with different retained austenite contents

Effects of particle abrasive sizes on wear resistance of mottled cast iron with different retained austenite contents were studied. Abrasive wear tests using a pin test on alumina paper were carried out, using abrasive sizes between 16 mu m and 192 mu m. Retained austenite content of the matrix was determined by X-ray diffraction. The wear surface of samples and the alumina paper were examined by scanning electron microscopy for identifying the wear micromechanism. The results show that at lower abrasive sizes the mass loss was similar for the iron with different austenite contents. However, at higher abrasive sizes the samples with higher retained austenite content presented higher abrasion resistance. For lower abrasive sizes tested, samples with higher and lower retained austenite content both presented microcutting. On the other hand, the main wear micromechanism for the samples with higher retained austenite content and higher abrasive sizes was microploughing. The samples with lower retained austenite content presented microcutting and wedge formation at higher abrasive sizes. Higher abrasive size induced more microcutting in samples with lower retained austenite. The iron with lower retained austenite content presented wider grooves for the different abrasive sizes measured. SEM on the abrasive paper used on samples with higher retained austenite showed continuous and discontinuous microchips and the samples with lower retained austenite showed discontinuous microchips at 66 and 141 mu m. This research demonstrates the relation between abrasive size, wear resistance, groove width and wear micromechanism for mottled cast iron with different retained austenite contents. (C) 2009 Elsevier B.V. All rights reserved.

EROSION-CORROSION SYNERGISM OF AN AISI 410 MARTENSITIC STAINLESS STEEL

In this work, the behavior of an AISI 410 martensitic stainless steel under corrosion-erosion conditions is evaluated. Quenched and tempered samples were used for the wear test, using a low velocity jet-like device connected to a potentiostat. Potentiodynamic polarization curves were obtained with the electrolyte in static state, with flow conditions and under corrosion-erosion, adding quartz particles to the electrolyte. In addition, mass loss measurements under erosion and corrosion-erosion conditions were carried out. The topography of the surfaces was examined after the wear tests, using optical and scanning electron microscopy. This information, together with the results of mass losses and the electrochemical tests were used to establish the degradation mechanisms of the stainless steels under different testing conditions. The results showed that synergism is a significant part of the degradation process of this steel (66.5%) and that the mass removal process of steel was controlled by corrosion assisted by erosion.

Efeito da distribuição do tamanho das partículas abrasivas sobre as taxas e modos de desgaste para o ensaio de microabrasão

Neste trabalho, as distribuições de tamanhos das partículas de dois pós de Carboneto de Silício foram previamente avaliadas e os resultados indicaram uma distribuição Gaussiana para ambos, com tamanhos médios na ordem de 2 μm para o primeiro e 6 μm para o segundo. Posteriormente foram misturados os dois pós originais com diferentes frações mássicas, proporcionando uma nova série de pós de Carboneto de Silício (SiC), que seriam usados nos ensaios de microabrasão com configuração de esfera fixa. A caracterização desta nova série de pós mostrou larguras maiores para aqueles com alto porcentagem do abrasivo pequeno (2,11 μm), conservando a aparência Gaussiana dos originais. Por outro lado para os pós com uma quantidade maior do abrasivo grande (6,57 μm), foram obtidas curvas com uma leve tendência bimodal, mas também apresentaram maiores larguras. As provas foram conduzidas sobre aço carbono AISI 1020, para duas condições diferentes de carga normal e os resultados foram analisados em termos da taxa de desgaste, bem como dos micromecanismos de desgaste (abrasão por rolamento ou abrasão por riscamento). Os resultados indicaram que a fração mássica dos pós originais tem um efeito significante sobre os micromecanismos de desgaste observados e que as taxas de desgaste não segue uma relação linear com a fração mássica do pó com maior tamanho da partícula abrasiva. Além disso, a análise da severidade de contato determinou que esta diminui durante os ensaios conduzidos com carga constante. Este fenômeno está associado ao aumento da área da cratera de desgaste que produz uma diminuição da pressão de contato. Assim, um incremento para o número de eventos associado ao rolamento de partículas seria esperado, favorecendo a observação de múltiplas indentações ao longo dos sulcos formados previamente. Isto foi confirmado por meio de micrografias eletrônicas de varredura das amostras após ensaios de microabrasão.

O efeito da carga normal no comportamento tribológico de uma superliga de cobalto no ensaio pino-disco

O coeficiente de atrito e o desgaste nas superligas de cobalto são fortemente influenciados pela transformação de fase de CFC para HC que ocorre devido ao trabalho mecânico, conforme já reportado pela literatura. Após essa transformação, os valores de μ costumam se situar na faixa de 0,15 a 0,20. Este trabalho apresenta o comportamento do atrito e do desgaste em um ensaio de deslizamento sem lubrificação utilizando uma configuração pino-disco, sendo o pino feito de aço inoxidável supermartensítico e o disco de uma superliga de cobalto fundida, num tribômetro PLINT TE67. Os ensaios foram conduzidos em temperatura ambiente, com uma velocidade e variando-se a carga normal de deslizamento entre 5 e 500 N. O coeficiente de atrito e o potencial elétrico de contato foram monitorados durante os ensaios. Utilizou-se a MEV e a perfilometria 3D para caracterizar o volume e o mecanismo de desgaste. Para as cargas de 350, 400 e 450 N, após atingir condições de regime estacionário, um valor de coeficiente de atrito não usual (μ<0,01) e uma baixa taxa de desgaste foram encontradas. A análise da difração de raios-X revelou a presença de transformação de fases.

Mechanical and tribological characterization of TiB2 thin films

Titanium Diboride (TiB2) presents high mechanical and physical properties. Some wear studies were also carried out in order to evaluate its tribological properties. One of the most popular wear tests for thin films is the ball-cratering configuration. This work was focused on the study of the tribological properties of TiB2 thin films using micro-abrasion tests and following the BS EN 1071-6: 2007 standard. Due to high hardness usually patented by these films, diamond was selected as abrasive on micro-abrasion tests. Micro-abrasion wear tests were performed under five different durations, using the same normal load, speed rotation and ball. Films were deposited by unbalanced magnetron sputtering Physical Vapour Deposition (PVD) technique using TiB2 targets. TiB2 films were characterized using different methods as Scanning Electron Microscopy (SEM), Energy Dispersive X-ray Spectroscopy (EDS), Atomic Force Microscopy (AFM), X-ray Diffraction (XRD), Electron Probe Micro-Analyser (EPMA), Ultra Micro Hardness and Scratch-test Analysis, allowing to confirm that TiB2 presents adequate mechanical and physical properties. Ratio between hardness (coating and abrasive particles), wear resistance and wear coefficient were studied, showing that TiB2 films shows excellent properties for tribological applications.

Friction surfacing of aluminium alloys

Dissertação para a obtenção do grau de Mestre em Engenharia Mecânica

Desenvolvimento e caracterização tribológica de hidrogéis poliméricos de PVA reforçados com fosfato tricálcico para aplicação como cartilagem articular para implantes articulares

Dissertação de mestrado integrado em Engenharia de Materiais

Processamento e caracterização mecânica e metalográfica de compósitos adiamantados à base de cobre-níquel obtidos por hot pressing

Dissertação de mestrado em Engenharia de Materiais

Comportamento tribológico de biocompósitos de matriz de titânio

Dissertação de mestrado integrado em Engenharia de Materiais

Coatings on Composites

Polymer based composite materials coated with thin layers of wear resistant materials have been proposed as replacements for steel components for certain applications with the advantage of reduced mass. Magnetron sputtered coatings can be successfully deposited on composite materials. Nevertheless there are number of issues which must be addressed such as limited temperature, which the composite can withstand because of the epoxy binder which is used, the adhesion of the coating to the composite and the limited mechanical support, the hard coating can obtain from the relatively soft epoxy. We have investigated the deposition of chromium nitride, titanium carbide and titanium doped DLC coatings on carbon fibre reinforced composites and various polymers. The adhesion of the coatings has been studied by the pull-off adhesion tester. In general, the failure mechanism has been noticed to be due to the cohesive failure for a wide range of conditions. The wear behavior of the coatings has been noticed to be complicated. Wear tests on coated composites have shown that where the reinforcing fibres are near the surface, the composite samples do not perform well due to breakage of the fibres from the polymer matrix. A fibre free surface has been noticed to improve the wear resistance.

Microstructural, Mechanical and Tribological Characterisation of CVD and PVD Coatings for Metal Cutting Applications

The present thesis focuses on characterisation of microstructure and the resulting mechanical and tribological properties of CVD and PVD coatings used in metal cutting applications. These thin and hard coatings are designed to improve the tribological performance of cutting tools which in metal cutting operations may result in improved cutting performance, lower energy consumption, lower production costs and lower impact on the environment.  In order to increase the understanding of the tribological behaviour of the coating systems a number of friction and wear tests have been performed and evaluated by post-test microscopy and surface analysis. Much of the work has focused on coating cohesive and adhesive strength, surface fatigue resistance, abrasive wear resistance and friction and wear behaviour under sliding contact and metal cutting conditions. The results show that the CVD deposition of accurate crystallographic phases, e.g. α-Al2O3 rather than κ-Al2O3, textures and multilayer structures can increase the wear resistance of Al2O3. However, the characteristics of the interfaces, e.g. topography as well as interfacial porosity, have a strong impact on coating adhesion and consequently on the resulting properties.  Through the deposition of well designed bonding and template layer structures the above problems may be eliminated. Also, the presence of macro-particles in PVD coatings may have a significant impact on the interfacial adhesive strength, increasing the tendency to coating spalling and lowering the surface fatigue resistance, as well as increasing the friction in sliding contacts. Finally, the CVD-Al2O3 coating topography influences the contact conditions in sliding as well as in metal cutting. In summary, the work illuminates the importance of understanding the relationships between deposition process parameters, composition and microstructure, resulting properties and tribological performance of CVD and PVD coatings and how this knowledge can be used to develop the coating materials of tomorrow.

Desenvolvimento e caracterização de nanocompósito de resina epóxi com nanopartículas de sílica para revestimento de dutos para transporte de petróleo

The use of polymer based coatings is a promising approach to reduce the corrosion problem in carbon steel pipes used for the transport of oil and gas in the oil industry. However, conventional polymer coatings offer limited properties, which often cannot meet design requirements for this type of application, particularly in regard to use temperature and wear resistance. Polymer nanocomposites are known to exhibit superior properties and, therefore, offer great potential for this type of application. Nevertheless, the degree of enhancement of a particular property is greatly dependent upon the matrix/nanoparticle material system used, the matrix/nanoparticle interfacial bonding and also the state of dispersion of the nanoparticle in the polymer matrix. The objective of the present research is to develop and characterize polymer based nanocomposites to be used as coatings in metallic pipelines for the transportation of oil and natural gas. Epoxy/SiO2 nanocomposites with nanoparticle contents of 2, 4, and 8 wt % were processed using a high-energy mill. Modifications of the SiO2 nanoparticles‟ surfaces with two different silane agents were carried out and their effect on the material properties were investigated. The state of dispersion of the materials processed was studied using Scanning and Transmission Electron Microscopy (SEM and TEM) micrographs. Thermogravimetric analysis (TG) were also conducted to determine the thermal stability of the nanocomposites. In addition, the processed nanocomposites were characterized by dynamic mechanical analysis (DMA) to investigate the effect of nanoparticles content and silane treatment on the viscoelastic properties and on the glass transition temperature. Finally, wear tests of the pin-on-disc type were carried out to determine the effects of the nanoparticles and the silane treatments studied. According to the results, the addition of SiO2 nanoparticles treated with silane increased the thermal stability, the storage modulus and Tg of the epoxy resin and decreased wear rate. This confirms that the interaction between the nanoparticles and the polymer chains plays a critical role on the properties of the nanocomposites