Tribological Characterization of Ni-Free Duplex Stainless Steel Alloys Using the Taguchi Methodology
Abstract
:1. Introduction
2. Design of Experiments (DOE)
3. Experimental Procedures
3.1. Materials
3.2. Roughness and Hardness Measurements
3.3. Wear Test Procedure and the Taguchi Experimental Matrix
4. Results and Data Analysis
4.1. Hardness and Roughness Results
4.2. Effect of the Three Factors on Specific Wear Rate of the Developed DSS Samples
4.3. Effect of the Three Factors on Coefficient of Friction of the Developed DSS Samples
4.4. Evaluation of Involved Wear Mechanisms
4.5. Regression Modeling
4.5.1. Regression Model for Specific Wear Rate (SWR)
4.5.2. Regression Model for COF
4.6. Model Confirmation
5. Material Modification Effects
6. Conclusions
- The Taguchi technique was successfully implemented for designing the experiment, and the statistical results have offered a good reason to clarify and understand the effect of the operating factors on the tribological behavior of the DSS alloys.
- It was observed that all the three factors (composition, sliding speed and applied load) have a significant effect on SWR. However, it was observed that even though all three factors significantly affect the COF, the sliding velocity was found to be the most contributing factor to the COF behavior.
- The individual influence of the factors revealed that increasing the sliding speed decreases the SWR, and on the other hand, increasing the applied load increases SWR. For COF, the applied load shows the same behavior as SWR but opposite for the sliding speed. The COF increased with increasing the sliding speed, which was attributed to the increase in the localized temperature, which results in the softening of the metal leading to an increase in the contact area.
- It is also observed that the increase in the hardness of the DSS alloys improved their wear properties by reducing the SWR as compared to the ASS alloys. However, the DSS alloys showed a higher COF as compared to the ASS alloys, which is attributed to the high hardness of such materials compared to ASS.
- In conclusion, it can be stated that the DSS material is a promising candidate to be used in tribological applications due to their better wear resistance, corrosion resistance and high strength.
Author Contributions
Acknowledgments
Conflicts of Interest
References
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Structure | Grade | C | Si | Mn | P | S | N | Cr | Ni | Mo |
---|---|---|---|---|---|---|---|---|---|---|
Ferritic | 430 | 0.08 | 1 | 1 | 0.04 | 0.015 | - | 16.0/18.0 | - | - |
Austenitic | 304 | 0.07 | 1 | 2 | 0.045 | 0.015 | 0.11 | 17.5/19.5 | 8.0/10.5 | - |
Alloys | (x = 6, 5, 4, y = 0, 1, 2) | ||||||
---|---|---|---|---|---|---|---|
Fe (Balance) | Cr 16 | Mn x | Mo 1 | Si 1 | N 0.22 | Cu y | |
DSS 1 | Bal. | 16 | 6 | 1 | 1 | 0.22 | 0 |
DSS 2 | Bal. | 16 | 5 | 1 | 1 | 0.22 | 1 |
DSS 3 | Bal. | 16 | 4 | 1 | 1 | 0.22 | 2 |
Factors | Level1 | Level 2 | Level 3 |
---|---|---|---|
Composition | DSS 1 | DSS 2 | DSS 3 |
Speed (m/sec) | 0.1 | 0.2 | 0.3 |
Load (N) | 20 | 25 | 30 |
Runs | Composition | Speed (m/sec) | Load (N) |
---|---|---|---|
1 | DSS 1 | 0.1 | 20 |
2 | DSS 1 | 0.2 | 25 |
3 | DSS 1 | 0.3 | 30 |
4 | DSS 2 | 0.1 | 25 |
5 | DSS 2 | 0.2 | 30 |
6 | DSS 2 | 0.3 | 20 |
7 | DSS 3 | 0.1 | 30 |
8 | DSS 3 | 0.2 | 20 |
9 | DSS 3 | 0.3 | 25 |
Alloys | Average Hardness (BHR) |
---|---|
DSS 1 | 88.2 |
DSS 2 | 87.94 |
DSS 3 | 86.02 |
ASS 304 | 75.54 |
Runs | Composition | Speed (m/sec) | Load (N) | Specific Wear Rate (mm3/Nm) | S/N Ratio (dB) | |||
---|---|---|---|---|---|---|---|---|
Trial 1 | Trial 2 | Trial 3 | Mean | |||||
1 | DSS 1 | 0.1 | 20 | 0.000060 | 0.000060 | 0.000060 | 0.000060 | 84.44 |
2 | DSS 1 | 0.2 | 25 | 0.000070 | 0.000080 | 0.000110 | 0.000087 | 81.08 |
3 | DSS 1 | 0.3 | 30 | 0.000080 | 0.000080 | 0.000080 | 0.000080 | 81.94 |
4 | DSS 2 | 0.1 | 25 | 0.000120 | 0.000120 | 0.000080 | 0.000107 | 79.31 |
5 | DSS 2 | 0.2 | 30 | 0.000100 | 0.000090 | 0.000100 | 0.000097 | 80.28 |
6 | DSS 2 | 0.3 | 20 | 0.000140 | 0.000130 | 0.000130 | 0.000133 | 77.50 |
7 | DSS 3 | 0.1 | 30 | 0.000050 | 0.000080 | 0.000070 | 0.000067 | 83.37 |
8 | DSS 3 | 0.2 | 20 | 0.000140 | 0.000130 | 0.000130 | 0.000133 | 77.50 |
9 | DSS 3 | 0.3 | 25 | 0.000120 | 0.000100 | 0.000110 | 0.000110 | 79.15 |
Source | DF | Seq SS | Contribution | Adj SS | Adj MS | F-Value | P-Value |
---|---|---|---|---|---|---|---|
Composition | 2 | 0.00000 | 33.66% | 0.00000 | 0.00000 | 15.49 | 0.0000 |
Speed | 2 | 0.00000 | 25.71% | 0.00000 | 0.00000 | 11.83 | 0.0000 |
Load | 2 | 0.00000 | 18.89% | 0.00000 | 0.00000 | 8.69 | 0.002 |
Error | 20 | 0.00000 | 21.73% | 0.00000 | 0.00000 | - | - |
Lack-of-Fit | 2 | 0.00000 | 7.42% | 0.00000 | 0.00000 | 4.67 | 0.0230 |
Pure Error | 18 | 0.00000 | 14.31% | 0.00000 | 0.00000 | - | - |
Total | 26 | 0.00000 | 100.00% | - | - | - | - |
Runs | Composition | Speed (m/s) | Load (N) | COF | S/N Ratio (dB) | |||
---|---|---|---|---|---|---|---|---|
Trial 1 | Trial 2 | Trial 3 | Mean | |||||
1 | DSS 1 | 0.1 | 20 | 0.6761 | 0.6658 | 0.6744 | 0.6721 | 3.45 |
2 | DSS 1 | 0.2 | 25 | 0.5311 | 0.4579 | 0.4703 | 0.4864 | 6.24 |
3 | DSS 1 | 0.3 | 30 | 0.3779 | 0.4218 | 0.4299 | 0.4099 | 7.73 |
4 | DSS 2 | 0.1 | 25 | 0.5686 | 0.5473 | 0.5756 | 0.5638 | 4.98 |
5 | DSS 2 | 0.2 | 30 | 0.3807 | 0.4104 | 0.4581 | 0.4164 | 7.58 |
6 | DSS 2 | 0.3 | 20 | 0.4252 | 0.4386 | 0.4435 | 0.4358 | 7.21 |
7 | DSS 3 | 0.1 | 30 | 0.4473 | 0.5760 | 0.5325 | 0.5186 | 5.66 |
8 | DSS 3 | 0.2 | 20 | 0.4688 | 0.4738 | 0.4672 | 0.4699 | 6.56 |
9 | DSS 3 | 0.3 | 25 | 0.4130 | 0.4145 | 0.3954 | 0.4076 | 7.79 |
Source | DF | Seq SS | Contribution | Adj SS | Adj MS | F-Value | P-Value |
---|---|---|---|---|---|---|---|
Composition | 2 | 0.01776 | 8.83% | 0.01776 | 0.00888 | 9.29 | 0.001 |
Speed | 2 | 0.13710 | 68.17% | 0.13710 | 0.06855 | 71.69 | 0.000 |
Load | 2 | 0.02714 | 13.49% | 0.02714 | 0.01357 | 14.19 | 0.000 |
Error | 20 | 0.01912 | 9.51% | 0.01912 | 0.00096 | - | - |
Lack-of-Fit | 2 | 0.00194 | 0.97% | 0.00194 | 0.00097 | 1.02 | 0.381 |
Pure Error | 18 | 0.01718 | 8.54% | 0.01718 | 0.00095 | - | - |
Total | 26 | 0.20112 | 100.00% | - | - | - | - |
Sample | Comp. | Load (N) | Speed (m/s) | Specific Wear Rate (mm3/N.m) | COF | ||||
---|---|---|---|---|---|---|---|---|---|
Regression Model | Experiment | Error (%) | Regression Model | Experiment | Error (%) | ||||
1 | DSS1 | 20 | 0.25 | 12.6421 × 10−5 | 13.2879 × 10−5 | 4.86 | 0.4954 | 0.5913 | 16.22 |
2 | DSS1 | 25 | 0.3 | 10.1998 × 10−5 | 11.0936 × 10−5 | 8.06 | 0.4480 | 0.4734 | 5.38 |
3 | DSS2 | 22.5 | 0.1 | 7.75073 × 10−5 | 9.06494 × 10−5 | 14.50 | 0.5872 | 0.4628 | 26.88 |
4 | DSS2 | 30 | 0.15 | 9.25637 × 10−5 | 8.70125 × 10−5 | 6.38 | 0.4550 | 0.4918 | 7.48 |
5 | DSS3 | 27.5 | 0.2 | 10.1667 × 10−5 | 12.4108 × 10−5 | 18.08 | 0.4136 | 0.4124 | 0.29 |
6 | DSS3 | 20 | 0.3 | 14.595 × 10−5 | 13.5054 × 10−5 | 8.07 | 0.4347 | 0.3494 | 24.42 |
Optimum Operating Parameters | ASS | DSS1 | ||
---|---|---|---|---|
COF | SWR (mm3/N.m) | COF | SWR (mm3/N.m) | |
Low COF (Speed = 0.1m/s, Load = 20 N) | 0.3414 | 0.000088 | 0.6707 | 0.00006 |
Low SWR (Speed = 0.3 m/s, Load = 20 N) | 0.3072 | 0.000105 | 0.6721 | 0.00007 |
Material Used | Speed (m/s) | Load (N) | SWR (mm3/N.m) | Ref. |
---|---|---|---|---|
Untreated AISI 316 austenitic stainless steel | 0.2 | 5, 10, 20 | 0.00017–0.00020 | [29] |
Untreated AISI 304 austenitic stainless steel | 0.044 | up to 20 | 0.00009–0.000102 | [30] |
Super Duplex Stainless Steel AISI 2507 | 2, 4, 6 | 20, 40, 60 | 1.656–2.99 | [31] |
Duplex stainless steel | 0.1, 0.2, 0.3 | 20, 25, 30 | 0.00006–0.00014 | Current work |
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Daraghma, H.; Samad, M.A.; Toor, I.u.H.; M. Abdallah, F.; Patel, F. Tribological Characterization of Ni-Free Duplex Stainless Steel Alloys Using the Taguchi Methodology. Metals 2020, 10, 339. https://doi.org/10.3390/met10030339
Daraghma H, Samad MA, Toor IuH, M. Abdallah F, Patel F. Tribological Characterization of Ni-Free Duplex Stainless Steel Alloys Using the Taguchi Methodology. Metals. 2020; 10(3):339. https://doi.org/10.3390/met10030339
Chicago/Turabian StyleDaraghma, Hammam, Mohammed Abdul Samad, Ihsan ul Haq Toor, Farid M. Abdallah, and Faheemuddin Patel. 2020. "Tribological Characterization of Ni-Free Duplex Stainless Steel Alloys Using the Taguchi Methodology" Metals 10, no. 3: 339. https://doi.org/10.3390/met10030339