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Wear and Corrosion Behaviour of Metals and Alloys

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A special issue of Lubricants (ISSN 2075-4442).

Deadline for manuscript submissions: closed (31 March 2024) | Viewed by 8920

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Dr. Fatih Erdemir

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Department of Metallurgical and Materials Engineering, Faculty of Engineering, Karadeniz Technical University, Trabzon, Turkey
Interests: corrosion; energy storage; Al alloys; supercapacitors; composites; coating; powder metallurgy

Special Issue Information

Dear Colleagues,

Corrosion can frequently occur with a lack of mechanical wear, although corrosion accompanies wear practice to nearly the same degree in entire environments, excluding inert atmospheres. The corrosion and wear of metals and alloys frequently combine to begin serious damage during their service. Investigation of corrosion and wear mechanisms is important for revealing the relationships between abrasion, impact, and corrosion. There are many studies on improving the corrosion and wear resistance of metals and alloys. Metals and alloys are used in a variety of applications and have wide families. It will be possible to improve the metal industry with the optimization of the properties of new products, metal and alloys.

This Special Issue will focus on the important areas of research of corrosion and wear, investigating the phenomenon of corrosion and wear of metals and alloys with various scientific approaches. It is a useful guide to the use of titanium, magnesium, stainless steel, high-entropy, and aluminum alloys based on their corrosion and wear behaviors. I would like to invite you to contribute to this Special Issue, which can benefit both academics and engineers working in the industry.

Dr. Fatih Erdemir
Guest Editor

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Keywords

titanium alloys
aluminium alloys
magnesium alloys
stainless steels
high-entropy alloys

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Published Papers (6 papers)

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Research

16 pages, 16144 KiB

Open AccessArticle

Effect of Substrate Preheating Temperature on the Microstructure and Properties of Laser Cladding Fe/TiC Composite Coating

by Wenqing Shi, Cai Cheng, Bingqing Zhang, Fenju An, Kaiyue Li, Zhaoting Xiong, Yuping Xie and Kuanfang He

Lubricants 2024, 12(6), 216; https://doi.org/10.3390/lubricants12060216 - 14 Jun 2024

Viewed by 1116

Abstract

In this study, Fe/TiC composite coating was fabricated on the surface of 65Mn steel using substrate preheating combined with laser cladding technology. In order to characterize the impact of various preheating temperatures, four coatings were fabricated on a 65Mn substrate using laser cladding at different temperatures (ambient temperature, 100 °C, 200 °C, and 300 °C). The microstructures and properties of four Fe/TiC composite coatings were investigated using SEM, XRD, EDS, a Vickers microhardness meter, a wear tester, and an electrochemical workstation. The research results show that the cladding angle of the Fe/TiC composite coating initially increases and then decreases as the substrate preheating temperature rises. The solidification characteristics of the Fe/TiC composite coating structure are not obviously changed at substrate preheating temperatures ranging from room temperature to 300 °C. However, the elemental distribution within the cladding layer was significantly influenced by the preheating temperature. An increase in the preheating temperature led to a more uniform elemental distribution. Regarding the comprehensive properties, including hardness, wear characteristics, and corrosion resistance, the optimum substrate preheating temperature for the cladding layer was found to be 300 °C. Full article

(This article belongs to the Special Issue Wear and Corrosion Behaviour of Metals and Alloys)

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20 pages, 16762 KiB

Open AccessArticle

Investigation of the Nitriding Effect on the Adhesion and Wear Behavior of CrN-, AlTiN-, and CrN/AlTiN-Coated X45CrMoV5-3-1 Tool Steel Formed Via Cathodic Arc Physical Vapor Deposition

by Gülşah Aktaş Çelik, Konstantinos Fountas, Şaban Hakan Atapek, Şeyda Polat, Eleni Kamoutsi and Anna D. Zervaki

Lubricants 2024, 12(5), 170; https://doi.org/10.3390/lubricants12050170 - 10 May 2024

Viewed by 1069

Abstract

Monolayer (CrN, AlTiN) and bilayer (CrN/AlTiN) coatings are formed on the surface of conventional heat-treated and gas-nitrided X45CrMoV5-3-1 tool steel via Cathodic Arc Physical Vapor Deposition (CAPVD), and the adhesion characteristics and room- and high-temperature wear behavior of the coatings are compared with those of the un-nitrided ones. Scratch tests on the coatings show that the bilayer coating exhibits better adhesion behavior compared to monolayer ones, and the adhesion is further increased in all coatings due to the high load carrying capacity of the diffusion layer formed by the nitriding process. Dry friction tests performed at room temperature reveal that, among ceramic-based coatings, the coating system with a high adhesion has the lowest specific wear rate (0.06 × 10⁻⁶ mm³/N·m), and not only the surface hardness but also the nitriding process is important for reducing this rate. Studies on wear surfaces indicate that the bilayer coating structure has a tendency to remove the surface over a longer period of time. Hot wear tests performed at a temperature (450 °C) corresponding to aluminum extrusion conditions show that high friction coefficient values (>1) are reached due to aluminum transfer from the counterpart material to the surface and failure develops through droplet delamination. Adhesion and tribological tests indicate that the best performance among the systems studied belongs to the steel–CrN/AlTiN system and this performance can be further increased via the nitriding process. Full article

(This article belongs to the Special Issue Wear and Corrosion Behaviour of Metals and Alloys)

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15 pages, 13297 KiB

Open AccessArticle

Effects of Drilling Parameters and Mud Types on Wear Factors and Mechanisms of SM2535 Casings

by Omer Osman, Necar Merah, Mohammed Abdul Samad, Amjad Al-Shaarawi and Meshari Alshalan

Lubricants 2023, 11(10), 420; https://doi.org/10.3390/lubricants11100420 - 30 Sep 2023

Cited by 3 | Viewed by 1251

Abstract

This work aims to explore the impact of side loads, drill-pipe tool-joint (DP-TJ) speed (rpm), and mud type on the austenitic stainless steel SM2535-110 casing wear characteristics. Actual field drill pipe tool joints, casings, and drilling muds are used in this study. The results of the study show that under both types of lubrication, the wear volume increased with radial load and DP-TJ speed. SM2535-110 casing specimens tested under oil-based mud (OBM) lubrication had higher casing wear volumes than those obtained under water-based mud (WBM) lubrication. This unexpected behavior is mainly due to the increase in the surface hardness of the casing specimens tested under WBM. The results also show that the specific wear rate or wear factor (K) (which is defined as the volume loss per unit load per unit distance sliding) values of specimens tested under WBM are in general two to four times higher than those obtained under OBM. While K values under WBM increase with both the side load and rpm, those under OBM show a sharp decrease with rpm. This behavior under OBM is due to this lubricant’s higher viscosity and the change of lubrication regime from thin film to thick film lubrication at higher rpm. Scanning electron microscopy (SEM) and the digital microscopic imaging (DMI) of SM235-110 casing specimens show that an aggressive combination of adhesive, abrasive, and plastic deformation was observed under WBM, while the dominant wear mechanism under OBM is abrasive wear. Full article

(This article belongs to the Special Issue Wear and Corrosion Behaviour of Metals and Alloys)

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17 pages, 9919 KiB

Open AccessArticle

Manipulate A2/B2 Structures in AlCrFe_xNi Alloys for Improved Mechanical Properties and Wear Resistance

by Guijiang Diao, Mingyu Wu, Anqiang He, Zhen Xu, Seyed Elias Mousavi and Dongyang Li

Lubricants 2023, 11(9), 392; https://doi.org/10.3390/lubricants11090392 - 12 Sep 2023

Cited by 4 | Viewed by 1474

Abstract

Precipitation strengthening of body-center cubic (A2) alloys via ordered B2 nanoprecipitates is expected to achieve a desirable combination of strength and ductility. In this work, the A2/B2 configuration is manipulated by adjusting Fe content in medium-entropy AlCrFe_xNi (x = 0, 0.5, 1.0, 1.5, 2.0, 2.5 and 3.0) alloys fabricated via arc-melting for improved mechanical properties and wear resistance. As Fe content increases, the fraction of A2 phase increases, and A2 nanoprecipitates in the B2 matrix change to a weave-like A2/B2 structure. Continuously increasing Fe content leads to a mixture of BMAP (B2 matrix with A2 precipitates) and AMBP (A2 matrix with B2 precipitates), and finally to a complete AMBP structure. The yield strength decreases and fracture strain increases with increasing Fe content except x = 0. The alloy of x = 0 displays slightly higher hardness because of its relatively brittle B2 matrix. Cracks tend to propagate along A2/B2 interfaces. AMBP structure exhibits greater toughness than the BMAP structure. The alloy of x = 0 displays the second-greatest wear volume loss due to its relatively brittle B2 matrix. When Fe is added, the wear volume loss decreases considerably but shows a trend of an upward parabola with respect to the Fe content. After achieving the highest volume loss at x = 1.5 with a mixture of AMBP and BMAP, the volume loss decreases again. A completely uniform AMBP structure at x = 3.0 shows the least volume loss. Full article

(This article belongs to the Special Issue Wear and Corrosion Behaviour of Metals and Alloys)

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14 pages, 18359 KiB

Open AccessArticle

Phase Structure, Microstructure, Corrosion, and Wear Resistance of Al_0.8CrFeCoNiCu_0.5 High-Entropy Alloy

by Yanzhou Li, Xingfu Wang, Zimu Shi and Juhua Liang

Lubricants 2023, 11(9), 358; https://doi.org/10.3390/lubricants11090358 - 23 Aug 2023

Cited by 6 | Viewed by 1341

Abstract

This study investigates the structure and corrosion behavior of the Al_0.8CrFeCoNiCu_0.5 high-entropy alloy prepared using non-consumable vacuum arc melting. XRD analysis identified BCC1 and BCC2 phases corresponding to (Fe-Cr) and Al-Ni, respectively, while the FCC phase aligned with Cu. SEM and EBSD observations confirmed an equiaxed grain structure with fishbone-like morphology at grain boundaries and modulated structures within the grains. The alloy exhibited minimal residual stress and strain. The alloy demonstrated a preferred orientation of grain growth along the <001> direction. Electrochemical testing in a 3.5% NaCl solution revealed a corrosion potential of −0.332 V and a corrosion current density of 2.61 × 10⁻⁶ A/cm². The intergranular corrosion regions exhibited significant depletion of Al and Cu elements, with the corrosion products primarily consisting of Al and Cu. Al and Cu elements are susceptible to corrosion. The wear scar width of Al_0.8CrFeCoNiCu_0.5 high-entropy alloy is 1.65 mm, which is less than 45# steel, and high-entropy alloy has more excellent wear resistance. Given its unique attributes, this high-entropy alloy could find potential applications in high-end manufacturing industries such as the aerospace engineering, the defense industry, energy production, and chemical processing where high corrosion resistance and wear resilience are crucial. Full article

(This article belongs to the Special Issue Wear and Corrosion Behaviour of Metals and Alloys)

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12 pages, 2624 KiB

Open AccessArticle

A Study on the Corrosion Resistance of a Coating Prepared by Electrical Explosion of 321 Metal Wire

by Ye Liu, Qiuzhi Song, Hongbin Deng, Yali Liu, Pengwan Chen and Kun Huang

Lubricants 2023, 11(7), 309; https://doi.org/10.3390/lubricants11070309 - 22 Jul 2023

Viewed by 1563

Abstract

Corrosion is known as a breakdown effect that causes the deterioration of substances in enriched petroleum/gas conditions. This reaction occurs in all materials, which is highlighted in alloys. In the present study, the morphological properties, as well as the corrosion resistance behavior of the AISI1045 steel substrate coated with 321 austenitic stainless steel metal particulate fillers, were investigated. The electro-explosive spraying technique was employed to achieve a homogenous coating on the substrate surface. According to the results, the grain size of the 321 austenitic stainless steel coating layer was shrunk and reduced to 1–3 μm after the coating procedure. The coated layer also showed a homogenous and uniform thickness with an average value of 137 μm. Also, the average adhesion strength of 49.21 MPa was obtained between the sprayed coating and the substrate. The analytical analysis found the presence of Fe-Cr and Fe-Ni phases in the coating layer. The hardness of the original metal wire is 186 HV, and the microhardness of the coating after spraying is 232 HV. After subjecting the specimen to the corrosion examination, a 0.1961 mm/a corrosion rate was obtained for up to 120 h. Moreover, the corrosion products of CaCO₃, Fe₃O₄, and MgFe₂O₄ were determined by XRD analysis. Furthermore, the observed results were further confirmed by the data obtained from EPMA and EDS evaluations. Hence, this study implies the beneficial role of electro-explosive sprayed alloy 321 austenitic stainless steel in creating a protective layer against corrosion on 45 steel substrate in an enriched oil/water environment. Full article

(This article belongs to the Special Issue Wear and Corrosion Behaviour of Metals and Alloys)

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