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The Abrasive Wear Processes of Modern Materials Used in Working Elements

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A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: closed (10 July 2023) | Viewed by 15850

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Prof. Dr. Jerzy Napiórkowski

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Guest Editor

Department of Building and Exploitation of Vehicles and Machines, Faculty of Technical Sciences, University of Warmia and Mazury in Olsztyn, 10-719 Olsztyn, Poland
Interests: wear processes; abrasive wear; surface layer; steels with boron content; sintered carbides; abrasive material; polymers; special layers

Dr. Magdalena Lemecha

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Guest Editor

Department of Building and Exploitation of Vehicles and Machines, Faculty of Technical Sciences, University of Warmia and Mazury in Olsztyn, 10-719 Olsztyn, Poland
Interests: welded layers; wear processes; abrasive wear; surface layer; surfacing layers; modeling of wear

Special Issue Information

Dear Colleagues,

A phenomenon accompanying the exploitations of working elements under abrasion conditions is their intense wear, which is a process of physico-chemical qualitative and quantitative changes taking place on the friction surface.

The process of intensive abrasive wear occurs in the working elements of, among others, mining, agricultural, construction, and road machines.

The selection of the constructional and technological of these elements and planning the course of exploitations is possible when the course of the depletion of their usable resource is known in the set time and conditions. An important and, at the same time, very difficult aspect is the proper selection of materials for the production of working elements. The developing technology results in the emergence of newer and more perfect materials that are more resistant to the increasingly difficult working and operating conditions prescribed for them. Currently, the limits of the strength of working elements have been pushed, but their durability is still one of the main problems. Boron steels are used more often, abrasive wear-resistant steels as well as sputter coatings, multi-layer welds containing metals and amphoteric elements, and sintered carbides and polymers.

Therefore, the cognitive process requires the identification of the wear relationship of working elements by describing the quantities characterizing the course of friction processes and modeling the wear of surface layers under various environmental conditions. This Special Issue will explore and describe relationships between the properties of the surface layer made of the modern materials to conditions of exploitations, and of the wear processes.

It will reveal new, key discoveries in the field of technology for the production of abrasion-resistant layers dedicated to various applications in practice. Articles describing new experimental and theoretical research in the field of ensuring adequate abrasion resistance of materials used in various operating conditions are very welcome in this exploitations.

Prof. Dr. Jerzy Napiórkowski
Dr. Magdalena Lemecha
Guest Editors

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Keywords

wear processes
abrasive wear
special surface layers
modelling wear process
polymers
wear testing
steel resistant to abrasive wear
galvanic coatings
paint coatings
abrasive properties
chemical composition
resistance to abrasive wear

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Published Papers (9 papers)

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Research

18 pages, 5698 KiB

Open AccessArticle

Experimental Investigation on the Corrosion Detectability of A36 Low Carbon Steel by the Method of Phased Array Corrosion Mapping

by Jan Lean Tai, Rafał Grzejda, Mohamed Thariq Hameed Sultan, Andrzej Łukaszewicz, Farah Syazwani Shahar, Wojciech Tarasiuk and Arkadiusz Rychlik

Materials 2023, 16(15), 5297; https://doi.org/10.3390/ma16155297 - 27 Jul 2023

Cited by 4 | Viewed by 1233

Abstract

Petrochemical plants use on-stream inspection often to detect and monitor the corrosion on the equipment and piping system. Compared to ultrasonic thickness gauging and pulse-echo A-scan, phased array corrosion mapping has better coverability and can scan a large area to detect general and localized corrosion. This paper’s objective is to obtain documentary evidence for the accuracy of corrosion detection from 30 °C to 250 °C on A36 low-carbon steel by carrying out simulation experiments every 10 °C step. A minimum of three sets of phased array corrosion mapping data in each temperature were collected to study and evaluate the detectability. The data evidence could enhance the confidence level of the plant’s end users in using phased array mapping in the future during inspections. The experiments were found to be insufficiently thorough despite addressing the initial concerns, leaving more area for discussion in further studies, such as expanding the investigation to thicker carbon steel, stainless steel, and wedge materials. Full article

(This article belongs to the Special Issue The Abrasive Wear Processes of Modern Materials Used in Working Elements)

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12 pages, 6663 KiB

Open AccessArticle

Effect of Modifier Form on Mechanical Properties of Hypoeutectic Silumin

by Tomasz Lipiński

Materials 2023, 16(15), 5250; https://doi.org/10.3390/ma16155250 - 26 Jul 2023

Cited by 2 | Viewed by 799

Abstract

Aluminum–silicon alloys require modification due to their coarse-grained microstructures and resulting low strength properties. So far, research into the modification process has focused on the use of various chemical components and technological processes, the tasks of which are to refine the microstructure and, thus, increase the mechanical properties of the alloy. In this paper, the answer to the question of whether the form of the modifier influences the modification effect of the hypoeutectic silumin will be found. The tests were carried out using the popular silumin AlSi7Mg. To answer our research question, the alloy was modified under comparable conditions using the following elements: Ti, B, and master alloys AlTi1.5 and AlB1.5. Modifiers in the form of Sr and master alloy AlSr1.5 were also used. All mentioned modifiers were produced and introduced into the liquid alloy in the form of a powder and a rod. Master alloys AlSr1.5 were also produced via cooling from the liquid state through cooling in air and the second variant at a speed of 200 °C/s (in the form of powder and a thin strip). The microstructure and mechanical properties were analyzed based on the following measures: tensile strength, elongation, and hardness of silumin. Based on the conducted research, it was found that the form of the modifier also affects the modification effect visible in the form of changes in the microstructure and mechanical properties. For the powder-modified alloy, greater fineness in the eutectic phase (α and B phases) and an increase in all analyzed mechanical properties were obtained. Full article

(This article belongs to the Special Issue The Abrasive Wear Processes of Modern Materials Used in Working Elements)

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14 pages, 2382 KiB

Open AccessArticle

Ultrasonic Velocity and Attenuation of Low-Carbon Steel at High Temperatures

by Jan Lean Tai, Mohamed Thariq Hameed Sultan, Andrzej Łukaszewicz, Farah Syazwani Shahar, Wojciech Tarasiuk and Jerzy Napiórkowski

Materials 2023, 16(14), 5123; https://doi.org/10.3390/ma16145123 - 20 Jul 2023

Cited by 4 | Viewed by 1909

Abstract

On-stream inspections are the most appropriate method for routine inspections during plant operation without undergoing production downtime. Ultrasonic inspection, one of the on-stream inspection methods, faces challenges when performed at high temperatures exceeding the recommended 52 °C. This study aims to determine the ultrasonic velocity and attenuation with known material grade, thickness, and temperatures by comparing theoretical calculation and experimentation, with temperatures ranging between 30 °C to 250 °C on low-carbon steel, covering most petrochemical equipment material and working conditions. The aim of the theoretical analysis was to obtain Young’s modulus, Poisson’s ratio, and longitudinal velocity at different temperatures. The experiments validated the theoretical results of ultrasonic change due to temperature increase. It was found that the difference between the experiments and theoretical calculation is 3% at maximum. The experimental data of velocity and decibel change from the temperature range provide a reference for the future when dealing with unknown materials information on site that requires a quick corrosion status determination. Full article

(This article belongs to the Special Issue The Abrasive Wear Processes of Modern Materials Used in Working Elements)

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14 pages, 11543 KiB

Open AccessArticle

Use of the Ball-Cratering Method to Assess the Wear Resistance of a Welded Joint of XAR400 Steel

by Krzysztof Ligier, Mirosław Bramowicz, Sławomir Kulesza, Magdalena Lemecha and Bartosz Pszczółkowski

Materials 2023, 16(13), 4523; https://doi.org/10.3390/ma16134523 - 22 Jun 2023

Cited by 1 | Viewed by 1133

Abstract

Wear-resistant steels are designed to allow for operation under extreme loading conditions. They combine large strength with resilience and resistance to abrasive wear. In stock, the steel is subjected to preliminary heat treatment. However, any further processing at temperatures higher than 200 °C results in tempering that influences the mechanical properties of the material. The presented paper aims to study changes in abrasive wear properties across the welded joint made out of this steel, and its prime novelty lies in using the ball-cratering method to test the wear resistance of the joints. To distinguish between different crystalline structures in the weld, metallographic and XRD analyses were performed that resulted in the determination of five primary zones for which wear tests were carried out. Abrasive wear rates, studied across the welded joint, indicate that the material in the HAZ has the lowest resistance to abrasive wear. Similarly, the obtained values of the wear index show decreasing resistance of the material approaching the joint axis. Full article

(This article belongs to the Special Issue The Abrasive Wear Processes of Modern Materials Used in Working Elements)

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32 pages, 26189 KiB

Open AccessArticle

Resistance to Abrasive Wear with Regards to Mechanical Properties Using Low-Alloy Cast Steels Examined with the Use of a Dry Sand/Rubber Wheel Tester

by Beata Białobrzeska and Robert Jasiński

Materials 2023, 16(8), 3052; https://doi.org/10.3390/ma16083052 - 12 Apr 2023

Cited by 6 | Viewed by 1721 | Correction

Abstract

This paper focuses on relationship between the mechanical properties and abrasive wear resistance, expressed by the K_b index, using an example of low-alloy cast steels. In order to achieve the aim of this work, eight cast steels of varying chemical composition were designed, cast and then heat treated. The heat treatment involved quenching and tempering at 200, 400 and 600 °C. Structural changes caused by tempering are demonstrated by the different morphologies of the carbide phases in the ferritic matrix. In the first part of this paper, the present state of knowledge about the influence of structure and hardness on the tribological properties of steels is discussed. This research involved the evaluation of a material’s structure, as well as its tribological and mechanical properties. Microstructural observations were performed using a light microscope and a scanning electron microscope. Next, tribological tests were carried-out with the use of a dry sand/rubber wheel tester. To determine the mechanical properties, Brinell hardness measurements and a static tensile test were carried out. The relationship between the determined mechanical properties and abrasive wear resistance was then investigated. The analyses also provided information regarding the heat treatment states of the analyzed material in the as-cast and as-quenched states. It was found that the abrasive wear resistance, expressed by the index K_b, was most strongly correlated with hardness and yield point. In addition, observations of the wear surfaces indicated that the main wear mechanisms were microcutting and microplowing. Full article

(This article belongs to the Special Issue The Abrasive Wear Processes of Modern Materials Used in Working Elements)

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18 pages, 10655 KiB

Open AccessArticle

Analysis of Wear Properties of Hardox Steels in Different Soil Conditions

by Krzysztof Ligier, Martyna Zemlik, Magdalena Lemecha, Łukasz Konat and Jerzy Napiórkowski

Materials 2022, 15(21), 7622; https://doi.org/10.3390/ma15217622 - 30 Oct 2022

Cited by 6 | Viewed by 1978

Abstract

This paper presents the results of wear tests of three types of commercial abrasion-resistant steels. The samples, cut from commercially available sheets of metal, were subjected to wear tests to a total friction path of 20,000 m. The tests were provided using the “rotating bowl” method in three types of natural soil masses. The soil moisture and test parameters were kept constant. The tests were carried out in six replications for each material. The testing results indicate that hardness does not determine the resistance to abrasive wear, which is supported by the weight loss results for particular materials. Hardox 600 steel, which is not characterized by the highest hardness, exhibited the lowest weight loss value compared to the other materials in all test soils. For the light soil, the weight loss for Hardox 600 was approx. 1.3 times lower than for Hardox 500 steel and approx. 1.6 times higher than for Hardox Extreme steel. With regards to the medium and heavy soil, the weight losses for Hardox 600 in relation to Hardox 500 steel were approx. 1.7 and 1.6 times lower, respectively, while in relation to Hardox Extreme steel the weight losses were 1.5 and 1.7 times higher, respectively. Full article

(This article belongs to the Special Issue The Abrasive Wear Processes of Modern Materials Used in Working Elements)

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17 pages, 23344 KiB

Open AccessArticle

Analysis of Wear Properties of Powder Metallurgy Steel in Abrasive Soil Mass

by Magdalena Lemecha, Jerzy Napiórkowski, Krzysztof Ligier, Wojciech Tarasiuk and Krzysztof Sztukowski

Materials 2022, 15(19), 6888; https://doi.org/10.3390/ma15196888 - 4 Oct 2022

Cited by 4 | Viewed by 1483

Abstract

This study presents the results of testing for abrasive wear of Vanadis 60 SuperClean powder metallurgy steel as compared to Hardox 600 steel and PMFe60P padding weld. The testing was conducted by the “rotating bowl” method using natural abrasive soil masses. Two types of abrasive masses with particle size distributions corresponding to light soil and medium soil were used. The obtained results enable the conclusion that the weight loss for Vanadis 60 SuperClean powder steel in both types of abrasive mass was approximately seven times lower than that for Hardox 600 steel and two times lower than PMFe60P padding weld. The high resistance of powder steel to abrasive wear in abrasive soil masses is related to the presence of a large number of fine M₆C (tungsten-molybdenum) and MC (vanadium) carbide precipitates in its microstructure. The obtained test results indicate that the application of Vanadis 60 SuperClean steel may be extended to working elements operating in mineral abrasive environments. Full article

(This article belongs to the Special Issue The Abrasive Wear Processes of Modern Materials Used in Working Elements)

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18 pages, 10109 KiB

Open AccessArticle

Comparative Analysis of the Influence of Chemical Composition and Microstructure on the Abrasive Wear of High-Strength Steels

by Martyna Zemlik, Łukasz Konat and Jerzy Napiórkowski

Materials 2022, 15(14), 5083; https://doi.org/10.3390/ma15145083 - 21 Jul 2022

Cited by 9 | Viewed by 2121

Abstract

The paper discusses the microstructural, chemical and tribological properties of the selected low-alloy, high-strength martensitic boron steels with a hardness of 500–600 HBW. These materials, due to their increased strength, and thus resistance to abrasive wear, are widely used in the mining, agricultural or building industries. Grades such as XAR, TBL and Creusabro were subjected to a comparative analysis. As a result of the conducted research, an attempt was made to determine the relation between the microstructural properties, chemical composition, hardness and abrasive wear resistance of the above-mentioned metallic materials belonging to the same material group. The scope of work involved a metallographic analysis, including the examination of the microstructure with an analysis of the prior austenite grain size. Tribological tests were carried out with the use of a T-07 tester, which is designed for testing abrasive wear resistance in the presence of a loose abrasive. As a result, it was found that the coefficient of relative abrasion resistance k_bAV in relation to as-normalized C45 steel is equal to 0.9–1.25 and may even have the same value among materials of different hardness in the as-delivered state. Full article

(This article belongs to the Special Issue The Abrasive Wear Processes of Modern Materials Used in Working Elements)

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16 pages, 16643 KiB

Open AccessArticle

Investigation into Changes of Microstructure and Abrasive Wear Resistance Occurring in High Manganese Steel X120Mn12 during Isothermal Annealing and Re-Austenitisation Process

by Mateusz Dziubek, Małgorzata Rutkowska-Gorczyca, Włodzimierz Dudziński and Dominika Grygier

Materials 2022, 15(7), 2622; https://doi.org/10.3390/ma15072622 - 2 Apr 2022

Cited by 2 | Viewed by 2519

Abstract

Hadfield steel, under unit pressure conditions, strengthens itself by forming a high density dislocation structure, which results in increased resistance to dynamic impact wear. However, under abrasion conditions, the homogeneous microstructure of the cast steel is insufficient to achieve the expected service life. The aim of the research is to conduct a comparative analysis of the material in its as-delivered state and after two-stage heat treatment (isothermal annealing followed by re-austenitisation). It was found that after isothermal annealing of X120Mn12 grade steel at a temperature of 510 °C, a microstructure with a complex morphology consisting of colonies of fine-grained pearlite, (Fe,Mn)₃C carbides distributed along the grain boundaries of the former austenite and needle-like (Fe,Mn)₃C carbides was obtained in the austenite matrix. The subsequent thermal treatment of the steel with the use of supersaturating annealing at 900 °C resulted in a heterogeneous microstructure consisting of evenly distributed globular carbide precipitations in a matrix of considerably finer austenite grains in comparison with the as-delivered original state. As a result of the final microstructural changes achieved, a 16.4% increase in abrasion resistance was obtained compared to the delivered condition. Full article

(This article belongs to the Special Issue The Abrasive Wear Processes of Modern Materials Used in Working Elements)

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