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Use of Modern Materials in Technological Processes Accompanied by Frictional Heating (Volume II)

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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: 20 April 2025 | Viewed by 11845

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Prof. Dr. Aleksander Yevtushenko

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Department of Mechanics and Applied Computer Science, Faculty of Mechanical Engineering, Bialystok University of Technology (BUT), 45C Wiejska Street, 15-351 Bialystok, Poland
Interests: processing of materials by friction; frictional heating process simulation; temperature fields and thermal stress state due to friction; thermal splitting, systems of heat dynamics of friction and wear at braking; selection of friction materials for braking couple
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Prof. Dr. Michal Kuciej

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Department of Mechanics and Applied Computer Science, Faculty of Mechanical Engineering, Bialystok University of Technology (BUT), 45C Wiejska Street, 15-351 Bialystok, Poland
Interests: analytical and numerical non-linear models of frictional heating; friction materials in aircraft and trail braking systems; Thermal Barrier Coating (TBC); contact conductivity and convective cooling at friction heating; Carbon-Carbon (C/C) composite materials; temperature mode of clutches
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Dr. Katarzyna Topczewska

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Department of Mechanics and Applied Computer Science, Faculty of Mechanical Engineering, Bialystok University of Technology (BUT), 45C Wiejska Street, 15-351 Bialystok, Poland
Interests: mathematical modelling of frictional heating process; temperature and thermal stresses in the brake discs and clutches; transient heat conduction in non-homogeneous materials

Special Issue Information

Dear Colleagues,

Friction is widely used in grinding, welding, cutting, and other technological processes. Thermal phenomena accompanying friction have a decisive influence on both the course of these processes and on the quality of the result. Due to the extensive use in the industry of alloys based on magnesium, titanium, and aluminum, as well as new marks of steel and other materials sensitive to thermal effects, the thermal processes of friction are extremely important. In particular, it is necessary to note the use of friction during braking. The frictional materials used in brake units should provide the necessary value and stability of the coefficient of friction. The problem is that in heavy braking modes, the coefficient of friction, as well as the material properties, become thermally sensitive. In this case, one way to improve the frictional properties is using the thermal barrier coating (TBC) method.

The physical and mechanical state of the surface layers of rubbing elements is determined not only by the contact temperature, which can be measured experimentally, but by the entire space–time temperature field. Gradients of temperature and the rate of changes in the temperature field have the most value. These factors have unambiguous functional relationships with the kinematic and dynamic parameters of the friction mode, material properties, cooling intensity, and many other parameters. There is a need for a comprehensive study, using all available methods, to investigate the temperature field and the resulting stress state. Reliable results can be obtained only with a reasonable combination of theory and experiment.

Prof. Dr. Aleksander Yevtushenko
Prof. Dr. Michal Kuciej
Dr. Katarzyna Topczewska
Guest Editors

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Keywords

frictional heating
braking, grinding, welding, cutting, drilling, etc.
temperature and thermal stresses
experimental methods and simulations
materials selection
thermal barrier coating.

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Published Papers (9 papers)

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Research

16 pages, 10429 KiB

Open AccessArticle

Friction and Wear Performances and Mechanisms of Graphite/Copper Composites Under Electrical Contact in Marine Environments

by Nenghui Wang, Chuanfeng Wang, Wenhu Xu, Weiping Cheng, Haihong Wu and Hongsheng Li

Materials 2025, 18(7), 1516; https://doi.org/10.3390/ma18071516 - 28 Mar 2025

Viewed by 172

Abstract

Marine environment-induced apparatus failures have led to substantial losses in marine engineering. Graphite/copper composites, known for their excellent electrical conductivity and wear resistance, are extensively utilized in various electric contact devices. However, research on the current-carrying friction and wear behavior of graphite/copper composites in marine environments is still limited. This study investigates the effects of mating materials, graphite content (30 wt.% and 45 wt.%), and electric voltage on the friction and wear mechanisms of graphite/copper composites in seawater. The results show that under seawater coupled with electricity, no mass loss was observed in the 30 wt.% graphite composites after friction tests against different counterparts. Electric voltage (3 V) affects the composite’s damage mechanism, inducing delamination wear, arc erosion and accelerating corrosion. Specifically, the electricity factor promotes oxidation recreations while inhibiting chlorine formation. Notably, when the composite is paired with gold-coated copper, it undergoes electrochemical reactions, leading to the formation of needle-like copper oxide. These oxides alter the surface morphology, elevate the mass of worn composites, and raise the friction coefficient of the tribopair to approximately 0.3, an increase from 0.2. Full article

(This article belongs to the Special Issue Use of Modern Materials in Technological Processes Accompanied by Frictional Heating (Volume II))

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15 pages, 6805 KiB

Open AccessArticle

Metallurgical and Mechanical Properties of Stellite 6 Deposition Developed Through Friction Surfacing Technique

by Mohammad Faseeulla Khan, Ramachandran Damodaram, Hussain Altammar and Gangaraju Manogna Karthik

Materials 2025, 18(5), 1003; https://doi.org/10.3390/ma18051003 - 25 Feb 2025

Viewed by 309

Abstract

Friction surfacing (FS) is a solid-state process for depositing metallurgically bonded coatings for corrosion and wear protection. It is particularly attractive for depositing coatings in materials that are difficult to fusion deposit. Stellite 6 is one such material, which is widely used as a protective coating on steel structures to combat wear and corrosion. In the current study, Stellite 6 was successfully friction-surfaced on low carbon steel plates without using any preheating. The microstructures and wear behavior of Stellite 6 coatings produced using FS were comparatively investigated with those produced using the plasma transferred arc (PTA) process. The PTA coatings showed a cast microstructure consisting of γ-dendrites and an inter-dendritic carbide network. On the other hand, the FS coatings showed a wrought microstructure with dynamically recrystallized grains and fine, uniformly distributed carbide particles. The FS coatings also showed uniform composition across the coating thickness and were undiluted, while the PTA coatings showed significant dilution as well as strong local variations in chemistry. The FS coatings exhibited a 22% increase in hardness (550 HV) compared to the PTA coatings (450 HV). Pin-on-disc dry sliding wear tests showed that the FS coatings (1.205 mm³) were more wear resistant compared to the PTA coatings (6.005 mm³), highlighting their superior mechanical performance. This study uniquely demonstrates the feasibility of depositing Stellite 6 coatings using FS without the need for preheating or post-deposition heat treatments, while achieving superior microstructural refinement, hardness, and wear resistance compared to conventional PTA coatings. Full article

(This article belongs to the Special Issue Use of Modern Materials in Technological Processes Accompanied by Frictional Heating (Volume II))

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12 pages, 1916 KiB

Open AccessArticle

Characteristics and Quality of Flame-Retarded Ramie Fabrics for the Development of Functional Textiles

by Asri Peni Wulandari, Erlin Karlina, Eric Tanudjaja, Abdul Rohmat, Joko Kusmoro, Muhammad Fadhlillah, Karlina Somantri, Roni Sahroni and Widya Fatriasari

Materials 2024, 17(6), 1416; https://doi.org/10.3390/ma17061416 - 20 Mar 2024

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Abstract

Cellulose fabric testing for flame-retardant studies is frequently necessary in various textile applications. Natural cellulose material from ramie (Boehmeria nivea) is being promoted as an alternative raw material for the development of fire-resistant fabrics. This research aims to optimize the coating process of ramie fabric using a phosphorus-based flame retardant (FR) to enhance its flame-retardant characteristics. The FR treatment involves bleaching the fabric with H₂O₂; followed by fabric finishing using a formula comprising 3% (v/v) hydroxymethyl resin; phosphoric acid (2%); and two formulations of the flammable agent Flamatic DM-3072N: 40% (v/v) and 50% (v/v), applied using the pad-dry-cure method. The flame-retardant properties of the treated fabric are evaluated through flammability testing based on the ASTM D6413-08 standard, limiting oxygen index (LOI) analysis, and micrograph surface structure analysis with SEM. The results indicate that ramie fabric treated with the FR-50% material exhibits superior fire resistance, preventing fire spread on the fabric with a char length of 15–30 mm and a LOI value of 29. These findings highlight the potential of FR-treated ramie fabrics for various industries, including the automotive and protective clothing industries. Full article

(This article belongs to the Special Issue Use of Modern Materials in Technological Processes Accompanied by Frictional Heating (Volume II))

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30 pages, 15008 KiB

Open AccessArticle

Stress Concentration Factors for Non-Load-Carrying Welded Cruciform Joints Subjected to Tension, Bending, and Shear

by Krzysztof L. Molski and Piotr Tarasiuk

Materials 2024, 17(3), 609; https://doi.org/10.3390/ma17030609 - 26 Jan 2024

Viewed by 1841

Abstract

This paper deals with the problem of stress concentration at the weld toe of non-load-carrying-type plate cruciform joints under tension, bending, and shear. Theoretical stress concentration factors were derived using the finite element method. Five of the most important geometrical parameters: the thickness of the main plate and the attachments, the weld throat thickness, the weld toe radius, and the weld face inclination angle were treated as independent variables. For each loading mode—tension, bending, and shear—parametric expression of high accuracy was obtained, covering the range used in real structures for cruciform connections. The maximum percentage error was lower than 2.5% as compared to numerical values. The presented solutions proved to be valid for the toe radius ρ tending to zero. Full article

(This article belongs to the Special Issue Use of Modern Materials in Technological Processes Accompanied by Frictional Heating (Volume II))

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16 pages, 7254 KiB

Open AccessArticle

Effect of Residual Stress and Microstructure on the Fatigue Crack Growth Behavior of Aluminum Friction Stir Welded Joints

by Yanning Guo and Peiyao Li

Materials 2024, 17(2), 385; https://doi.org/10.3390/ma17020385 - 12 Jan 2024

Viewed by 1241

Abstract

Friction stir welding (FSW) has been adopted in the aerospace industry for fabricating structural alloys due to the low melting point and high thermal conductivity of aviation aluminum alloys. However, welding residual stresses can lead to secondary deformation in friction stir welded (FSWed) structures. Additionally, microstructural characteristics impact the crack growth rates and directions in these structures. Therefore, it is necessary to investigate the effects of residual stress and microstructure on the fatigue responses of FSWed joints. In this paper, we studied the fatigue crack growth behavior of two homogeneous and dissimilar FSWed joints with varying welding parameters, namely 2024-T3 and 7075-T6. The residual stresses were measured with the X-ray diffraction method. The dislocations and precipitates in different zones of the FSWed joints were analyzed via transmission electron microscopy (TEM). The results demonstrated that the residual stress significantly affected the fatigue crack growth rate and direction; the tensile residual stress promoted fatigue crack growth and offset the decrease in the fatigue crack growth rate that occurred due to grain refinement. The results of the microstructural analysis indicated that dislocation density and sliding resistance increased with the decrease in rotational speed and led to a decreased rate of fatigue crack propagation. Full article

(This article belongs to the Special Issue Use of Modern Materials in Technological Processes Accompanied by Frictional Heating (Volume II))

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25 pages, 3290 KiB

Open AccessArticle

The Mutual Influence of Thermal Contact Conductivity and Convective Cooling on the Temperature Field in a Tribosystem with a Functionally Graded Strip

by Aleksander Yevtushenko, Katarzyna Topczewska and Przemysław Zamojski

Materials 2023, 16(22), 7126; https://doi.org/10.3390/ma16227126 - 10 Nov 2023

Cited by 2 | Viewed by 955

Abstract

An analytical model to find the temperature field that has been developed for friction systems consists of a strip and semi-space. The strip is made of a two-component functionally graded material (FGM) with an exponentially changing coefficient of thermal conductivity. In contrast, the material of the semi-space is homogeneous. An appropriate boundary-value problem of heat conduction with constant specific friction power was formulated and solved using the Laplace integral transform method. The model takes into consideration the imperfect thermal friction contact between the strip and the semi-space, and also the convective cooling on the exposed surface of the strip. The appropriate asymptotic solutions to this problem for low and high values of Fourier number were obtained. It is shown how the determined exact solution can be generalized using Duhamel’s formula for the case of a linearly reduction in time-specific friction power (a braking process with constant deceleration). Numerical analysis for selected materials of the friction pair was carried out in terms of examining the mutual impact on the temperature of the two Biot numbers, characterizing the intensity of the thermal contact conductivity and convective heat exchange on the exposed surface of the strip. The obtained results can be used to predict the temperature of friction systems containing elements made of FGM. In particular, such systems include modern disc braking systems. Full article

(This article belongs to the Special Issue Use of Modern Materials in Technological Processes Accompanied by Frictional Heating (Volume II))

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18 pages, 2378 KiB

Open AccessArticle

Effect of Convective Cooling on the Temperature in a Friction System with Functionally Graded Strip

by Aleksander Yevtushenko, Michał Kuciej, Katarzyna Topczewska and Przemysław Zamojski

Materials 2023, 16(15), 5228; https://doi.org/10.3390/ma16155228 - 25 Jul 2023

Cited by 1 | Viewed by 1476

Abstract

An exact solution of the boundary-value problem of heat conduction was obtained with consideration of heat generation due to friction and convective cooling for the strip/semi-space system. Analytical solutions to this problem are known for the case with both friction elements made of homogeneous materials or a composite layer with a micro-periodic structure. However, in this study, the strip is made of a two-component functionally gradient material (FGM). In addition, the exact, asymptotic solutions were also determined at small and large values of the Fourier number. By means of Duhamel’s theorem, it was shown that the developed solution for a constant friction power allows to obtain appropriate solutions with a changing time profile of this value during heating. Numerical analysis in dimensionless form was carried out for the FGM (ZrO₂—Ti-6Al-4V) strip in combination with the cast iron semi-space. The influence of the convective cooling intensity (Biot number) on the temperature field in the considered friction system was investigated. The developed mathematical model allows for a quick estimation of the maximum temperature of systems, in which one of the elements (FGM strip) is heated on the friction surface and cooled by convection on the free surface. Full article

(This article belongs to the Special Issue Use of Modern Materials in Technological Processes Accompanied by Frictional Heating (Volume II))

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20 pages, 3279 KiB

Open AccessArticle

Influence of Functionally Graded Protective Coating on the Temperature in a Braking System

by Aleksander Yevtushenko, Katarzyna Topczewska and Przemysław Zamojski

Materials 2023, 16(12), 4308; https://doi.org/10.3390/ma16124308 - 10 Jun 2023

Cited by 2 | Viewed by 1567

Abstract

A mathematical model of heat generation due to friction in a disc–pad braking system was developed with consideration of a thermal barrier coating (TBC) on the friction surface of the disc. The coating was made of functionally graded material (FGM). The three-element geometrical scheme of the system consisted of two homogeneous half-spaces (pad and disc) and a functionally graded coating (FGC) deposited on the friction surface of the disc. It was assumed that the frictional heat generated on the coating-pad contact surface was absorbed to the insides of friction elements along the normal to this surface. Thermal contact of friction between the coating and the pad as well as the heat contact between the coating and the substrate were perfect. On the basis of such assumptions, the thermal friction problem was formulated, and its exact solution was obtained for constant and linearly descending specific friction power over time. For the first case, the asymptotic solutions for small and large values of time were also found. A numerical analysis was performed on an example of the system containing a metal ceramic (FMC-11) pad, sliding on the surface of a FGC (ZrO₂–Ti-6Al-4V) applied on a cast iron (ChNMKh) disc. It was established that the application of a TBC made of FGM on the surface of a disc could effectively reduce the level of temperature achieved during braking. Full article

(This article belongs to the Special Issue Use of Modern Materials in Technological Processes Accompanied by Frictional Heating (Volume II))

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19 pages, 1933 KiB

Open AccessArticle

Use of Functionally Graded Material to Decrease Maximum Temperature of a Coating–Substrate System

by Aleksander Yevtushenko, Katarzyna Topczewska and Przemysław Zamojski

Materials 2023, 16(6), 2265; https://doi.org/10.3390/ma16062265 - 11 Mar 2023

Cited by 9 | Viewed by 1924

Abstract

A mathematical model for determining the temperature distribution in the system consisting of a coating deposited on the surface of substrate was proposed. The foundation material is homogeneous, while the coating is made of a functionally gradient material (FGM) with thermal conductivity increasing exponentially along the thickness. Heating processes of the outer surface of the coating were considered with a constant and linearly decreasing in time intensity of the heat flux. Such thermal loads are common in thermal problems of friction, particularly regarding frictional heating during braking. An exact (in quadrature) solution of the corresponding boundary-value problems of parabolic heat conduction was obtained. Asymptotic solutions to these problems were also found for small and large values of the Fourier number. Calculations were performed for a coating made of two-component FGM ZrO₂—Ti-6Al-4V, applied on a cast iron substrate. In order to explain the effect of FGM on temperature, corresponding analysis was carried out for the coating made of a homogeneous (ZrO₂) material. Full article

(This article belongs to the Special Issue Use of Modern Materials in Technological Processes Accompanied by Frictional Heating (Volume II))

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