Search Results (37)

High-density polyethylene (HDPE) is a widely used thermoplastic known for its chemical resistance and ease of processing, but it has limited wear performance and moderate mechanical properties. In this study, recycled polyvinyl butyral (rPVB) was incorporated into HDPE at 5, 10, 15, and 20 wt.% to evaluate its effect on tribological performance. Pin-on-disk wear tests were conducted at 12, 15, and 18 N to assess the coefficient of friction (CoF) and wear resistance. Mean CoF values decreased by up to 40% with rPVB addition, with the best performance observed at 15 wt.% rPVB, although some variation was observed across replicates. SEM analysis revealed that rPVB promotes finer debris and transfer film formation, explaining the CoF reduction. However, wear resistance exhibited a complex trend: while rPVB improved adhesion and reduced material loss at lower loads, volume loss increased at higher loads, likely due to rPVB’s lower hardness. Mechanical testing showed an increase in elastic modulus at low rPVB contents due to higher crystallinity, confirmed by DSC; however, tensile strength and impact resistance decreased with rPVB. The results suggest that incorporating 10–15 wt.% of rPVB into HDPE can enhance frictional performance without severely compromising mechanical integrity, offering a sustainable way to valorize rPVB. Full article

This article compares the properties of the diamond-like carbon (DLC) coating with those of ZrN and (Zr,Hf)N coatings deposited on the Ti-6Al-4V titanium alloy substrate. To improve substrate adhesion during the deposition of the DLC coating, preliminary etching with chromium ions was conducted, ensuring the formation of a chromium-saturated diffusion surface layer in the substrate. A Si-DLC layer followed by a pure DLC layer was then deposited. The hardness of the coatings, their surface morphology, fracture strength in the scratch test, and tribological properties and wear resistance in the pin-on-disk test in contact with Al₂O₃ and steel indenters were investigated. The structure of the DLC coating was studied using transmission electron microscopy, and its corrosion resistance in an environment simulating blood plasma was also investigated. In the pin-on-disk test in contact with Al₂O₃ and AISI 52100 indenters, the DLC-coated sample demonstrates a much lower friction coefficient and significantly better wear resistance compared to the nitride-coated and uncoated samples. Both nitride coatings—(Zr,Hf)N and ZrN—and the DLC coating slow down the corrosive dissolution of the base compared to the uncoated sample. The corrosion currents of the (Zr,Hf)N-coated samples are 37.01 nA/cm², 20% higher than those of the ZrN-coated samples. The application of (Zr,Hf)N, ZrN, and DLC coatings on the Ti-6Al-4V alloy significantly inhibits dissolution currents (by 30–40%) and increases polarization resistance 1.5–2.0-fold compared to the uncoated alloy in 0.9% NaCl at 40 °C. Thus, the DLC coating of the described structure simultaneously provides effective wear and corrosion resistance in an environment simulating blood plasma. This coating can be considered in the manufacture of medical products (in particular, implants) from titanium alloys, including those functioning in the human body and subject to mechanical wear (e.g., knee joint endoprostheses). Full article

Considering energy conservation and emission reductions, lightweight automobiles have become a research focus in the automotive industry. Steel/aluminum joining is regarded as an ideal lightweight structure, which can not only reduce the energy consumption but also ensure safety and is already attracting extensive attention. In this study, aluminum alloy 6061 and B410LA steel sheets were successfully joined by refill friction stir spot welding. The tensile properties, microhardness distribution and interfacial microstructure characteristics of the steel/Al welded joints were investigated. The maximum tensile load of the steel/Al joint was 4.3 kN. The mechanical properties of the steel/Al refill friction stir spot welded joint were largely determined by the bonding quality of the sleeve-plunging zone. With the stirring of the sleeve and the pin during the refill friction stir spot welding, work hardening occurred in the stir zone (SZ). The microhardness of the SZ was significantly higher than that of the steel base metal (BM) and could be detected on the steel side. The Fe-Al intermetallic compound (IMC) layer was continuously distributed at the interface of the sleeve-plunging zone, revealing good uniformity in the thickness. In particular, a hook-and-vortex-like structure formed during the refill friction stir spot welding process in the sleeve-plunging zone, producing a mechanical interlock effect at the interface. The ideal mechanical properties of the welded joint could be attributed to the good quality of the metallurgical and mechanical bonding at the interface, especially the mechanical interlock effect, thereby depending on the hook-and-vortex-like structure. Full article

During petroleum drilling, the reciprocating motion in the seal device leads to piston and sleeve wear, which may cause leakage of the sealing medium. Selecting appropriate materials for the piston and sleeve, along with surface modifications, can effectively prolong the seal service life of the seal. The friction and wear properties of piston and sleeve pairs of different materials in a metal sealing device were simulated by the laboratory “pin-on-block” reciprocating friction test. Pins made of 45# steel, 35CrMo, and 20Cr13 were used to simulate piston bulges, while 35CrMo samples were used to simulate sleeves. Additionally, the influence of DLC (diamond-like carbon) coating and QPQ (Quench–Polish–Quench) nitriding on the wear resistance of the materials was studied. Based on this, the friction and wear properties, along with the wear mechanism of different material pairs, were analyzed. The results show that the friction coefficient curves of the three piston base materials and the 35CrMo sleeve are similar, and the friction coefficient of 45# steel is lower than that of 35CrMo and 20Cr13 at the initial stage. The DLC surface coating exhibited the best anti-wear performance, with the lowest friction coefficient, minimal wear, and the most stable friction coefficient. Surface QPQ nitriding treatment can also improve the wear resistance of the base material. However, due to the oxide formed during nitriding being prone to flaking, the friction coefficient fluctuates significantly at the initial stage of testing, and its anti-wear performance was inferior to that of the DLC coating. This study on material pairing and surface modification provides theoretical support for material selection and surface modification design of pistons and sleeves in oil drilling sealing devices. Full article

Polymer additive manufacturing has advanced from prototyping to producing essential parts with improved precision and versatility. Despite challenges like surface finish and wear resistance, new materials and metallic reinforcements in polymers have expanded its applications, enabling stronger, more durable parts for demanding industries like aerospace and structural engineering. This research investigates the tribological behaviour of FFF surfaces by integrating copper and aluminium reinforcement particles into a PLA (polylactic acid) matrix. Pin-on-disc tests were conducted to evaluate friction coefficients and wear rates. Statistical analysis was performed to study the correlation of the main process variables. The results confirmed that reinforced materials offer interesting characteristics despite their complex use, with the roughness of the fabricated parts increasing by more than 300%. This leads to an increase in the coefficient of friction, which is related to the variation in the material’s mechanical properties, as the hardness increases by more than 75% for materials reinforced with Al. Despite this, their performance is more stable, and the volume of material lost due to wear is reduced by half. These results highlight the potential of reinforced polymers to improve the performance and durability of components manufactured through additive processes. Full article

The aim of this study was to identify the areal surface parameters that correlated with lowering of sliding friction. Different ground surfaces were created on stainless steel and the lubricated sliding friction generated at the contact interface with a flat-faced aluminum pin was studied. The frictional force encountered is an order of magnitude lower for a P1200-finished surface than the other ground surfaces. Using 3D surface profilometry, a unique surface parameter ratio “Spk/Sk” was found to predict the frictional performance of these surfaces. When this surface parameter ratio was less than 1, average sliding friction was close to 0.1. When this ratio was greater than 1, the coefficient was an order of magnitude lower. Using energy dispersive spectrometry, such surfaces after wear showed the presence of a uniform dispersed layer of iron oxide on the surface of the pin. This was absent on the surfaces having high friction, indicating the role of the steel counter surface in building this beneficial transfer layer. Scanning electron microscopy provided topography images to visualize the surface wear. The motivation for the authors was to use a commercially scaled process like precision grinding for the surface modifications on stainless steel. Full article

To meet the demand for energy-efficient and, at the same time, durable, functional components, the improvement of tribological behavior is playing an increasingly important role. One approach to reducing friction in lubricated tribological systems is the microtexturing of the surfaces tailored to the application, but in most cases, this leads to increased manufacturing costs and thus often makes their use in industry more difficult. In this work, we, therefore, present an approach for an efficient design and fully integrated production process using a cam tappet as an example. For the used cam tappet contact, we first determined the optimal texture geometries using two differently complex EHL (elastohydrodynamic lubrication) simulation models. Based on these, textured tappets were manufactured in a combined manner using sheet-bulk metal-forming and deposition with a diamond-like-carbon (DLC) coating for additional wear protection without further post-processing of the coating. We show that the simulation approach used has a rather subordinate influence on the optimization result. The combined forming of components with textured surfaces is limited by the local material flow, the resulting texture distortion, and tool wear. However, a targeted process design can help to exploit the potential of single-stage forming. The applied DLC coating has good adhesion and can completely prevent wear in subsequent reciprocal pin-on-disc tests, while the friction in the run-in behavior is initially higher due to the soothing effects of the coating. The experiments also show a tendency for shallow textures to exhibit lower friction compared to deeper ones, which corresponds to the expectations from the simulation. Full article

The reduction of friction-induced noise is a crucial research area for enhancing vehicle comfort, and this paper proposes a method based on circular pit texture to achieve this goal. We conducted a long-term sliding friction test using a pin-on-disc friction and a wear test bench to verify the validity of this method. To compare the friction noise of different surfaces, texture units with varying line densities were machined on the surface of friction disk samples. The resulting friction-wear and noise characteristics of the samples were analyzed in conjunction with the microscopic morphology of the worn surfaces. The results indicate that surfaces with textures can delay the onset of squeal noise, and the pattern of its development differs from that of smooth surfaces. The noise reduction effect is most evident due to the proper distribution of textures that can form furrow-like wear marks at the wear interface. The finite element results demonstrate that this morphology can improve pressure distribution at the leading point and reduce the tendency of system instability. Full article

Carbon fiber-reinforced polymers (CFRPs) are being used extensively in modern industries that require a high strength-to-weight ratio, such as aerospace, automotive, motorsport, and sports equipment. However, although reinforcement with carbon fibers improves the mechanical properties of polymers, this comes at the expense of abrasive wear resistance. Therefore, to efficiently utilize CFRPs in dry sliding contacts, solid lubricant is used as a filler. Further, to facilitate the fabrication of objects with complex geometries, selective laser sintering (SLS) can be employed. Accordingly, in the present work, graphite-filled carbon fiber-reinforced polyamide 12 (CFR-PA12) specimens were prepared using the SLS process to explore the dry sliding friction and wear characteristics of the composite. The test specimens were aligned along four different orientations in the build chamber of the SLS machine to determine the orientation-dependent tribological properties. The experiments were conducted using a pin-on-disc tribometer to measure the coefficient of friction (COF), interface temperature, friction-induced noise, and specific wear rate. In addition, scanning electron microscopy (SEM) of tribo-surfaces was conducted to specify the dominant wear pattern. The results indicated that the steady-state COF, contact temperature, and wear pattern of graphite-filled CFR-PA12 are orientation-independent and that the contact temperature is likely to approach an asymptote far below the glass transition temperature of amorphous PA12 zones, thus eliminating the possibility of matrix softening. Additionally, the results showed that the Z-oriented specimen exhibits the lowest level of friction-induced noise along with the highest wear resistance. Moreover, SEM of tribo-surfaces determined that abrasive wear is the dominant wear pattern. Full article

This paper investigates the interaction of edge dislocations with voids in concentrated solid solution alloys (CSAs) using atomistic simulations. The simulation setup consists of edge dislocations with different periodicity lengths and a periodic array of voids as obstacles to dislocation motion. The critical resolved shear stress (CRSS) for dislocation motion is determined by static simulations bracketing the applied shear stress. The results show that shorter dislocation lengths and the presence of voids increase the CRSS for dislocation motion. The dislocation–void interaction is found to follow an Orowan-like mechanism, where partial dislocation arms mutually annihilate each other to overcome the void. Solute strengthening produces a ‘friction stress’ that adds to the Orowan stress. At variance with classical theories of solute pinning, this stress must be considered a function of the dislocation line length, in line with the idea that geometrical constraints synergetically enhance the pinning action of solutes. Modifying the equation by Bacon, Kocks and Scattergood for void strengthening to account for the solute hardening in CSAs allows one to quantitatively predict the CRSS in the presence of voids and its dependency on void spacing. The predictions show good agreement with the simulation data without invoking any fit parameters. Full article

The key objective of the presented study was to use a commercially feasible and scalable approach to modifying surfaces to reduce friction. In an industrial setting, surface grinding is commercially viable and scalable as compared to other surface modifying processes like laser surface texturing, plasma, or ion beam milling. Frictional force plots are generated from the lubricated contact interface between a flat-faced aluminum pin and a reciprocating stainless steel countersurface driven by a scotch yoke follower mechanism. Using a surface grinder and selecting coated abrasive sheets, different stainless steel surface specimens, classified as P320, P1200, and mirror were prepared and tested in this study. The frictional force encountered by the pin was recorded using a data acquisition system at discrete intervals in the reciprocating path and averaged along the sliding cycles. The shape of the frictional force plots thus generated were found to be different from each other. Various mechanisms of friction prevalent at the contact were presumed to influence the shape of these frictional plots. These mechanisms were tested by varying the sliding speeds, lubricating oil viscosities, and using tribofilm-forming additives. We used Group 1 base oil of two different viscosities in our tests. At lower speeds, the frictional force plot for the mirror-finished surface seemed to conform to the Stribeck curve, while in the same scale of reference, the P1200 surface had a force plot that was nearly flat and of very low magnitude. At the contact interface, there seemed to be a fine balance existing between adhesion and abrasion phenomena, while oil retention was promoted to achieve extremely low sliding friction. Full article

This study focused on investigating the adhesion and tribological properties of niobium-doped titanium nitride (TiNbN) coatings deposited on D2 steel substrates at various substrate temperatures (Ts) under simulated cutting conditions. X-ray diffraction confirmed the presence of coatings with an FCC crystalline structure, where Nb substitutes Ti atoms in the TiN lattice. With increasing Ts, the lattice parameter decreased, and the crystallite material transitioned from flat-like to spherical shapes. Nanoindentation tests revealed an increase in hardness (H) with Ts, while a decrease in the elastic modulus (E) resulted in an improved elastic strain limit for failure (H/E) and plastic deformation resistance (H³/E²), thereby enhancing stiffness and contact elasticity. Adhesion analysis showed critical loads of ~50 N at Ts of 200 and 400 °C, and ~38 N at Ts of 600 °C. Cohesive failures were associated with lateral cracking, while adhesive failures were attributed to chipping spallation. The tribological behavior was evaluated using a pin-on-disk test, which indicated an increase in friction coefficients with Ts, although they remained lower than those of the substrate. Friction and wear were influenced by the surface morphology, facilitating the formation of abrasive particles. However, the absence of coating detachment in the wear tracks suggested that the films were capable of withstanding the load and wear. Full article

Bismuth oxide (Bi₂O₃) coatings and composite coatings containing this oxide have been studied due to their potential applications in gas sensing, optoelectronics, photocatalysis, and even tribology. Two parametric models based on chemical features have been proposed with the aim of predicting the lubricity response of oxides. However, such models predict contradictory values of the coefficient of friction (COF) for Bi₂O₃. In this study, we deposited Bi₂O₃ coatings, via magnetron sputtering, on AISI D2 steel substrates to evaluate the tribological responses of the coatings and determine which parametric model describes them better. Experimentally, only coatings presenting the cubic defective fluorite-like δ-Bi₂O₃ phase could be evaluated. We performed pin-on-disk tests at room temperature and progressively increasing temperatures up to 300 °C using alumina and steel counter-bodies. Low wear and COFs (0.05 to 0.15) indicated that the δ-phase behaves as a lubricious solid, favoring the validity of one of the models. An alternative explanation is proposed for the low COF of the defective fluorite-like structure since it is well known that it contains 25% of anionic vacancies that can be ordered to form low shear-strength planes, similar to the Magnéli phases. Two challenges for future potential applications were observed: one was the low adhesion strength to the substrate, and the other was the thermal stability of this phase. Full article

This paper studies the properties of the Preisach model and the play model, and compare their similarities. Both are history-dependent hysteresis models that are used to model magnetic hysteresis. They are described as discrete sums of simple hysteresis operators but can easily be reformulated as integral equations of continuous distribution functions using either a Preisach weight distribution function or a play distribution function. The models are mostly seen as phenomenological or mathematical tools but can also be related to friction-like pinning of domain-wall motions, where Rayleigh’s law of magnetic hysteresis can be seen as the simplest case on either the play model or the Preisach model. They are poor at modeling other domain behavior, such as nucleation-driven hysteresis. Yet another hysteresis model is the stop model, which can be seen as the inverted version of the play model. This type of model has advantages for expressions linked to energy and can be related to Steinmetz equation of hysteresis losses. The models share several mathematical properties, such as the congruency property and wiping-out property, and both models have a history of dependence that can be described by the series of past reversal points. More generally, it is shown that the many models can be expressed as Preisach models, showing that they can be treated as subcategories of the Preisach type models. These include the play model, the stop model and also the alternative KP-hysteron model. Full article

The friction stir process (FSP) is becoming a highly utilized method to manufacture composites since it refines the microstructure and improves the physical characteristics like hardness, strength, and wear resistance of their surfaces. In this study, the hardness and wear behaviours of Al6061-based surface composites prepared by the FSP were investigated and compared for the influences of various parameters—FSP tool geometry, reinforcement composition, number of FSP passes, pin load, etc. The Taguchi design with an L27 orthogonal array was developed to analyze the influence of five input parameters on the output parameter, i.e., wear rate during wear tests. The hardness of the composite samples for different reinforcement compositions was investigated, and the results were statistically compared with the obtained wear rates. It was concluded from the results that various parameters influenced the surface wear and hardness of the composites. Tool geometries cylindrical pin and square pin had the maximum and minimum wear rates, respectively. Additionally, the optimal composition of the reinforcements copper and graphene as 1:3 possessed the maximum wear rate and minimum hardness. However, the reinforcement composition 3:3 (Cu:Gr) by weight had the minimum wear rate and maximum hardness. The higher the FSP pass numbers, the lesser the wear rate and the higher the hardness, and vice-versa. This work helps identify the influence of numerous factors on the wear and hardness aspects of surface composites prepared by the FSP. In the future, this study can be modified by combining it with thermal analysis, sensor data analysis of the composites, and optimization of the parameters for desirable microstructure and physical properties. Full article