Influence of Fly Ash and Emery based particulate reinforced AA7075 surface composite processed through friction stir processing

The novel friction stir technology is adopted in modern automotive industries to meet the desired properties like hardness, impact toughness and tribological behaviour over the conventional techniques like stir casting, compo casting, squeeze casting, electroplating and infiltration methods. AA7075 surface composites fabricated with different volume fractions of fly ash and emery particles is said to enhance the aforementioned properties. The composites are processed through friction stir process (rotational speed −1200 rpm, transverse speed – 56 mm/min, tool tilt angle – 2 °). During characterization, the Microstructural examination of surface composites depicts fine and homogenous distribution of reinforcements in the friction stir process region owing to severe plastic deformation and dynamic recrystallization process. Substantially, good interface is formed between the reinforcement particulates and base substrate. Inclusion of Fe3O4, Al2O3 and SiO2 constituents through fly ash and emery reinforcements associated with the homogenous dispersion strengthening mechanism favours for the superior hardness of surface hybrid composite specimen 50E50FA. Decremented grain size and load bearing capacity of the reinforcements is beneficial for the crack propagation resistance that enhances the impact toughness behaviour (17.4 J/cm2) of the same specimen. Wear rate of the specimens are evaluated through pin on disc tribometer. The decrease in the wear rate of hard specimen 50E50FA is observed due to the reduced contact area between its surface and counter disc. The morphology of worn specimens using SEM analysis shows the combined abrasive and adhesive wear as the worn mechanism.

Ionic Liquid Additives in Water-Based Lubricants for Bearing Steel – Effect of Electrical Conductivity and pH on Surface Chemistry, Friction and Wear

Water-based lubricants have the potential to become the largest environmentally friendly lubricants in applications such as electric vehicles and the newly emerging green technologies of the future due to their inherent low viscosity and cooling properties. In order to be environmentally acceptable (EAL), both base lubricants and additives should comply with biodegradability, non-toxicity, and non-bioaccumulation requirements. Additives for water-based lubricants should ideally be polar and soluble in water and, at the same time, should not increase the electrical conductivity to critical levels for corrosion. However, most additives used in synthetic or mineral oils are non-polar. Ionic liquids have recently gained attention as lubricant additives due to their high polarity, making them highly surface-active (i.e. high tendency to adsorb on metal surfaces). However, they are seen as highly corrosive for many metal alloys. In this work, a water-glycol lubricant containing two different ionic liquids has been investigated as a potential green lubricant for a bearing steel AISI 52100 with accurate control on electrical conductivity and pH. The selected ionic liquids were tributylmethylphosphonium dimethylphosphate (PP) and 1-butyl-1-methylpyrrolidinium tris(pentafluoroethyl)trifluorophosphate (BMP). The tribological behaviour of the ionic liquids was compared with a well-known organic friction modifier, dodecanoic acid (C12). The ionic liquids showed lower friction and wear rate than the water-based lubricant alone. However, they showed higher friction than the lubricant formulated with C12, in which PP gave lower friction than BMP due to low pH. A detailed subsurface analysis of the wear track using scanning-transmission electron microscopy (STEM) showed that a thick oxide tribofilm was built on the wear track for both lubricants formulated with ionic liquids due to high electrical conductivity. This tribofilm gave beneficial effect on wear. Although PP and BMP gave thicker tribofilms than C12, it was not durable, resulting in cracking and detachment.

Effect of Coating Bath Parameters on Properties of Electroless Nickel-Boron Alloy Coatings

Electroless nickel-boron binary coatings were obtained with various bath compositions to investigate the effect of bath parameters on tribological and mechanical behaviours of the coating. Characterisation of the coating for surface morphology and phase structure is done using Scanning Electron Microscopy (SEM) and X-ray Diffraction (XRD), respectively, whereas tribological behaviour of coatings is evaluated on a pin-on-disc tribo-tester. Elastic modulus and surface hardness of coatings have been obtained using nano-indentation technique, while the scratch behaviour of the coatings has been determined using micro-scratch test. Corrosion resistance of coatings is also determined. It is observed that surface roughness of the coatings increased with increase in sodium borohydride concentration but decreased slightly with increase in nickel chloride concentration. Friction and wear characteristics are found to increase with surface roughness which occurs due to increased boron content. Surface hardness and scratch hardness are also seen to vary with coating bath parameters.

Dimensional Stability of Low Temperature Surface Hardened Stainless Steel Components*

Stainless steels are commonly used for high precision components, which often are exposed to corrosive media. However, their inferior tribological behaviour restrict the use of these materials in many technical applications. Thermochemical surface hardening is one way to overcome these weaknesses. Solution nitriding in the austenitic range above 1000 °C is mainly used for hardening martensitic and ferritic stainless grades. In austenitic and duplex stainless grades, however, the hardening effect is limited. Additionally, the high process temperatures combined with a necessary rapid cooling may lead to non-desired dimensional changes. Low temperature surface hardening processing below 500 °C here offers interesting alternatives for increasing the wear properties, while maintaining the corrosion resistance. This paper demonstrates the influence of high and low process temperatures of thermochemical surface hardening treatments on the tight dimensional tolerances of a rotationally symmetrical precision component made from cold worked AISI 304. Based on these results, current and new industrial applications, which benefit from low temperature surface hardening, will be discussed.

Effect of Microstructure and Hardness on Cavitation Erosion and Dry Sliding Wear of HVOF Deposited CoNiCrAlY, NiCoCrAlY and NiCrMoNbTa Coatings

Metallic coatings based on cobalt and nickel are promising for elongating the life span of machine components operated in harsh environments. However, reports regarding the ambient temperature tribological performance and cavitation erosion resistance of popular MCrAlY (where M = Co, Ni or Co/Ni) and NiCrMoNbTa coatings are scant. This study comparatively investigates the effects of microstructure and hardness of HVOF deposited CoNiCrAlY, NiCoCrAlY and NiCrMoNbTa coatings on tribological and cavitation erosion performance. The cavitation erosion test was conducted using the vibratory method following the ASTM G32 standard. The tribological examination was done using a ball-on-disc tribometer. Analysis of the chemical composition, microstructure, phase composition and hardness reveal the dry sliding wear and cavitation erosion mechanisms. Coatings present increasing resistance to both sliding wear and cavitation erosion in the following order: NiCoCrAlY < CoNiCrAlY < NiCrMoNbTa. The tribological behaviour of coatings relies on abrasive grooving and oxidation of the wear products. In the case of NiCrMoNbTa coatings, abrasion is followed by the severe adhesive smearing of oxidised wear products which end in the lowest coefficient of friction and wear rate. Cavitation erosion is initiated at microstructure discontinuities and ends with severe surface pitting. CoNiCrAlY and NiCoCrAlY coatings present semi brittle behavior, whereas NiCrMoNbTa presents ductile mode and lesser surface pitting, which improves its anti-cavitation performance. The differences in microstructure of investigated coatings affect the wear and cavitation erosion performance more than the hardness itself.

Experimental and modelling studies of the transient tribological behaviour of a two-phase lubricant under complex loading conditions

The transient tribological phenomenon and premature lubricant breakdown have been widely observed in metal forming, leading to excessive friction at the contact interfaces. In this research, the transient tribological behaviour of a two-phase lubricant were studied under complex loading conditions, featuring abrupt interfacial temperature, contact load, and sliding speed changes, thus representing the severe interfacial conditions observed in warm/hot metal forming applications. The strong experimental evidence indicates that the evolution of friction was attributed to the physical diminution and chemical decomposition effects. As such, a visco-mechanochemical interactive friction model was developed to accurately predict the transient tribological behaviour of the two-phase lubricant under complex loading conditions. The new friction model exhibited close agreements between the modelling and experimental results.

Fabrication and characterization of composite MoS2-TiO2 coating material

Molybdenum disulphide (MoS2) is a popularly used solid lubricant in various applications due to its superior tribological behaviour. However, it possesses poor wear resistance which requires further improvement. In the present study efforts have been made to enhance the tribological properties of pure MoS2 coating film by doping TiO2 nanoparticles as a reinforcement material. The Manganese phosphating is selected as a pre-treatment method to improve the bond strength between coating and substrate. The coating is bonded with the substrate material employing sodium silicate as a binder. The effects of wt. % of TiO2 onto the mechanical properties of composite MoS2-TiO2 coating such as hardness and bond strength have been studied. In addition coating microstructure before and after experimental test was studied using optical microscope and scanning electron microscope. It was also found that with increase in wt. % addition of TiO2 upto 15% into MoS2 base matrix, the hardness of coating increases proportionally. Beyond 15 wt. % addition of TiO2, the coating becomes brittle in nature. This leads to reduction in the scratch resistance.