Search results

This paper aims to compare the wear behavior, surface roughness, friction coefficient and volume loss of high-velocity oxy-fuel (HVOF) sprayed WC–Co and WC–Cr₃C₂–Ni coatings on AISI 1095 steel with spraying times of 10 and 15 s.

In this study, the pin-on-disc testing technique was used to evaluate the wear characteristics at a speed of 0.24 m/s, load of 40 N and test time of 60 min under dry conditions at room temperature. The wear characteristics were examined and analyzed by scanning electron microscopy and energy dispersive X-ray spectroscopy. The surface roughness of a coated surface was measured, and microhardness measurements were performed on the cross-sectioned and polished surfaces of the coating.

Spraying time and powder material affected the hardness of HVOF coatings due to differences in the porosity of the coated layers. The average hardness of the WC–Cr₃C₂–Ni coating with a spaying time of 15 s was approximately 14% higher than that of the WC–Cr₃C₂–Ni coating with a spraying time of 10 s. Under an applied load of 40 N, the WC–Co coating with a spraying time of 15 s had the lowest variation in the friction coefficient compared with the other coatings. The WC–Co coating with a spraying time of 10 s had the lowest average and variation in volume loss compared to the other coatings. The WC–Cr₃C₂–Ni coating with a spraying time of 10 s exhibited the highest average volume loss. The wear features changed slightly with the spraying time owing to variations in the hardness and friction coefficient.

This study investigated tribological performance of WC–Co; WC-Cr₃C₂-Ni coatings with spraying times of 10 and 15 s using pin-on-disc tribometer by rotating the relatively soft pin (C45 steel) against hard coated substrate (disc).

The purpose of this study is therefore to detail an additive manufacturing process for printing TiD parts for implant applications. Titanium–diamond (TiD) is a new composite that provides biocompatible three-dimensional multimaterial structures. Thus, the authors report a powder-deposition and print optimization strategy to overcome the dual-functionality gap by printing bulk TiD parts. However, despite favorable customization outcomes, relatively few additive manufacturing (AM) feedstock powders offer the biocompatibility required for medical implant and device technologies.

AM offers a platform to fabricate customized patient-specific parts. Developing feedstock that can be 3D printed into specific 3D structures while providing a favorable interface with the human tissue remains a challenge. Using laser metal deposition, feedstock powder comprising diamond and titanium was co-printed into TiD parts for mechanical testing to determine optimal manufacturing parameters.

TiD parts were fabricated comprising 30% and 50% diamond. The composite powder had a Hausner ratio of 1.13 and 1.21 for 30% and 50% TiD, respectively. The flow analysis (Carney flow) for TiD 30% and 50% was 7.53 and 5.15 g/s. The authors report that the printing-specific conditions significantly affect the integrity of the printed part and thus provide the optimal manufacturing parameters for structural integrity as determined by micro-computed tomography, nanoindentation and biocompatibility of TiD parts. The hardness, ultimate tensile strength and yield strength for TiD are 4–6 GPa (depending on build position), 426 MPa and 375 MPa, respectively. Furthermore, the authors show that increasing diamond composition to 30% results in higher osteoblast viability and lower bacteria count than titanium.

In this study, the authors provide a clear strategy to manufacture TiD parts with high integrity, performance and biocompatibility, expanding the material feedstock library and paving the way to customized diamond implants. Diamond is showing strong potential as a biomedical material; however, upscale is limited by conventional techniques. By optimizing AM as the avenue to make complex shapes, the authors open up the possibility of patient-specific diamond implant solutions.

This paper aims to improve the corrosion resistance of AH36 carbon steel, an epoxy resin (EP)-based superhydrophobic coating was prepared on the surface of AH36 carbon steel.

The hydroxylated multi-walled carbon nanotubes were used as nanocontainers, and the corrosion inhibitor L-proline was loaded by negative pressure method and then modified it with 3-aminopropyltriethoxysilane and 3-mercaptopropyltrimethoxysilane, got functionalized hydroxy carbon nanotubes (KH-CNTs@LP). The KH-CNTs@LP was mixed with the EP, and the KH-CNTs@LP/EP superhydrophobic coating was successfully prepared on the surface of the AH36 carbon steel matrix by spraying.

The results showed that the water contact angle of the KH-CNTs@LP/EP superhydrophobic coating is 155.2° and the rolling angle is 5°. The KH-CNTs@LP/EP superhydrophobic coating had a good corrosion resistance in the pH = 4 corrosion environment, |Z|0.01 Hz was 7.21 × 10⁷ Ω·cm².

The KH-CNTs@LP/EP superhydrophobic coating is pH-responsive and releases L-proline, which increased the impedance of the coating and can effectively improve the protection efficiency of the coating on the metal. The active protection is provided by loaded L-proline inhibitor from KH-CNTs@LP, whereas the passive protection is achieved through the water rejection of superhydrophobic surfaces.

The aim of this study is to investigate the effects of the laser cladding process on the microstructure, hardness and corrosion resistance properties of high-entropy alloys (HEA).

Laser cladding technology was used, using AlCoCrFeNiCu HEA powder as the cladding material. HEA coatings were prepared on the surface of 45 steel using a coaxial powder feeding method. The microstructure, phase composition, hardness and corrosion resistance properties of the HEA cladding layer were analyzed using optical microscopy (OM), X-ray diffractometer, digital microhardness tester and electrochemical workstation.

Laser power affects the coating surface; lower power reveals more visible unmelted powder particles. Higher power results in increased melt width and height, a brighter, smoother surface. Phase structure remains consistent, but the coating hardness is significantly higher than the substrate. The hardness of the melted zone in the substrate peaks at approximately 890.5 HV. The cladding zone hardness is about 60 HV higher than the substrate zone. Electrochemical corrosion parameters of the cladding show that, compared to the substrate, Ecor shifts positively by 113 mV, Icor decreases by one order of magnitude and Rp increases by one order of magnitude. These results indicate that the cladding has superior corrosion resistance to the substrate. The bonding strength between the coating and the substrate is greater than 93.6 MPa.

First, based on preliminary pilot experiments, nine sets of single-factor experiments were designed. Through these experiments, a specimen with relatively favorable cross-sectional morphology was observed. This specimen was then subjected to coating research, revealing that its microstructure and properties had significantly improved compared to the substrate. This enhancement holds remarkable significance for prolonging the service life of components.

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-11-2024-0413/

Aluminum alloy is considered an ideal material in aerospace, automobile and other fields because of its lightweight, high specific strength and easy processing. However, low hardness and strength of the surface of aluminum alloys are the main factors that limit their applications. The purpose of this study is to obtain a composite coating with high hardness and lubricating properties by applying GO–PVA over MAO coating.

A pulsed bipolar power supply was used as power supply to prepare the micro-arc oxidation (MAO) coating on 6061 aluminum sample. Then a graphene oxide-polyvinyl alcohol (GO–PVA) composite coating was prepared on MAO coating for subsequent experiments. Samples were characterized by Fourier infrared spectroscopy, X-ray diffraction, Raman spectroscopy and thermogravimetric analysis. The friction test is carried out by the relative movement of the copper ball and the aluminum disk on the friction tester.

Results showed that the friction coefficient of MAO samples was reduced by 80% after treated with GO–PVA composite film.

This research has made a certain contribution to the surface hardness and tribological issues involved in the lightweight design of aluminum alloys.

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-12-2023-0427/

Two friction models of Fe-Fe and Diamond-like carbon (DLC)-Fe were established by molecular dynamics (MD) method to simulate the friction behavior of traditional fracturing pump plunger and new DLC plunger from atomic scale. This paper aims to investigate the effects of temperature and load on the friction behavior between sealed nitrile butadiene rubber (NBR) and DLC films.

In this study, MD method is used to investigate the friction behavior and mechanism of DLC film on plungers and sealing NBR based on Fe-Fe system and DLC-Fe system.

The results show that the friction coefficient of DLC-Fe system exhibits a downward trend with increasing load and temperature. And even achieve a superlubricity state of 0.005 when the load is 1 GPa. Further research revealed that the low interaction energy between DLC and NBR promoted the proportion of atoms with larger shear strain in NBR matrix and the lower Fe layer in DLC-Fe system to be much lower than that in Fe-Fe system. In addition, the application of DLC film can effectively inhibit the temperature rise of friction interface, but will occur relatively large peak velocity.

In this paper, two MD models were established to simulate the friction behavior between fracturing pump plunger and sealing rubber. Through the analysis of mean square displacement, atomic temperature, velocity and Interaction energy, it can be seen that the application of DLC film has a positive effect on reducing the friction of NBR.

This study aims to research the erosion wear characteristics and sealing performance of V-regulating ball valve in coal chemical process pipelines, which provides a theoretical reference for improving its antiwear and sealing performance.

Taking the V-regulating ball valve as the research object, based on the computational fluid dynamics and the theory of erosion wear, the authors studied its erosion characteristics under different medium parameters and analyzed the sealing performance under the heat-fluid–solid coupling working condition.

The erosion wear mechanism of the valve sealing surface is the simultaneous action of cutting and deformation. When the medium flow velocity, particle mass flow rate and particle size increase, the maximum erosion rate and average erosion rate in the V-regulating valve increase. The inner diameter Mises contact stress of the sealing surface is symmetrically distributed in a “wing shape,” and the contact stress of the outer diameter is distributed in a “butterfly shape.” Due to the superposition of thermal stress and pressure stress in the contact transition zone to produce a significant stress concentration.

The findings will provide a theoretical basis for improving the erosion resistance and sealing performance of V-regulating ball valve in coal chemical industry.

V-type regulating ball valve is widely favored by coal chemical enterprises and petrochemical enterprises because of its wide adjustment ratio and good erosion resistance.

The V-regulating ball valve wear mechanism for cutting and deformation simultaneously, and its wear rate is positively correlated with the medium flow rate, particle mass flow rate and particle size. After the valve is opened, there is a significant stress concentration occurs in the contact transition zone due to the superposition of thermal stress and compressive stress. The findings will provide a theoretical basis for improving the erosion resistance and sealing performance of V-regulating ball valve in coal chemical industry.

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-06-2024-0205/

The purpose of this paper is to develop a new type of embedded solid self-lubricating thrust ball bearing for conditions where grease lubrication cannot be used and to analyze its tribological performance under different lubrication characteristics (lubrication position, width and filling amount).

Lubrication parameters such as position (a), width (W) and filling amount (Q) were considered. Grooves were made on the raceway with a fiber laser and solid self-lubricating materials were applied through scraping. The frictional behavior of the new bearing was analyzed using a vertical test rig and the bearing’s surface topography was examined with a noncontact profilometer to study wear mechanisms.

The new inlay thrust ball bearings exhibited excellent lubrication effects and effectively controlled the temperature rise of the bearings. When a is 0 degrees, W is 0.5 mm and Q is 16 mg, the bearing experiences the least wear, and the friction coefficient and temperature are the lowest, measuring 0.001 and 41.52 degrees, respectively. Under the same experimental conditions, compared to smooth bearings without solid lubrication, the friction coefficient decreased by 96.88% and the temperature decreased by 59.74%.

This study presents a self-lubricating thrust ball bearing designed for conditions where grease lubrication is not feasible. A comprehensive investigation was conducted on its surface morphology, wear mechanisms and tribological performance. This work provides valuable insights into the research of self-lubricating thrust ball bearings.

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-03-2024-0073/

This study aims to investigate the erosion wear rate of a stainless steel automobile exhaust manifold, both computationally and physically.

The experiment was performed on a motorcycle exhaust manifold as well as on a 3D model, created using SolidWorks 2022 CAD software. The analysis was later achieved using ANSYS 19.2 simulation software using Fluent – code.

The analysis of solid particle erosion in the exhaust manifold revealed that erosion wear is concentrated predominantly at the extrados of the manifold, with the most significant wear occurring at the lowermost bend. The erosion wear rate increases with larger particulate sizes and varies among bends, with negligible wear observed in straight pipes. The SEM analysis further confirmed surface degradation, with rugged textures, pits and grooves indicating abrasive wear. Spine-like structures and fractured soot particles suggest erosive and abrasive forces caused by high-speed contact of exhaust gas compounds. Energy dispersive X-ray spectroscopy revealed significant carbon abundance, indicating carbonaceous compounds from fuel combustion, along with notable amounts of oxygen and iron, typical of oxidized metallic constituents. The discrete phase modeling (DPM) analysis highlighted peak particulate matter deposition at the first bend exit, with maximum concentrations observed at specific angles. This deposition is influenced by centrifugal force, leading to increased PM concentration at outer bend walls. Velocity magnitude contours showed asymmetrical flow profiles, with high turbulence levels and secondary flow induced by centrifugal effects in bend areas. Dynamic pressure contours revealed varying pressures at intrados and extrados, with maximum pressure observed at the intrados of the manifold’s bends. These findings provide valuable insights into erosion wear, particulate dispersion and flow dynamics within the exhaust manifold.

The study investigated an automobile exhaust manifold model using ANSYS Fluent code and DPM to analyze erosion wear rate phenomena and its various constituents. This analysis was conducted in comparison with a physically eroded sample. The study offers insights into the mechanism underlying the exhaust manifold of an automobile.

This study aims to study the formation mechanism of micro-arc oxidation (MAO) coating on AZ31 magnesium alloy and how the annealing process affects its corrosion resistance.

This study involved immersion experiments, electrochemical experiments and slow strain rate tensile experiments, along with scanning electron microscopy, optical microscopy observation and X-ray diffraction analysis.

The findings suggest that annealing treatment can refine the grain size of AZ31 magnesium alloy to an average of 6.9 µm at 300°C. The change in grain size leads to a change in conductivity, which affects the performance of MAO coatings. The MAO coating obtained by annealing the substrate at 300°C has smaller pores and porosity, resulting in better adhesion and wear resistance.

The coating acts as a barrier to prevent corrosive substances from entering the substrate. However, the smaller pores and porosity reduce the channels for the corrosive solution to pass through the coating. When the coating cracks or falls off, the corrosive medium and substrate come into direct contact. Smaller and uniform grains have better corrosion resistance.