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Introduction To Wear: Surface Damage Removal of Material

The document discusses the main types of wear that can occur between solid surfaces in contact, including abrasive, adhesive, erosive, corrosive, fatigue, and fretting wear. It provides details on the mechanisms, factors influencing the rate of wear, and methods for preventing each type of wear.

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Selvamuthu Kumaran
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© Attribution Non-Commercial (BY-NC)
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295 views33 pages

Introduction To Wear: Surface Damage Removal of Material

The document discusses the main types of wear that can occur between solid surfaces in contact, including abrasive, adhesive, erosive, corrosive, fatigue, and fretting wear. It provides details on the mechanisms, factors influencing the rate of wear, and methods for preventing each type of wear.

Uploaded by

Selvamuthu Kumaran
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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Introduction to Wear

Wear is a process of surface damage or removal of material from one or both of two solid surfaces in solid state contact, occurring when two solid surfaces are in sliding, rolling or impact motion together. The rate of removal is generally slow, but steady and continuous

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Flow chart -various Wear Mechanisms

Wear Processes

Abrasion

Adhesion

Erosion

Corrosion

Surface Fatigue

Low Stress High Stress Gouging Polishing

Fretting Adhesive Seizure Galling Oxidative Wear

Solid & Fluid Impingement Cavitation Slurry Erosion

Pitting Spalling Impact Brinelling

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I. Abrasive wear
Abrasive wear occurs when material is removed from one surface by another harder material. Also be called scratching, gouging or scoring. These hard particles might be commercial abrasives or naturally occurring contaminates.
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Abrasive wear contd.,


Abrasive wear occurs in two conditions:

Two-body abrasive wear - A form of abrasive wear in which the hard particles that produce the wear of one body are fixed on the surface of the opposing body.
Three-body wear - A form of abrasive wear in which wear is produced by loose particles introduced or generated between the contacting surfaces.
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Abrasive wear of metals

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Microscale of Abrasion

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II. Adhesive wear


Wear due to localized bonding between contacting solid surfaces leading to material transfer between the two surfaces or loss from either surface. Often called galling or scuffing. An adequate supply of lubricant resolves the adhesive wear problem.

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Adhesive wear of metals

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Adhesive wear contd.,


In order to minimize rate of wear, we need to minimize the size of metal pieces removed. 1. Minimize the area of contact, a since a = P / y reducing the loading on the surfaces will reduce the wear. 2. Increase y i.e., hardness
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III. Erosive wear


Progressive loss of original material from a solid surface due to mechanical interaction between that surface and a fluid, multicomponent fluid, or impinging liquid or solid particles The erosive effects on materials at high temperatures is important for the selection of turbine engine materials in the aerospace industry.
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Erosive wear contd.,


Impingement or liquid drops varies greatly depending on Class of material, Material properties, and Environmental parameters Impact angle Impact velocity, and Particle size/type.

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Erosive wear contd.,

Cavitation erosion fluid becoming unstable, bubbling up and imploding against the surface of the solid. Cavitation erosion roughens a surface much.
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IV. Corrosive wear


Wear in which chemical or electrochemical reaction with the environment (dynamic interaction between the environment and mating material surfaces). Surfaces react with environment and reaction products are formed on the surface asperities (result of crack formation, and/or abrasion). This process results in increased reactivity of the asperities due to increased temperature and changes in the asperity mechanical properties.
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V. Fatigue wear
When mechanical machinery move in periodical motion, stresses to the metal surfaces occur. All repeating stresses in a rolling or sliding contact can give rise to fatigue failure. When two surfaces slide across each other, the maximum shear stress lies - causing microcracks. These cracks initiate from the point where the shear stress is maximum, and propagate to the surface. Failure is influenced by inclusions, porosity, microcracks and other factors.
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Fatigue wear contd.,

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VI. Fretting wear


Wear between two solid surfaces experiencing oscillatory relative motion of low amplitude. It occurs where there is oscillatory motion with a small displacement ( ~1 micron) of the contacting surfaces under load.

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Fretting wear contd.,

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Fatigue & Fretting wear

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Wear Prevention
To minimize the wear are,

lubricants Surface hardening treatments, and Case carburizing - engine crankshaft Ion implantation surgical instruments Hard faced ceramic coatings - turbine blades and fibre guides in the textile industry. Wear resistant materials.
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Conditions Promoting Wear

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Adhesion wear
High loads, speeds and/or temperatures Use of stainless steels or aluminum Insufficient lubricant Lack of anti-scuff additives Abrasive wear interrupting film allowing adhesion

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Abrasion wear
Hard particles contaminating oil Insufficient metal hardness Hard metal with rough surface against soft metal

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Erosive wear
High velocity containing solids surface gas or impinging liquid on a

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Corrosive wear
Corrosive environment Corrodible metals Rust promoting conditions High temperatures

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Fatigue wear
Cyclic stress over long periods Water, dirt, in oil Inclusions in steel Particles of metal with sharp edges Metal spheres by microscopy

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Fretting wear
Vibration causing relative motion

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Prevention

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Adhesion wear
Reduce load, speed and temperature Improve oil cooling Use compatible metals Apply surface coatings such as phosphating Modify surface, such as ion implantation

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Abrasion wear
Remove abrasive by improved air and oil filtering, clean oil handling practices, improved seals, flushing and frequent oil changes Minimize shot peening, beading, or sand blasting of surfaces because abrasives cannot be completely removed Increase hardness of metal surfaces
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Erosive wear
Remove abrasive by improved air and oil filtering, clean oil handling practices, improved seals, flushing and frequent oil changes Increase hardness of metal surfaces Reduce impact angle to less than 15 degrees
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Corrosive wear
Use more corrosion resistant metal (not stainless) Reduce operating temperature Eliminate corrosive material

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Fatigue wear
Reduce contact pressures and frequency of cyclic stress Use high quality vacuum melted steels Use less abusive surface finish

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Fretting wear
Reduce or stop vibration by tighter fit or higher load Improve lubrication between surfaces by rougher (then honed) surface finish LUBRICANT Use oil of lower viscosity Relubricate frequently Use oxidation inhibitors in oil
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