L-9: Wear I

Wear

Introduction
Mode of Wears
Examples of Wear
Ways to Minimize Wear
 Wear
Progressive loss of material from the metal surface due to
relative motion between the surface and a contacting substance
and substances.

Friction

Friction is defined as the resistance against movement of a body

Laws of Friction

Static friction may be greater than kinetic (or dynamic) friction

Friction is independent of sliding velocity
Friction force is proportional to applied load
Friction force is independent of contact area

K. G. Budinski, Surface engineering for wear resistance, Englewood Cliffs, N.J. : Prentice Hall, c1988
 Chronology of tribosystems and techniques to deal with wear.

K. G. Budinski, Surface engineering for wear resistance, Englewood Cliffs, N.J. : Prentice Hall, c1988
 Classification

K. G. Budinski, Surface engineering for wear resistance, Englewood Cliffs, N.J. : Prentice Hall, c1988
• Abrasive wear
• It is defined as the wear because of hard particles or hard protuberances forced
against and moving along the solid surface.

Adhesive wear
Wear due to localized bonding between contacting solid surfaces
leading to material transfer between the two surfaces or the loss
from either surface.

Erosion
Removal of material from a surface due to mechanical interaction
between that surface and a fluid, a multicomponent fluid, or impinging
liquid or solid particles.

Fatigue Wear
Fracture of material from a solid surface caused by the cyclic
stresses produced by repeated rolling or sliding on a surface.
 Low stress abrasion
Examples:

Particles sliding on chutes, plowing sandy soils, sliding systems in

dirty environments, ash handling equipment, mineral handling equipment.

Applicable surface treatment:

Hard plating, case hardening, selective hardening, CVD coating.

(a) Schematic of a low stress abrasion, (b) LSA of a shaft from hard
Contaminants in a plastic bushing

K. G. Budinski, Surface engineering for wear resistance, Englewood Cliffs, N.J. : Prentice Hall, c1988
1. Abrasion rates increase with the sharpness of the abradant.
2. Abrasion rate decreases as the hardness of the surface subjected to abrasion
increases.
3. Abrasion rate decreases as the size of the abradant decreases., Below a particle size
of about 3 m (0.0012 in.), scratching abrasion ceases; polishing wear commences
and microchip formation no longer occurs.
4. Abrasion rate is directly proportional to the sliding distance and the load on the
particles or protuberances.
5. Abrasion rates significantly increase when the hardness of the abradant is more than
twice the hardness of the surface subjected to the abrasion.
6. In metals, microstructure (carbon content, carbides, hard phases, etc.) affects
abrasion rates. The presence of hard micro constituents reduces wear.
7. Fixed abrasives produce more abrasion than the same abrasive used in a three body,
lapping mode, The abradant can roll in the wear interface, and the microchip
formation (scratching) is reduced.
8. Elastomers resist low-stress abrasion by elastically deforming when the sharp
surfaces of the abradant are imposed on the surface. They often have better low-
stress abrasion resistance than metals.
9. Ceramics and cermets can have effective resistance to low-stress abrasion if the
ceramic is harder than the abrasive and if cermets have a significant volume fraction
of a phase that is harder than the abrasive.
 High stress abrasion

Examples:
Milling of minerals, Rollers running over dirty tracks, earth moving equipments,
heavily loaded metal to metal sliding systems in dirty environment.

Applicable surface treatments:

Heavy carburized case, cemented carbide wear tiles, heavy flame hardening,
cast white iron wear plates.

(a) Schematic of high-stress abrasion (b) star wheels on a refuse grinder

that have been subjected to high stress abrasion

K. G. Budinski, Surface engineering for wear resistance, Englewood Cliffs, N.J. : Prentice Hall, c1988
 Gauging abrasion

Examples:
Hammermills hammers, Gyratory crusher parts, Ball mill parts,
Agricultural equipments in rocky soils.

Applicable surface treatment: Hardfacing.

(a) Schematic of gauging abrasion (b) gauging damage

(b) caused by grinding of rocks

K. G. Budinski, Surface engineering for wear resistance, Englewood Cliffs, N.J. : Prentice Hall, c1988
Fig: An optical macrograph of a segment of the attrition mill wear plate showing gouging
abrasion near the inner ring and grinding abrasion near the outer ring

http://fdjpkc.fudan.edu.cn/_upload/article/files/6e/be/a9a5492d4edea81807c7a9de7279/ab452849-53dd-
461c-ad71-e0be2a004c7a.pdf
Polishing wear
Example:
Increased use of magnetic media for data collection, mixing
device for grains and fine solids.

Applicable surface treatment

Hard plating, thin film hard compound, case hardening,
selective hardening, wear tiles, hard CVD.

(a) Polishing metal removal with a buffing wheel, (b) pump sleeve polished
by the action of inorganic fibers in packing that ran against the sleeve

K. G. Budinski, Surface engineering for wear resistance, Englewood Cliffs, N.J. : Prentice Hall, c1988
Fig: Effect of abrasive hardness, relative to material hardness, on abrasive wear.

http://shodhganga.inflibnet.ac.in/bitstream/10603/117772/13/13_chapter%204.pdf
 Fig: Hardness of some minerals and alloy microconstituents

J. R. Davis, Surface Engineering for Corrosion and Wear Resistance, ASM International, 2001
References
• K. G. Budinski, Surface engineering for wear resistance, Englewood Cliffs, N.J. :
Prentice Hall, c1988
• http://fdjpkc.fudan.edu.cn/_upload/article/files/6e/be/a9a5492d4edea81807c7a9de727
9/ab452849-53dd-461c-ad71-e0be2a004c7a.pdf
• http://shodhganga.inflibnet.ac.in/bitstream/10603/117772/13/13_chapter%204.pdf
• J. R. Davis, Surface Engineering for Corrosion and Wear Resistance, ASM
International, 2001