Wear Behavior of WC–Cu Deposited ZE41A Magnesium Alloy Using Wear Mechanism Map

The present investigation studied the dry sliding wear behavior of WC–Cu deposited ZE41A magnesium alloy under various parameters such as normal load, sliding speed and sliding time and the responses are wear rate and coefficient of friction. In this investigation, WC–Cu deposited magnesium alloy specimens were tested using pin on disc apparatus against EN31 steel disc. Wear mechanism map is developed for wear rate of the deposited magnesium alloy against normal load and sliding speed to identify the different wear modes such as mild, severe and ultra sever wear. Worn surface samples is assessed by Scanning Electron Microscope (SEM) and Energy Dispersive Spectroscope (EDS) to confirm the different wear mechanism such as abrasion, oxidation, delamination and melting. Normal load is identified as the most dominant process parameter in this experiment. Magnesium alloy deposited using WC–Cu composite coating by EDC improved the wear behavior in the lower ranges of sliding conditions.

WEAR MECHANISM MAP OF MAGNESIUM ALLOY COATED WITH WC/CU ELECTRODE USING ELECTRO DISCHARGE ALLOYING

The objective of this research is to study the wear mechanism of ZE41A magnesium alloy coated with WC/Cu material using EDC (Electro discharge coating). Dry sliding experiments were conducted with pin on disc method with different sliding condition such as normal load (1.5 kg - 3.5 kg), sliding speed (100rpm - 300 rpm) and sliding time (3min - 7min). Wear mechanism map was drawn against sliding condition of normal load and sliding speed which has been utilized to study the dominance of particular wear mechanism that dominates a particular wear regime. Different wear regime such as mild wear, severe wear ultra severe wear was developed by adjustment of contour line of the wear rate map. Various mechanisms such as abrasion, oxidation, delamination, plastic deformation and melting were observed in the worn surface

Wear Behavior of Aluminum Alloys at Slow Sliding Speeds

The investigated slow sliding speeds presented in this work enable the understanding of the wear behavior on aluminum alloys and could possibly facilitate the completion of the previously proposed wear mechanism map for aluminum at this slow sliding speed range. Dry sliding block-on-ring wear tests were carried out on aluminum alloys, AA5754 (Al-Mg), AA6082 (Al-Mg-Si), and AA7075 (Al-Zn-Cu), at a very slow sliding speed range (<0.01 m/s). A bearing steel ring of AISI 52100 was used as the counterbody. Tests were performed at varying contact pressures, 20, 100, and 140 MPa, and sliding speeds ranging from 0.001 to 1.5 m/s. The wear tracks and debris collected were examined by scanning electron microscopy (SEM), energy-dispersive spectroscopy (EDS), and X-ray diffraction (XRD), with the aim of analyzing their morphology and composition. At relatively slow sliding speeds (>0.01 m/s), the specimens exhibited a wear process placed at the mild wear regime, characterized by oxidation and delamination mechanisms of both the aluminum specimen and the steel ring. However, at very slow speed range (<0.01 m/s), an increase in the wear rate and the friction coefficient is observed for all of the aluminum alloys, thus suggesting that an alternative wear mechanism could be taking place.

Detecting Safety Zone Drill Process Parameters for Uncoated HSS Twist Drill in Machining GFRP Composites by Integrating Wear Rate and Wear Transition Mapping

The previous research investigations informed that the tool wear of any machining operation could be minimized by controlling the machining factors such as speed, feed, geometry, and type of cutting tool. Hence the present research paper aims at controlling the process parameters to minimize the drill tool wear, during the machining of Glass Fiber Reinforced Polymer (GFRP) composites. Experiments were carried out to find the tool wear rate and a wear mechanism map of uncoated High Speed Steel (HSS) drill of 10 mm diameter was developed for the drilling of GFRP composite laminates. The surface micrograph images on the drill land surface displayed dominant wear mechanisms induced on HSS drill during machining of GFRP and they were found to be adhesive wear, adhesive and abrasive wear, abrasive wear, and diffusion and fatigue wear. A “safety wear zone” was identified on the wear mechanism map, where the minimum tool wear of the HSS drill occurs. From the safety zone boundaries, it was inferred that the drill spindle speed should be set between 1200 and 1590 rpm and feed rate must be set within a range of 0.10–0.16 mm/rev for GFRP work and HSS tool combination to enhance the service life of 10 mm HSS drills and to minimize the tool wear.