The paper presents the results of studies of hybrid composite layers Ni/Al2O3/Cgraphite produced by the electrodeposition method. Three variants of hybrid composite layers were prepared in electrolyte solutions with the same amounts of each dispersion phases which were equal to 0.25; 0.50 and 0.75 g/dm3. The structure of Ni/Al2O3/Cgraphite layers as well as the Al2O3 and graphite powders, which were used as dispersion phases was investigated. The results of morphology and surface topography of produced layers are presented. The modulus of elasticity and microhardness of the material of produced layers were determined by DSI method. Tribological and corrosion resistance tests of produced layers were carried out. Realized studies have shown that the material of the produced layers is characterized by a nanocrystalline structure. Incorporation of dispersion phases into the nickiel matrix increases the degree of surface development of layers. Ni/Al2O3/Cgraphite layers are characterized by high hardness and abrasion resistance by friction, furthermore, they provide good corrosion protection for the substrate material.
This paper presents the results of the abrasive wear resistance of selected types of nodular cast iron, including ADI, cooperating with quartz sand and 100 grit abrasive paper. It has been shown that carbides in nodular cast iron cause an increase in wear resistance of 6 to 12% depending on the surface fraction of the carbides and type of the matrix. For the same unit pressure the mass loss of the cast iron cooperating with quartz sand is many times larger than the cast iron cooperating with abrasive paper. For both abrasives the highest wear resistance showed nodular cast iron with upper and lower bainite and carbides.
In spite of the fact that in most applications, magnesium alloys are intended for operation in environments with room temperature, these alloys are subject to elevated temperature and oxidizing atmosphere in various stages of preparation (casting, welding, thermal treatment). At present, the studies focus on development of alloys with magnesium matrix, intended for plastic forming. The paper presents results of studies on oxidation rate of WE43 and ZRE1 magnesium foundry alloys in dry and humidified atmosphere of N2+1%O2. Measurements of the oxidation rate were carried out using a Setaram thermobalance in the temperature range of 350-480°C. Corrosion products were analyzed by SEM-SEI, BSE and EDS. It was found that the oxide layer on the WE43 alloy has a very good resistance to oxidation. The high protective properties of the layer should be attributed to the presence of yttrium in this alloy. On the other hand, a porous, two-layer scale with a low adhesion to the substrate forms on the ZRE1 alloy. The increase in the sample mass in dry gas is lower than that in humidified gas.
The paper deals with hypereutectic high chromium cast irons. The subject of examination was the effect of various alloying elements (Ti, W, Mo, V) on the size of primary carbides and on the resultant material hardness. Using a scanning electron microscope with a wave dispersion analyser, the carbon content in carbides was established. To determine the other elements, an energy dispersion analyser was used. It was found that both the primary and the eutectic carbides were of the M7C3 type and very similar in composition. The carbides always contained Cr and Fe, and also W, Mo, V or Ti, in dependence on the alloying elements used. The structure of materials containing only chromium without any alloying additions exhibited coarse acicular primary carbides. The structure of materials alloyed with another element was always finer. Marked refinement was obtained by Ti alloying.
Commercially pure titanium is less expensive, generally more corrosion resistant and lower in strength than its alloys, and is not heat-treatable. The use of Ti and its alloys as construction materials under severe friction and wear conditions is limited due to their poor tribological properties. Nevertheless, proper addition of hard ceramic particles into Ti and its alloys has proved to be an efficient way to enhance their mechanical and wear properties. Our purpose in this work was to analyze the corrosion, tribocorrosion, mechanical and morphological effects of combining titanium carbide with titanium metal, to create a unique composite via spark plasma sintering technique (SPS). Composites with different mass percentage (1, 5, 10, 15 and 20 wt %) of ceramic phase were produced. The samples of pure Ti and Ti-6Al-4V alloy were also tested, as a reference. These composites were examined for mechanical properties and corrosion resistance in an environment similar to the human body (Ringer’s solution). Open circuit potential (OPC) and anodic polarization measurements were performed. The properties of titanium composites reinforced with micro- and nanocrystalline TiC powders were compared. It was stated that wear properties were significantly improved with increasing amount of TiC in matrix, especially in the case of nanocrystalline reinforcement. In terms of corrosion resistance, the composites showed slightly worse properties compared to pure titanium and Ti-6Al-4V alloy.
The present investigation focuses on the study of the influence of titanium inoculation on tribological properties of High Chromium Cast Iron. Studies of tribological properties of High Chromium Cast Iron, in particularly the wear resistance are important because of the special application of this material. High Chromium Cast Iron is widely used for parts that require high wear resistance for example the slurry pumps, brick dies, several pieces of mine drilling equipment, rock machining equipment, and similar ones. Presented research described the effects of various amounts of Fe-Ti as an inoculant for wear resistance. The results of wear resistance were collated with microstructural analysis. The melts were conducted in industrial conditions. The inoculation was carried out on the stream of liquid metal. The following amount of inoculants have been used; 0.17% Fe-Ti, 0.33% Fe-Ti and 0.66% Fe-Ti. The tests were performed on the machine type MAN. The assessment of wear resistance was made on the basis of the weight loss. The experimental results indicate that inoculation improve the wear resistance. In every sample after inoculation the wear resistance was at least 20% higher than the reference sample. The best result, thus the smallest wear loss was achieved for inoculation by 0.66% Fe-Ti. There is the correlation between the changing in microstructure and wear resistance. With greater amount of titanium the microstructure is finer. More fine carbides do not crumbling so quickly from the matrix, improving the wear resistance.
The present investigation aims at fabricating a functionally graded Al-6Cr-Y2O3 composite and its microstructural and property characterization. Al-6Cr-alloys with varying percentage of Y2O3 (5-10 vol. %) have been used to fabricate FGM by powder metallurgy route. The samples were subsequently subjected to solution treatment at 610°C for 4 h followed by artificially aged at 310°C for 4 h. The microstructure, hardness and wear behavior of these FGM have been evaluated. FGM exhibited superior hardness (360 ± 5 VHN) as compared to the unprocessed composites (220 ± 5 VHN) due to the uniform dispersion of Y2O3 particles. Wear resistance of Al-6Cr-10 Y2O3 FGM were compared that of with pure Al-6Cr alloy by dry abrasive wear test. Al-6Cr-10 Y2O3 FGM composites were found to exhibit higher wear resistance with the minimum wear rate of 0.009 mm3/m compared to the Al- 6Cr alloy wear rate 0.02 mm3/m.
The present study addresses the utilization of induction furnace steel slag which is an anthropogenic waste, for enhancing the mechanical properties of a commercial aluminium alloy A356. Different weight percentage (3wt%, 6wt%, 9wt%, and 12wt%) of steel slag particles in 1 to 10 μm size range were used as reinforcing particles in aluminium alloy A356 matrix. The composites were prepared through stir casting technique. The results revealed an improvement in mechanical properties (i.e. microhardness and tensile strength) and wear resistance with an increase in weight percentage of the steel slag particles. This research work shows promising results for the utilization of the steel slag for enhancing the properties of aluminium alloy A356 at no additional cost while assisting at same time in alleviating land pollution.
In this work, three ceramic composite coatings Al2O3-3TiO2 C, Al2O3-13TiO2 C, and Al2O3-13TiO2 N were plasma sprayed on steel substrates. They were deposited with two conventional powders differing the volume fraction of TiO2 and nanostructured powder. The mechanical and tribological properties of the coatings were investigated and compared. The increase in TiO2 content from 3 wt.% to 13 wt.% in the conventional feedstock improved the mechanical properties and abrasion resistance of coatings. However, the size of the used powder grains had a much stronger influence on the properties of deposited coatings than the content of the titania phase. The Al2O3-13TiO2 coating obtained from nanostructured powder revealed significantly better properties than that plasma sprayed using conventional powder, i.e. 22% higher microhardness, 19% lower friction coefficient, and over twice as good abrasive wear resistance. In turn, the Al2O3-13TiO2 conventional coating showed an increase in microhardness and abrasive wear resistance, 36% and 43%, respectively, and 6% higher coefficient of friction compared to the Al2O3-3TiO2 conventional coating.
This study investigated the effect of T6 heat treatment on the microstructure and scratch wear behavior of hypoeutectic Al-12wt.%Si alloy manufactured by extrusion. Microstructural observation identified spherical eutectic Si phases before and after the heat treatment of alloys (F, T6). Phase analysis confirmed Al matrix and Si phase as well as Al2Cu and Al3Ni, Mg2Si in both alloys. In particular, Al2Cu was finer and more evenly distributed in T6 alloy. This resulted in Vickers hardness of T6 alloy that was 2.3 times greater compared to F alloy. The scratch wear test was conducted using constant load scratch test (CLST) mode and multi-pass scratch test (MPST) mode. The scratch coefficient and worn out volume obtained by such were used to evaluate wear properties before and after heat treatment. In the case of T6 alloy, its scratch coefficient was lower than F alloy in all load ranges. After 15 repeated tests to measure worn out volume, F alloy and T6 alloy measured 1.2×10–1 mm3 and 7.8×10–2 mm3, respectively. In other words, the wear resistance of T6 alloy were confirmed to be better than those of F alloy. In addition, this study attempted to identify the microstructural factors that contribute to the better scratch wear resistance of T6 alloy and wear mechanism from surface and cross-section observations after the wear tests.
Nanostructured, biocompatible, TiC/Ti Supersonic Cold Gas Sprayed coatings were deposited onto a Ti6Al4V alloy and their microstructure, wear resistance and hardness were investigated. The starting nanostructured powder, containing a varied mixture of Ti and TiC particles, was produced by high energy ball milling. Scanning and transmission electron microscopy, energy-dispersive X-ray spectroscopy, and X-ray diffraction were used for structural and chemical analyses of powder particles and coatings. Coatings, 250-350 μm thick, preserving the nanostructure and chemical powder composition, with low porosity and relatively high hardness (~850 HV), were obtained. These nanostructured TiC/Ti coatings exhibited better tribological properties than commonly used biomedical benchmark materials, due to an appropriate balance of hard and soft nano-phases.
Within the presented work, the effect of austenite transformation on abrasive wear as well as on rate and nature of corrosive destruction of spheroidal Ni-Mn-Cu cast iron was determined. Cast iron contained: 3.1÷3.4 %C, 2.1÷2.3 %Si, 2.3÷3.3 %Mn, 2.3÷2.5 %Cu and 4.8÷9.3 %Ni. At a higher degree of austenite transformation in the alloys with nickel equivalent below 16.0%, abrasive wear resistance was significantly higher. Examinations of the corrosion resistance were carried out with the use of gravimetric and potentiodynamic method. It was shown that higher degree of austenite transformation results in significantly higher abrasive wear resistance and slightly higher corrosion rate, as determined by the gravimetric method. However, results of potentiodynamic examinations showed creation of a smaller number of deep pinholes, which is a favourable phenomenon from the viewpoint of corrosion resistance.
Wear resistance of TiC-cast steel metal matrix composite has been investigated. Composites were obtained with SHSB method known as SHS synthesis during casting. It has been shown the differences in wear between composite and base cast steel. The Miller slurry machine test were used to determine wear loss of the specimens. The slurry was composed of SiC and water. The worn surface of specimens after test, were studied by SEM. Experimental observation has shown that surface of composite zone is not homogenous and consist the matrix lakes. Microscopic observations revealed the long grooves with SiC particles indented in the base alloy area, and spalling pits in the composite area. Due to the presence of TiC carbides on composite layer, specimens with TiC reinforced cast steel exhibited higher abrasion resistance. The wear of TiC reinforced cast steel mechanism was initially by wearing of soft matrix and in second stage by polishing and spalling of TiC. Summary weight loss after 16hr test was 0,14÷0,23 g for composite specimens and 0,90 g for base steel
The paper presents the results of abrasive wear resistance tests carried out on high-vanadium cast iron with spheroidal VC carbides. The cast iron of eutectic composition was subjected to spheroidising treatment using magnesium master alloy. The tribological properties were examined for the base cast iron (W), for the cast iron subjected to spheroidising treatment (S) and for the abrasion-resistant steel (SH). Studies have shown that high-vanadium cast iron with both eutectic carbides and spheroidal carbides has the abrasion resistance twice as high as the abrasion-resistant cast steel. The spheroidisation of VC carbides did not change the abrasion resistance compared to the base high-vanadium grade.
The results of the modification of austenitic matrix in cast high-manganese steel containing 11÷19% Mn with additions of Cr, Ni and Ti were discussed. The introduction of carbide-forming alloying elements to this cast steel leads to the formation in matrix of stable complex carbide phases, which effectively increase the abrasive wear resistance in a mixture of SiC and water. The starting material used in tests was a cast Hadfield steel containing 11% Mn and 1.34% C. The results presented in the article show significant improvement in abrasive wear resistance and hardness owing to the structure modification with additions of Cr and Ti.
The paper concerns evaluation of the coefficient of friction characterising a friction couple comprising a commercial brake disc cast of flake graphite grey iron and a typical brake pad for passenger motor car. For the applied interaction conditions, the brake pressure of 0.53 MPa and the linear velocity measured on the pad-disc trace axis equalling 15 km/h, evolution of the friction coefficient μ values were observed. It turned out that after a period of 50 minutes, temperature reached the value 270°C and got stabilised. After this time interval, the friction coefficient value also got stabilised on the level of μ = 0.38. In case of a block in its original state, stabilisation of the friction coefficient value occurred after a stage in the course of which a continuous growth of its value was observed up to the level μ = 0.41 and then a decrease to the value μ = 0.38. It can be assumed that occurrence of this stage was an effect of an initial running-in of the friction couple. In consecutive abrasion tests on the same friction couple, the friction coefficient value stabilisation occurred after the stage of a steady increase of its value. It can be stated that the stage corresponded to a secondary running-in of the friction couple. The observed stages lasted for similar periods of time and ended with reaching the stabile level of temperature of the disc-pad contact surface.
The paper presents the results of tests on the spheroidising treatment of vanadium carbides VC done with magnesium master alloy and mischmetal. It has been proved that the introduction of magnesium master alloy to an Fe-C-V system of eutectic composition made 34% of carbides crystallise in the form of spheroids. Adding mischmetal to the base alloy melt caused 28% of the vanadium carbides crystallise as dendrites. In base alloy without the microstructure-modifying additives, vanadium carbides crystallised in the form of a branched fibrous eutectic skeleton. Testing of mechanical properties has proved that the spheroidising treatment of VC carbides in high-vanadium cast iron increases the tensile strength by about 60% and elongation 14 - 21 times, depending on the type of the spheroidising agent used. Tribological studies have shown that high-vanadium cast iron with eutectic, dendritic and spheroidal carbides has the abrasive wear resistance more than twice as high as the abrasion-resistant cast steel.
The paper presents an innovative method of creating the layered castings. The innovation relies on application the 3D printing insert obtaining in SLM (selective laser melting) method. This type of scaffold insert made from pure Ti powder, was placed into mould cavity directly before pouring by grey cast iron. In result of used method was obtained grey cast iron casting with surface layer reinforced by titanium carbides. In range of studies were carried out metallographic researches using light microscope and scanning electron microscope, microhardness measurements and abrasive wear resistance. On the basis of obtaining results was stated that there is a possibility of reinforcing surface layer of the grey cast iron casting by using 3D printing scaffold insert in the method of mould cavity preparation. Moreover there was a local increase in hardness and abrasive wear resistance in spite of the precipitation of titanium carbides in surface layer of grey cast iron. While the usable properties of composite surface layer obtained in result of use of the method presented in the paper, strongly depend of dimensions of scaffold insert, mainly parameters Re and Ri.
In order to increase wear resistance cast steel casting the TiC-Fe-Cr type composite zones were fabricated. These zones were obtained by means of in situ synthesis of substrates of the reaction TiC with a moderator of a chemical composition of white cast iron with nickel of the Ni-Hard type 4. The synthesis was carried out directly in the mould cavity. The moderator was applied to control the reactive infiltration occurring during the TiC synthesis. The microstructure of composite zones was investigated by electron scanning microscopy, using the backscattered electron mode. The structure of composite zones was verified by the X-ray diffraction method. The hardness of composite zones, cast steel base alloy and the reference samples such as white chromium cast iron with 14 % Cr and 20 % Cr, manganese cast steel 18 % Mn was measured by Vickers test. The wear resistance of the composite zone and the reference samples examined by ballon-disc wear test. Dimensionally stable composite zones were obtained containing submicron sizes TiC particles uniformly distributed in the matrix. The macro and microstructure of the composite zone ensured three times hardness increase in comparison to the cast steel base alloy and one and a half times increase in comparison to the white chromium cast iron 20 % Cr. Finally ball-on-disc wear rate of the composite zone was five times lower than chromium white cast iron containing 20 % Cr.
High-chromium cast irons are used as abrasion resistant materials. Their wear resistance depends on quantity of carbides and the matrix supporting these carbides. The paper presents the results of cast irons of chemical composition (in wt. %) 19–22 Cr and 2–4.5 C alloyed by 1.7 Mo + 5 Ni + 2 Mn to improve their toughness, which were tested in working conditions of ferroalloys crushing. Tests showed that these as-cast chromium cast irons with mostly austenitic matrix achieved the hardness of 38-45 HRC, but their relative abrasion resistance Ψ ranged from 1.3 to 4.6, was higher comparing to the tool made from the X210Cr12 steel heat treated on hardness 61 HRC. The transformation of austenite into martensite occurs not only at the worn strained areas (on a surface of scratch) but also in their neighbourhood. Due to the work hardening of relatively large volumes of transformed austenite the cast iron possesses high abrasion resistance also on the surfaces where low pressures are acting. The tough abrasion-resistant cast iron well proved for production of dynamic and wear stressed castings e.g., crusher hammers, cutting tools for ceramic etc.
Cast Hadfield steel is characterised by high abrasion resistance, provided, however, that it is exposed to the effect of dynamic loads. During abrasion without loading, e.g. under the impact of loose sand jet, its wear resistance drops very drastically. To increase the abrasion resistance of this alloy under the conditions where no pressure is acting, primary vanadium carbides are formed in the metallurgical process, to obtain a composite structure after the melt solidification. The primary, very hard, carbides uniformly distributed in the austenitic matrix are reported to double the wear resistance of samples subjected to the effect of a silicon carbide-water mixture.
The paper presents results of studies on the effect of the nodular cast iron metal matrix composition on the abrasive and adhesive wear resistance. Nodular cast iron with different metal matrix obtained in the rough state and ADI were tested. To research of abrasive and adhesive wear the pearlitic and bainitic cast iron with carbides and without this component were chosen. The influence of the carbides amount for cast iron wear resistance was examined. It was found, that the highest abrasive and adhesive wear resistance under conditions of dry friction has a nodular cast iron with carbides with upper and lower bainite. Carbides in bainitic and pearlitic cast iron significantly increase the wear resistance in these conditions. In terms of fluid friction the largest wear resistance had cast iron group with the highest hardness.
The resistance of cast iron to abrasive wear depends on the metal abrasive hardness ratio. For example, hardness of the structural constituents of the cast iron metal matrix is lower than the hardness of ordinary silica sand. Also cementite, the basic component of unalloyed white cast iron, has hardness lower than the hardness of silica. Some resistance to the abrasive effect of the aforementioned silica sand can provide the chromium white cast iron containing in its structure a large amount of (Cr, Fe)7C3 carbides characterised by hardness higher than the hardness of the silica sand in question. In the present study, it has been anticipated that the white cast iron structure will be changed by changing the type of metal matrix and the type of carbides present in this matrix, which will greatly expand the application area of castings under the harsh operating conditions of abrasive wear. Moreover, the study compares the results of abrasive wear resistance tests performed on the examined types of cast iron. Tests of abrasive wear resistance were carried out on a Miller machine. Samples of standard dimensions were exposed to abrasion in a double to-and-fro movement, sliding against the bottom of a trough filled with an aqueous abrasive mixture containing SiC + distilled water. The obtained results of changes in the sample weight were approximated with a power curve and shown further in the study.