Tribology in Industry

286-296

Authors: L. Giorgini, C. Fragassa, G. Zattini, A. Pavlovic

This paper investigates the effect of a prolonged acid and thermal attack, on the surface of PTFE by Fourier Transform Infrared Micro-Spectroscopy (FT-IR). The materials are commercialized by two alternative producers in form of Teflon tapes. These tapes are installed in process plants where tires moulds are cleaned inside a multistage ultrasonic process. In these cases, Teflon tapes, having a role of gaskets, show inexplicably phenomena of degradation in relatively short operation periods. Even considering that these gaskets are exposed to the combined effect of ultrasonic waves, temperature, humidity and acid attack, the PTFE properties of resistance nominally exclude the possibility of these severe erosion phenomena. An interesting explanation can be related to the potential presence in the cleaning solution, mainly based on sulfamic acid, of highly reactive chemical compounds, as chlorides and fluorides, originated by the disaggregation of elements from the tire composition and/or additives used as processing aids and/or by catalytic effect generated by fluorine produced by PTFE degradation. In general, up to 300 different chemical elements, both organic and inorganic, natural and synthetic, are merged in a tire. Since this composition is practically unknown, especially regarding additives and “unusual elements”, representing a secrecy of each tire manufactures, it is really complex to define the chemical composition of the cleaning solution with an appropriate precision. As a consequence, the gaskets have been treated with different mixtures of acids in the way to combine a larger range of possibilities. Thus, the FT-IR experimental characterization of PTFE surface properties followed an appropriate accelerated aging, aiming at actuating the specific mechanics of wearing as in industrial use. The different acid treatments adopted for accelerating the aging of gaskets have highlighted the different behaviour of the PTFE matrix, but also differences between manufacturers.

308-317

Authors: K.A. Widi, I. Wardana, W. Suprapto, Y.S. Irawan

The surface layer characteristics of the AISI 4140 tool steel treated by nitriding gas before and after hard chrome plating utilizing pure nitrogen diffusion media (fluidized bed reactor) and the without gas (muffle reactor) has been studied experimentally. The result shows that nitriding substrate with hard chrome layers has nitrogen atoms concentration almost twice greater than that without hard chrome layers. After being given a hard chrome plating, nitriding on AISI 4140 steel generally has a nitrogen concentration of up to 4 times more than the substrate without hard chrome coating. Almost the entire specimen showed the highest concentration of N atoms in the area below the surface (hardening depth of 200 to 450 µm). N atoms diffusion depth profile has a correlation with hardening depth profile, especially on the specimens layered with hard chromium. The substrate without hard chrome plating tends to have higher surface hardness than the sub-surface. The results show that the effectiveness and efficiency of the gas nitriding diffusion process can be produced without the use of gas in the muffle reactor but the specimens must be hard chromium coated first. This phenomenon can be explained by the role of the passive layer formation that works as a barrier to keeps the spreading of N atoms concentrated in sub-surface areas.

332-337

Authors: R. Anyszka, D.M. Bieliński, M. Imiela, M. Siciński, T. Gozdek, D. Strzelecki

Tribological properties of commercially available silicone-based ceramizable composites were studied. Friction forces of three different types of ceramizable composites were measured against three different-shape steel samples. Each friction pair contact was loaded with 15, 30, 45 or 60 N. Conducted studies reveal that tribological behavior of the composites vary considerably depending on the composite type and friction contact. However, friction force was increasing with an increase of the load, which mean that the composites behave accordingly to the classic friction theory.

347-360

Authors: I.O. Oladele, J.L. Olajide, M. Amujede

Epoxy resin is one of the strongest commercially exploitable thermosetting polymers in the polymer family; however its expensive nature in comparison with other thermosetting polymers such as vinylester and polyester limits its applications as a structural material. Inexpensive fillers on the other hand, especially those derived from agro-industrial wastes are very important in reducing the overall cost of polymer composites and furthermore influential in enhancing some of their engineering properties. In the present study, the wear resistance and mechanical behaviour of epoxy polymer matrix filled with <75 and 75 μm calcined particles of African land snail shells have been comparatively investigated. The wear resistance and the mechanical behaviour of the composites were studied via Taber Abraser and INSTRON universal testing machine. Also, the elemental constituents of the calcined snail shell and the epoxy biocomposites were characterized by X-Ray Fluorescence Spectroscopy and Scanning Electron Microscopy/Energy Dispersion Spectroscopy. From the experimental results, it was observed that, at the highest filler loading, smaller particle size presented a biocomposite with significant enhancement in wear and mechanical properties. However, it was also observed that increase in particle size showed no significant enhancement in the mechanical properties of the biocomposites.

371-384

Authors: S.C. Ram, K. Chattopadhyay, I. Chakrabarty

In present study, the effect of dry sliding wear conditions of A356 alloy/Mg2Sip functionally graded in-situ composites developed by centrifugal casting method has been studied. A pure commercial A356 alloy (Al–7.5Si–0.3Mg) was selected to be the matrix of the composites and primary Mg2Sip reinforcing particles were formed by in-situ chemical reaction with an average grain size of 40-47.8 µm. The Al–(Mg2Si)p functionally graded metal matrix composites (FGMMC’s) were synthesized by centrifugal casting technique with radial geometry, using two different mould rotating speeds ( 1200 and 1600 rpm). The X-ray diffraction (XRD) characterization technique was carried out to confirm the in-situ formed Mg2Si particles in composites. Optical microscopy examination was carried out to reveals the grain refinement of Al-rich grains due to in-situ formed Mg2Si particles. Scanning electron microscope (SEM) and Energy dispersive X-ray spectroscopy (EDS) techniques were carried out to reveal the distribution of phases, morphological characteristics and confirmation of primary Mg2Si particles in the matrix. The sliding wear behavior was studied using a Pin-on-Disc set-up machine with sliding wear parameters: effect of loads (N), effect of sliding distances (m) and effect of Mg on wear at room temperature with a high-carbon chromium steel disc (HRC-64) as counter surfaces. A good correlation was evidenced between the dry sliding behaviour of functionally graded in-situ composites and the distribution of Mg2Si reinforcing particles. Beside the above processing conditions, the dominant wear mechanisms of functionally graded in-situ composites have been correlated with the microstructures. The hardness and wear resistance properties of these composites increase with increasing volume percent of reinforced primary Si/Mg2Si particles toward inner zone of cast cylindrical shapes. The objective of this works was to study the tribological characteristics under dry sliding conditions of fabricated composites for automotives engine blocks and cylinder liners.

392-401

Authors: M.B. Amor, S. Belghith, S. Mezlini

The present study considers finite element analysis of an elastic and elastic-plastic contact between a rigid flat and a real rough surface taking into account the asperities interaction. Numerical modeling and measurement of the normal interfacial stiffness were conducted. Surfaces with different rms roughness values were investigated in the elastic and power-law hardening models to highlight the combined effect of the topography and the strain hardening on the contact characteristics. The influence of the surface roughness on the interaction between neighboring micro-contacts, the residual stress and deformation for the power-law hardening material was analyzed. The obtained results have shown the importance of considering the strain hardening in the modeling of a rough contact especially for rougher surface.

412-424

Authors: O.O. Ajibola

The electroless-nickel composite (ENC) consisting of bright metallic electroless-nickel (EN) and dull electroless-nickel-phosphorus (EN-P) were deposited on the polypropylene (PP) substrate from the sodium hypophosphite baths. The ENC plated specimens were subjected to abrasive wear-adhesion test of 1750, 3500, 7000 and 14000 cycles; thermal cycle-adhesion tests, and tensile strength and creep tests. The deposition of ENC influenced the strength and creep strain properties of the PP. The maximum stress σ of 118 (MPa) was obtained from EN-PP specimen at strain  of 0.1 mm/mm as compared with the PP having stress σ of 36 (MPa) at strain  of 0.07 mm/mm before failure The surface appearances and microstructures of ENC film on PP substrates were examined under the higher resolution metallurgical microscope with digital camera and microscopic camera. The composition of ENC film was characterized using Scanning Electron Microscopy and Energy Dispersive X-Ray analyses (Jeol JSM-7600F Field Emission) SEM/EDX, The micrographs and spectra lines data generated were used to interpret the results.