Friction and Wear of Ceramics Principles and Case Studies

This book covers the area of tribology broadly, providing important introductory chapters to fundamentals, processing, and applications of tribology. The book is designed primarily for easy and cohesive understanding for students and practicing scientists pursuing the area of tribology with focus on materials. This book helps students and practicing scientists alike understand that a comprehensive knowledge about the friction and wear properties of advanced materials is essential to further design and development of new materials.

The description of the wear micromechanisms of various materials will provide a strong background to the readers as how to design and develop new tribological materials. This book also places importance on the development of new ceramic composites in the context of tribological applications.

Some of the key features of the book include: Fundamentals section highlights the salient issues of ceramic processing and mechanical properties of important oxide and non-oxide ceramic systems; State of the art research findings on important ceramic composites are included and an understanding on the behavior of silicon carbide (SiC) based ceramic composites in dry sliding wear conditions is presented as a case study; Erosion wear behavior of ceramics, in which case studies on high temperature erosion behavior of SiC based composites and zirconium diboride (ZrB2) based composites is also covered; Wear behavior of ceramic coatings is rarely discussed in any tribology related books therefore a case study explaining the abrasion wear behavior of WC-Co coating is provided. Finally an appendix chapter is included in which a collection of several types of questions including multiple choice, short answer and long answer are provided.

BIKRAMJIT BASU, PHD, is a Professor at the Materials Research Center with joint appointment at the Centre for Biosystems Science and Engineering, and Interdisciplinary Center for Energy Research at Indian Institute of Science, Bangalore. Encompassing experimental and theoretical analysis, his research, at the intersection of Materials Science and Mechanical Engineering, has laid the foundation of next generation of wear resistant ceramics and provided deeper understanding into their wear mechanisms.

MITJAN KALIN, PHD, is a Professor at the Faculty of Mechanical Engineering, University of Ljubljana, where he is the Head of the Laboratory for Tribology and Interface Nanotechnology and the Chair for Tribology and Maintenance Technology. Dr Kalin's areas of research are the wear and friction mechanisms of advanced materials, nanoscale interface phenomena, and boundary films for novel green-lubrication technologies, including his widely recognized contribution to the lubrication of DLC coatings.

B. VENKATA MANOJ KUMAR, PHD, is an Associate Professor at the Department of Metallurgical and Materials Engineering, Indian Institute of Technology, Roorkee. With the primary theme of understanding microstructure-property relations, Dr. Kumar has been actively involved in processing advanced ceramic systems and studying the influence of microstructural characteristics on their material removal mechanisms when subjected to varieties of wear and machining conditions.

About the Authors

Foreword by Dr. Sanak Mishra

Foreword by Prof. Koji Kato

Preface

Section I: Fundamentals of Ceramics

Chapter 1: Introduction: Ceramics and Tribology

1.1 Introduction

1.2 Classification of engineering materials

1.3 Engineering ceramics

1.4 Structural ceramics: typical properties and tribological applications

1.5 Structure of the book

1.6 Closure

References

Chapter 2: Processing of bulk ceramics and coatings

2.1 Introduction

2.2 Conventional processing of ceramics

2.2.1 Sintering mechanism

2.2.2 Conventional processing of ceramics

2.2.2.1 Powder processing and Compaction

2.2.2.2 Pressureless sintering

2.2.3 Advanced processing of ceramics

2.2.3.1 Hot pressing

2.2.3.2 Microwave sintering

2.2.3.3. Spark plasma sintering

2.3 Thermal spray based coating deposition

2.3.1. Basics of thermal spray deposition

2.3.1.1 Plasma spray deposition

2.3.1.1.2 Flame spray deposition

2.3.1.3 Wire arc spray deposition

2.3.1.4 High-velocity-oxy-fuel (HVOF) spray deposition

2.3.1.5 Detonation sprayed coatings (DSC)

2.3.2 Bond strength of thermal sprayed coatings

2.3.2.1 Bond mechanism

2.3.2.2 Test methods

2.3.3 Coating structure

2.3.3.1 Particle and substrate material properties

2.3.3.2 Particle temperature and velocity

2.3.4 Case study: WC-Co coating

2.4 Closure

References

Chapter 3:  Conventional and advanced machining processes

3.1 Introduction 

3.2 Conventional machining

3.3. Advanced machining processes

3.3.1 Electrodischarge machining (EDM)

3.3.1.1 Working principle

3.3.1.2 EDM process variables

3.3.1.3 EDM parameters

3.3.1.4 Surface analysis

3.3.1.5 EDM of ceramic-based composites

3.4 Closure

References

Chapter 4: Mechanical properties of ceramics

4.1 Defining stress and strain

4.2 Comparison of tensile behavior

4.3 Brittle fracture of ceramics

4.4. Cracking in Brittle Materials

4.5 Experimental assessment of mechanical properties

4.5.1 Hardness

4.5.2 Compressive strength

4. 5.3 Flexural Strength

4.5.4 Tensile strength

4.5.5 Elastic modulus

4.5.6 Fracture toughness

4.5.6.1 Notched beam tests

4.5.6.2 Indentation microfracture method

4.5.7 Practical guidelines for the for reliable measurements

4.6 Closure

References

Section II: Fundamentals of Tribology

Chapter 5:  Contact surface characteristics

5.1 Nature and roughness of contact surfaces

5.2 Surface roughness measurement

5.2.1 Stylus method

5.2.2 Atomoc force microscopy

5.2.3 Optical interferometry

5.2.4 Laser surface profilometry

5.2.5. Scanning electron microscopy

5.3 Bearing area curve and cumulative distribution function

5.4 Nominal vs. real contact area

5.5 Hertzian contact stress

5.6 Closure

References

Chapter 6: Friction and interface temperatures

6.1 Theory of friction

6.1.1. Friction laws and mechanisms

6.2 Types of friction

6.2.1 Static and kinetic friction

6.2.2 Slip-stick friction

6.2.3 Rolling friction

6.3 Friction of engineering material classes

6.4 Frictional heating and temperature at the interface

6. 4. 1 Heating due to friction

6. 4. 2 Understanding the temperature in the contact: the bulk and flash temperatures

6.5 Analytical models to predict the temperatures in the contact

6.6 Implications of important contact temperature models

6.6.1. Archard model

6.6.2. Kong-Ashby model

6.6 Closure

References

Chapter 7: Wear of ceramics and lubrication

7.1 Introduction

7.2. Testing methods and quantification of wear of materials

7.3 Classification of wear mechanisms

7.3.1 Tribomechanical wear

7.3.1.1 Adhesive wear

7.3.1.2 Abrasive wear

7.3.1.3 Fatigue wear

7.3.1.4 Fretting wear

7.3.1.5 Erosive wear

7.3.2 Tribochemical wear

7.3.2.1. Oxidative wear

7.4 Lubrication

7.4.1 Regimes of lubrication and the Stribeck curve

7.4.2 Influence of lubricant composition, contact pressure and temperature on lubrication

7.5 Closure

References

Section III: Sliding Wear of Ceramics

Chapter 8: Case Study: Sliding wear of SiC ceramics

8.1 Introduction

8.2. Materials and experiments

8.3 Friction and wear behavior SiC ceramics sintered with small amount of yttria additive

8.4 Influence of mechanical properties on sliding wear of SiC ceramics

8.5. Wear mechanisms

8.6 Closure

References

Chapter 9: Case study: Counterbody and temperature dependent sliding wear of SiC-WC Ceramics

9.1 Introduction

9.2. Microstructure and mechanical characteristics of SiC-WC composites

9.3. Influence of counterbody and WC content

9.3.1. Friction and wear behavior

9.3.2. Mechanisms of material removal

9.3.3. Friction and wear of SiC-WC composites: system-dependent properties

9.3.4 Wear mechanisms as function of counterbody and WC content

9.4. Reciprocated sliding wear behavior of SiC-WC composites

9.4.1. Frictional and wear behavior

9.4.2. Critical analysis of wear mechanisms

9.4.2.1.Debris analysis

9.4.2.2. Effect of temperature

9.4.2.3. Effect of test configuration on wear behavior

9.5. Sub-surface investigation of worn SiC-WC composites

9.5.1. Sub-surface damages and corresponding inferences

9.5.2 Cross-sectional microstructural analysis and interfacial characteristics

9.5.3. Sub-surface plastic deformation:

9.6. Closure:

Chapter 10: Sliding wear of zirconia-toughened alumina

10.1 Introduction

10.2 Mechanical properties of ZTA

10.3 Sliding wear properties of ZTA

10.4 Correlating cracking mediated wear with theoretical analysis

10.5 Closure

Chapter 11: Case study: Abrasive wear of detonation sprayed WC-12Co coatings

11.1 Introduction

11.2 Coatings and abrasive wear

11.3. Abrasive wear results

11.4 Surface and sub-surface damage mechanisms

11.5 Closure

References

Chapter 12: Case study: Solid-lubricant interaction and friction at lubricated contacts

12.1 Introduction

12.2 Materials and sliding wear experiments

12.3 Wetting and spreading properties

12.4 Surface energies of different class of materials

12.5 Wetting evaluation of engineering surfaces

12.6 Effect of wetting on EHL friction

12.7 Correlation between spreading parameter and friction

12.8 Closure

References

Section IV: Erosive Wear of Ceramics

Chapter 13: Case Study: Erosive wear of SiC-WC composites

13.1 Introduction

13.2 Materials and erosion tests

13.3 Influence of type of erodent on erosion behaviour

13.4 Influence of impingement angle and WC content on erosion behavior

13.5 Correlating erosion behaviour with microstructural characteristics

13.6 Correlating erosion behaviour with mechanical properties

13.7 Erosion behaviour at high temperature

13.8 Closure

References

Chapter 14: Case Study: Thermo-erosive behavior of ZrB2-SiC composites 

14.1 Introduction

14.2 High temperature erosion tests and computational modeling

14.3 Computational modeling of thermo-erosive behaviour

14.4 High temperature erosion test results

14.5 Transient thermal studies using Finite Element analysis

14.6 Coupled thermo-structural analysis

14.7 Thermo-erosive behavior

14.8 Closure

References

Chapter 15: Case Study: Erosive wear of WC-Co coating

15.1 Introduction

15.2 Materials and erosion experiments

15.3 Erosion wear mechanisms (surface damage)

15.4 Erosion wear mechanisms (sub-surface damage)

15.5 Correlating wear mechanism with erodent and coating properties

15.6 Closure

References

Section V: Machining induced wear of cermets

Chapter 16: Crater wear of TiCN cermets in conventional machining  

16.1 Introduction

16.2 TiCN cermets and machining conditions

16.3 Wear mechanisms of TiCN-WC-Ni cermets

16.4 Machining with TiCN-WC-TaC-Ni-Co cermet tools

16.5 Correlating cermet composition, microstructure and wear during machining

16.6 Closure

References

Chapter 17:  Wear of TiCN-based cermets in electrodischarge machining 

17.1 Introduction

17.2 Materials and EDM tests

17.3 Wear of TiCN-cermets during EDM

17.4 Mechanisms of material removal during EDM

17.5 Closure

References

Section VI: Future scope

Chapter 18: Perspective

18.1 Innovation cycle for wear resistant materials

18.2 in situ diagnosis of tribological interactions

18.3 High temperature wear testing

18.4 Modeling and simulation in tribology

18.5 Tribomaterialomics- a new concept

18.6 Education and mentoring of next generation researchers

References

Appendix: Appraisal

A. I Multiple choice questions

A. II Select the appropriate combination

A. III Fill in the blanks with the most appropriate response

A. IV Mention the appropriate material/equipment in the blank

A. V Identify whether the following statements are True/False:

A. VI Short review questions and descriptive questions

A. VII Analytical questions

A. VIII Model answers

The New copy of this book will include any supplemental materials advertised. Please check the title of the book to determine if it should include any access cards, study guides, lab manuals, CDs, etc.

The Used, Rental and eBook copies of this book are not guaranteed to include any supplemental materials. Typically, only the book itself is included. This is true even if the title states it includes any access cards, study guides, lab manuals, CDs, etc.