Wear Materials, Mechanisms and Practice

by Stachowiak, Gwidon W.

• ISBN13: 9780470016282
• ISBN10: 0470016280
• Edition: 1st
• Format: Hardcover
• Copyright: 2005-12-23
• Publisher: WILEY

Summary

Tribology is emerging from the realm of steam engines and crank-case lubricants and becoming key to vital new technologies such as nanotechnology and MEMS. Wear is an integral part of tribology, and an effective understanding and appreciation of wear is essential in order to achieve the reliable and efficient operation of almost any machine or device. Knowledge in the field has increased considerably over recent years, and continues to expand: this book is intended to stimulate its readers to contribute towards the progress of this fascinating subject that relates to most of the known disciplines in physical science.Wear - Materials, Mechanisms and Practice provides the reader with a unique insight into our current understanding of wear, based on the contributions of numerous internationally acclaimed specialists in the field. Offers a comprehensive review of current knowledge in the field of wear. Discusses latest topics in wear mechanism classification. Includes coverage of a wide variety of materials such as metals, polymers, polymer composites, diamonds, and diamond-like films and ceramics. Discusses the chemo-mechanical linkages that control tribology, providing a more complete treatment of the subject than just the conventional mechanical treatments. Illustrated throughout with carefully compiled diagrams that provide a unique insight into the controlling mechanisms of tribology.The state of the art research on wear and the mechanisms of wear featured will be of interest to post-graduate students and lecturers in engineering, materials science and chemistry. The practical applications discussed will appeal to practitioners across virtually all sectors of engineering and industry including electronic, mechanical and electrical, quality and reliability and design.

Author Biography

Gwidon Stachowiak is Professor and Head of the Tribology Laboratory in the School of Mechanical Engineering at the University of Western Australia. He has published more than 130 journal papers and 90 conference papers. He has written/ contributed to several books, including “Engineering Tribology” (Elsevier, 1993) that is due for a 3^rd edition in 2005 and which is considered to be the best book available in the field of tribology. His most recent title is Experimental Methods in Tribology”, (Elsevier 2004). He serves on the advisory board for the Elsevier Tribology and Interface Engineering Book Series, and on the editorial board of 7 different journals.

Table of Contents

List of Contributors	xiii
Series Editors' Foreword	xvii
Preface	xix
The Challenge of Wear	1	(8)
I.M. Hutchings
Abstract	1	(1)
Introduction	1	(1)
Definitions and Development of Wear Studies	1	(1)
Scope and Challenges	2	(4)
Conclusions	6	(3)
References	6	(3)
Classification of Wear Mechanisms/Models	9	(12)
K. Kato
Abstract	9	(1)
Introduction	9	(1)
Classification of Wear Mechanisms and Wear Modes	10	(5)
Mechanical, Chemical and Thermal Wear	10	(1)
Wear Modes: Abrasive, Adhesive, Flow and Fatigue Wear	11	(3)
Corrosive Wear	14	(1)
Melt and Diffusive Wear	15	(1)
General Discussion of Wear Mechanisms and Their Models	15	(3)
Material Dependence	15	(1)
Wear Maps	16	(1)
Wear Mode Transition	17	(1)
Erosion	17	(1)
Conclusion	18	(3)
Acknowledgements	18	(1)
References	18	(3)
Wear of Metals: A Material Approach	21	(16)
S.K. Biswas
Abstract	21	(1)
Introduction	21	(1)
Mild Wear and Transition to Severe Wear	22	(5)
Mild Wear	22	(1)
Transition to Severe Wear	23	(4)
Strain Rate Estimates and Bulk Surface Temperature	27	(7)
Strain Rate Response Maps	28	(2)
Bulk Surface Temperature	30	(1)
The Phenomenological Argument	30	(1)
Micrographic Observations	31	(3)
Summary	34	(3)
Homogeneous Deformation -- Severe Wear	34	(1)
Homogeneous Deformation -- Mild Wear	35	(1)
Inhomogeneous Deformation -- Severe Wear	35	(1)
Acknowledgements	35	(1)
References	35	(2)
Boundary Lubricated Wear	37	(34)
S.M. Hsu
R.G. Munro
M.C. Shen
R.S. Gates
Abstract	37	(1)
Introduction	37	(1)
Lubricated Wear Classification	38	(1)
Lubricated Wear Versus ``Dry'' Wear	38	(4)
Wear Measurement in Well-Lubricated Systems	42	(2)
Measurement Procedures	44	(17)
Run-In Process	46	(3)
General Performance Wear Test (GPT)	49	(3)
Enhanced Oxidation Wear Test (EOT)	52	(1)
Boundary Film Persistence Test (BFPT)	53	(2)
Case Study with GPT and BFPT	55	(2)
Boundary Film Failure Test (BFFT)	57	(4)
Wear Mechanisms Under Lubricated Conditions	61	(4)
Modeling of Lubricated Wear	65	(3)
Wear	65	(1)
Contact Area	65	(1)
Rheology	66	(1)
Film Thickness	67	(1)
Contact Stress	67	(1)
Flash Temperatures	67	(1)
Summary	68	(3)
Acknowledgments	69	(1)
References	69	(2)
Wear and Chemistry of Lubricants	71	(24)
A. Neville
A. Morina
Encountering Wear in Tribologicai Contacts	71	(2)
Lubricant Formulations -- Drivers for Change	73	(3)
Tribochemistry and Wear	76	(1)
Antiwear Additive Technologies	77	(11)
Antiwear Technologies	77	(1)
ZDDP -- Antiwear Mechanism	78	(5)
Interaction of ZDDP with Other Additives	83	(4)
New Antiwear Additive Technologies	87	(1)
Extreme Pressure Additives	88	(1)
Lubricating Non-Fe Materials	89	(6)
References	90	(5)
Surface Chemistry in Tribology	95	(28)
A.J. Gellman
N.D. Spencer
Abstract	95	(1)
Introduction	95	(1)
Boundary Lubrication and Oiliness Additives	95	(8)
Introduction	95	(1)
Monolayers, Multilayers and Soaps	96	(6)
Viscous Near-Surface Layers	102	(1)
Boundary Lubrication in Natural Joints	102	(1)
Summary	103	(1)
Zinc Dialkyldithiophosphate	103	(6)
Background	103	(1)
Analytical Approaches	104	(1)
Summary of Film-Formation Mechanism	104	(1)
Studies of Film Structure, Composition, and Thickness	105	(4)
Hard Disk Lubrication	109	(3)
Vapor-Phase Lubrication	112	(3)
Tribology of Quasicrystals	115	(3)
Conclusions	118	(5)
Acknowledgments	118	(1)
References	118	(5)
Tribology of Engineered Surfaces	123	(44)
K. Holmberg
A. Matthews
Abstract	123	(1)
Introduction	123	(2)
Definition of an Engineered Surface	125	(1)
Tribomechanisms of Coated Surfaces	125	(14)
Scales of Tribology	125	(1)
Macromechanical Friction and Wear	126	(5)
Micromechanical Mechanisms	131	(1)
Modelling Stresses and Strains in a Coated Microcontact	132	(1)
Tribochemical Mechanisms	133	(2)
Nanoscale Mechanisms	135	(1)
Debris Generation and Transfer Layers	136	(3)
Contact Types	139	(5)
Sliding	139	(2)
Abrasion	141	(1)
Impact	141	(1)
Surface Fatigue	141	(1)
Fretting	142	(1)
Chemical Dissolution	143	(1)
Lubricated	143	(1)
Advanced Coating Types	144	(8)
Hard Binary Compound Coatings	145	(1)
Multilayer Coatings	146	(3)
Nanocomposite Coatings	149	(2)
Hybrid and Duplex Coatings	151	(1)
Applications	152	(2)
Conclusions	154	(13)
References	155	(12)
Wear of Ceramics: Wear Transitions and Tribochemical Reactions	167	(24)
S. Jahanmir
Abstract	167	(1)
Introduction	168	(1)
Structure and Properties of Ceramics	168	(2)
Alumina Ceramics	168	(1)
Silicon Nitride Ceramics	169	(1)
Silicon Carbide Ceramics	170	(1)
Wear Transitions	170	(7)
Alumina	171	(3)
Silicon Nitride	174	(1)
Silicon Carbide	175	(2)
Damage Formation in Hertzian Contacts	177	(4)
Brittle Behavior	177	(1)
Quasi-Plastic Behavior	177	(3)
Brittleness Index	180	(1)
Transition Loads in Sliding Contacts	181	(4)
Quasi-Plastic Behavior	181	(2)
Brittle Behavior	183	(1)
Transition from Brittle Fracture to Quasi-Plasticity	184	(1)
Ceramics in Tribological Applications	185	(6)
Acknowledgments	187	(1)
References	187	(4)
Tribology of Diamond and Diamond-Like Carbon Films: An Overview	191	(32)
A. Erdemir
Ch. Donnet
Abstract	191	(1)
General Overview	192	(2)
Diamond Films	194	(13)
Deposition and Film Microstructure	194	(1)
Tribology of Diamond Films	195	(9)
Practical Applications	204	(3)
Diamond-like Carbon Films	207	(12)
Structure and Composition	207	(2)
Tribology of DLC Films	209	(6)
Synthesis of Carbon Films with Superlow-Friction and -Wear Properties	215	(2)
Practical Applications	217	(2)
Summary and Future Direction	219	(4)
Acknowledgments	219	(1)
References	220	(3)
Tribology of Polymeric Solids and Their Composites	223	(46)
B.J. Briscoe
S.K. Sinha
Abstract	223	(1)
Introduction	224	(1)
The Mechanisms of Polymer Friction	225	(3)
The Ploughing Term -- Brief Summary	225	(2)
The Adhesion Term -- Brief Summary	227	(1)
Wear	228	(21)
Semantics and Rationalizations	228	(2)
Wear Classification Based on Generic Scaling Responses	230	(2)
Phenomenological Classification of Wear Damages	232	(8)
Wear Classification Based on Polymeric Responses	240	(9)
Tribology of Polymer Composites	249	(5)
`Soft and Lubricating' Phases in a Harder Matrix	249	(1)
`Hard and Strong' Phases in a `Soft' Matrix	250	(3)
Hybrid Polymer Composites	253	(1)
Environmental and Lubrication Effects	254	(2)
A Case Study: Polymers in Hip and Knee Prosthetic Applications -- Ultrahigh-Molecular-Weight Poly(ethylene) (UHMWPE)	256	(4)
Concluding Remarks	260	(9)
Acknowledgements	261	(1)
References	261	(8)
Wear of Polymer Composites	269	(22)
K. Friedrich
Z. Zhang
P. Klein
Abstract	269	(1)
Introduction	269	(1)
Sliding Wear of Filler Reinforced Polymer Composites	270	(10)
Short Fibres and Internal Lubricants	270	(2)
PTFE Matrix Composites	272	(3)
Micro- and Nanoparticle Reinforcements	275	(2)
Integration of Traditional Fillers with Inorganic Nanoparticles	277	(2)
Functionally Graded Tribo-Materials	279	(1)
Artificial Neural Networks Approach for Wear Prediction	280	(2)
Fibre Orientation, Wear Mechanisms and Stress Conditions in Continuous Fibre Reinforced Composites	282	(4)
Conclusions	286	(5)
Acknowledgements	286	(1)
References	287	(4)
Third-Body Reality -- Consequences and Use of the Third-Body Concept to Solve Friction and Wear Problems	291	(26)
Y. Berthier
Abstract	291	(1)
Introduction	292	(1)
Relationship Between the Third Body and Friction	292	(1)
Boundary Conditions	292	(1)
Friction Analysis	292	(1)
Relationship Between the Third Body and Wear	293	(1)
Wear Laws	293	(1)
Material Hardness and Wear	294	(1)
What Methods Exist for Studying Friction and Wear?	294	(4)
The Scientific Context Surrounding Tribology	294	(1)
Physical Difficulties Related to Studying Contacts	295	(2)
So Where to from Here?	297	(1)
The Third-Body Concept	298	(2)
Artificial and Natural Third Bodies	298	(1)
Contact Without the Third Body	299	(1)
Types of ``Solid'' Third Body from the Mechanical Viewpoint	299	(1)
``Action Heights'' of Third Bodies	300	(1)
Functions and Behaviour of the Third Body	300	(4)
Functions of the Third Body	300	(1)
Operation of Solid Third Bodies	301	(1)
Tribological Circuit of Third-Body Flows	302	(1)
Rheology of the Third Body	303	(1)
Scientific and Technological Consequences of the Tribological Circuit	303	(1)
Roles of the Materials in a Tribological Contact	304	(2)
Indirect Role of the Materials -- Scale of the Actual Mechanism or Mechanical Device	304	(1)
Direct Role of the Materials -- Scale of First Bodies	304	(1)
Optimal Direct Response of Material to the Tribological Contact	305	(1)
Consequences on the Approach Used for Solving Technological Problems	306	(1)
Taking into Account the Effects of the Mechanism	306	(1)
Choosing the Conditions to be Modelled	306	(1)
Technological Consequences of the Effects of the Mechanism	307	(1)
Taking into Account the Effect of the First Bodies	307	(1)
Local Contact Dynamics	307	(1)
Technological Consequences of the Effects of the First Bodies	307	(1)
``Solid'' Natural Third-Body Modelling	308	(2)
Reconstruction of the Tribological Circuit	308	(1)
Technological Consequences of the Third Body	309	(1)
Correspondence of the Strategy Proposed to Reality	310	(1)
Control of Input Conditions	310	(2)
Objectives	310	(1)
Procedure	311	(1)
Precautions	311	(1)
Performing Experiments	312	(2)
Initial Conditions	312	(1)
Exterior of the Contact	313	(1)
Interior of the Contact	313	(1)
Conclusions	314	(3)
Acknowledgements	314	(1)
References	315	(2)
Basic Principles of Fretting	317	(22)
P. Kapsa
S. Fouvry
L. Vincent
Abstract	317	(1)
Introduction	317	(2)
Wear	319	(1)
Industrial Needs	320	(1)
Fretting in Assemblies	321	(1)
Fretting Processes	322	(8)
Fretting Parameters	330	(6)
Nature of Loading	330	(1)
Nature of the First Bodies	331	(1)
Coatings	332	(2)
Environment	334	(1)
Frequency	335	(1)
Temperature	335	(1)
Conclusions	336	(3)
References	337	(2)
Characterization and Classification of Abrasive Particles and Surfaces	339	(30)
G.W. Stachowiak
D.V. De Pellegrin
P. Podsiadlo
Abstract	339	(1)
Introduction	340	(1)
General Descriptors of Particle Shape	340	(1)
Particle Angularity Parameters	341	(12)
Angularity Parameters SP and SPQ and Their Relation to Abrasive and Erosive Wear	342	(2)
Cone-Fit Analysis (CFA)	344	(5)
Sharpness Analysis	349	(4)
Particle Size Effect in Abrasive Wear	353	(3)
Sharpness of Surfaces	356	(3)
Characterization of Surface Sharpness by the Modified SPQ Method	356	(2)
Characterization of Surface Sharpness by SA	358	(1)
Classification of Abrasive Surfaces	359	(5)
Summary	364	(5)
Acknowledgements	365	(1)
References	365	(4)
Wear Mapping of Materials	369	(56)
S.M. Hsu
M.C. Shen
Introduction	369	(3)
Wear -- A System Perspective	370	(1)
Historical Material Selection Guide	370	(2)
Basic Definition of Wear	372	(3)
Nature of Wear	372	(1)
Wear Characterization	372	(3)
Wear as a System Function	375	(1)
Wear Maps as a Classification Tool to Define the System	376	(1)
Wear as an ``Intrinsic'' Material Property as Defined by Wear Maps	377	(1)
Different Kinds of Wear Maps	378	(2)
Application of Wear Maps	380	(31)
Material Comparison Based on Wear Maps	381	(4)
Wear Transition Diagrams	385	(4)
Material Selection Guided by Wear Maps	389	(2)
Wear Mechanism Identification	391	(5)
Wear Modeling Guide Based on Wear Maps	396	(9)
Wear Prediction Based on Wear Maps	405	(6)
Construction Techniques of Wear Maps	411	(9)
Conducting Wear Experiments	411	(1)
Wear Data	412	(1)
Data Trend Analysis	413	(1)
Wear Mapping	414	(2)
Selection of Parameters for Mapping	416	(2)
Assumptions in the Step-Loading Test Procedure	418	(2)
Application Map Concept and Examples	420	(1)
Future Wear Map Research	421	(4)
References	422	(3)
Machine Failure and Its Avoidance -- Tribology's Contribution to Effective Maintenance of Critical Machinery	425	(28)
B.J. Roylance
Abstract	425	(1)
Introduction	425	(1)
Maintenance Practice and Tribological Principles	426	(6)
Maintenance Practice -- A Brief Historical Overview	426	(1)
Tribological Principles	427	(4)
Tribology and Maintenance	431	(1)
Failure Diagnoses	432	(4)
Failure Morphology and Analysis	432	(2)
Dealing with Failure -- Two Short Case Studies	434	(2)
Comment	436	(1)
Condition-Based Maintenance	436	(4)
Wear and Wear Debris Analysis	440	(8)
Wear Modes and Associated Debris Characteristics -- Some Experimental Results and Their Application to RAF Early Failure Detection Centres	443	(2)
Summary of Laboratory Test Results	445	(1)
Wear Particle Classification and Application	446	(2)
Predicting the Remaining Useful Life and Evaluating the Cost Benefits	448	(2)
Remaining Useful Life Predictions	448	(1)
Evaluating the Cost Benefits	449	(1)
Closure	450	(3)
Acknowledgements	450	(1)
References	451	(2)
Index	453