Tribology and Surface Engineering for Industrial Applications

Tribology is a multidisciplinary science that encompasses mechanical engineering, materials science, surface engineering, lubricants, and additives chemistry with tremendous applications. Tribology and Surface Engineering for Industrial Applications discusses the latest in tribology and surface engineering for industrial applications. This book: Offers information on coatings and surface diagnostics Explains a variety of techniques for improved performance Describes applications in automotive, wheel and rail materials, manufacturing, and wind turbines Written for researchers and advanced students, this book encompasses a wide-ranging view of the latest in industrial applications of tribology and surface engineering for a variety of cross-disciplinary applications. This book provides a comprehensive account of recent developments and applications in the field of tribology, lubrication, and surface engineering. The development of high performance in different material pairs such as metal-metal, ceramic-ceramic, ceramic-polymer and metal-polymer composites is essential to enhancing tribology behaviour. Cover 1 Half Title 2 Title Page 4 Copyright Page 5 Table of Contents 6 Preface 8 Editors 10 Contributors 12 Chapter 1 Mechanical and Sliding Wear Performance of AA2024-AlN/Si[sub(3)] N[sub(4)] Hybrid Alloy Composites Using Preference Selection Index Method 14 1.1 Introduction 15 1.2 Experimental Details and Methodology 16 1.2.1 Materials, Design Aspects, and Fabrication Procedure 16 1.2.2 Physical, Mechanical, Thermal Conductivity, and Fracture Toughness Characterization 16 1.2.3 Dry Sliding Wear Tribometer 18 1.2.4 PSI Method and Taguchi Design of Experiment Optimization 19 1.2.5 Surface Morphology Studies 19 1.3 Results and Discussion 20 1.3.1 Physical, Mechanical, Thermal Conductivity, and Fracture Toughness Analysis 20 1.3.2 Analysis Using PSI Method and Taguchi Design of Experiment Optimization 23 1.3.3 Steady-State-Specific Wear Rate and Coefficient-of-Friction Analysis 28 1.3.4 Worn Surface Micrograph Analysis 29 1.4 Conclusions 29 Acknowledgments 33 References 33 Chapter 2 Wear Properties of UHMWPE: A Case Study of Gas Spring 36 2.1 Introduction 36 2.2 Tribological Properties of UHMWPE 38 2.3 A Case Study: Wear Deformation on UHMWPE Piston Head in a Gas Spring 44 2.4 Wear Tests for UHMWPE 46 2.5 Conclusions 51 References 51 Chapter 3 Tribology of Spray-Formed Aluminum Alloys and Their Composites 54 3.1 Introduction 55 3.2 Wear and Friction Behavior 57 3.2.1 Test Operating Parameters 58 3.2.1.1 Effect of Sliding Distance 58 3.2.1.2 Effect of Normal Load 59 3.2.1.3 Effect of Sliding Speed 62 3.2.2 Material Parameters 62 3.2.2.1 Effect of Hardness 62 3.2.2.2 Effect of Multiple Reinforcements 63 3.2.2.3 Amount of Reinforcement Particles 63 3.2.2.4 Effect of Solid Lubricant 64 3.2.2.5 Effect of Porosity 64 3.2.3 Physical Parameters 64 3.2.3.1 Effect of Environment 64 3.2.3.2 Effect of Temperature 65 3.2.4 Other Parameters 65 3.2.4.1 Effect of Warm Rolling 65 3.2.4.2 Effect of Hot Pressing 67 3.2.4.3 Effect of Surface Treatment 67 3.2.4.4 Effect of Fabrication Process 68 3.2.4.5 Effect of Process Variables 69 3.3 Summary 69 References 69 Chapter 4 Ranking Analysis and Parametric Optimization of ZA27-SiC-Gr Alloy Composites Based on Mechanical and Sliding Wear Performance 74 4.1 Introduction 75 4.2 Materials and Methodology 76 4.2.1 Material, Design Aspects, and Fabrication of ZA27-SiC-Gr Alloy Composites 76 4.2.2 Physical and Mechanical Characterization 76 4.2.3 Dry Sliding Wear Tribometer 79 4.2.4 Taguchi Design of Experiment Optimization 80 4.2.5 Surface Morphology Studies 80 4.2.6 Hybrid AHP-TOPSIS Ranking Optimization Method 81 4.3 Results and Discussion 84 4.3.1 Physical and Mechanical Characterizations 84 4.3.2 Taguchi Analysis 87 4.3.3 Steady-State Wear/Friction Analysis (Effect of Sliding Distance) 89 4.3.4 Worn Surface Damage Analysis 90 4.3.5 Hybrid AHP-TOPSIS Ranking Optimization 91 4.4 Conclusion 94 Acknowledgments 94 References 94 Chapter 5 Surface Texture Properties and Tribological Behavior of Additive Manufactured Parts 98 5.1 Introduction 99 5.2 Additive Manufactured Surfaces 101 5.2.1 Additive Manufacturing Processes 101 5.2.2 Surface Post-Processing of AM Parts 104 5.2.2.1 Abrasive Blasting 105 5.2.2.2 Shot Peening 106 5.2.2.3 Polishing 107 5.2.2.4 Laser-Assisted Surface Finishing 109 5.2.2.5 Ultrasonic-Assisted Machining 109 5.2.2.6 Precision Grinding 110 5.2.2.7 Magnetic Field-Assisted Finishing 110 5.2.2.8 Chemical Post-Processing 110 5.2.3 Surface Texture Parameters and Their Effects on Tribological Behavior 111 5.2.3.1 Arithmetic Mean Deviation 112 5.2.3.2 Root Mean Square Height 113 5.2.3.3 Maximum Height of Profile 115 5.2.3.4 Skewness 116 5.2.3.5 Kurtosis 116 5.2.3.6 Mean Width of the Profile Elements 117 5.2.3.7 Material Ratio of the Profile 117 5.2.4 Additive Manufacturing Surfaces and Their Tribological Properties 120 5.3 Conclusion and Future Remarks 122 References 122 Chapter 6 Wear and Corrosion of Wind Turbines 128 6.1 Introduction 128 6.2 Components of Wind Turbines 130 6.3 Materials Used for Wind Turbine Components 131 6.3.1 Tower and Foundation 131 6.3.2 Nacelle, Gearbox, and the Rotor Hub 133 6.3.3 Rotor Blades 134 6.4 Tribological Failure Analysis of Wind Turbine Components 136 6.4.1 Vibration-Based Monitoring (Focus on Bearing Failure) 136 6.4.2 Oil Debris-Based Monitoring (Deterioration of Lubricant) 139 6.4.3 Blade Monitoring 140 6.5 Corrosion Aspects of Wind Turbines 141 6.5.1 Various Forms of Corrosion Occurring in Wind Turbine 143 6.5.2 Corrosion Protection 144 6.5.2.1 Active Corrosion Protection: Cathodic Corrosion Protection (CCP) 144 6.5.2.2 Passive Corrosion Protection 145 6.6 Corrosion Testing 149 6.6.1 Field Test 149 6.6.2 Laboratory Tests under Defined Artificial Stress Conditions 149 6.7 Conclusion and Future Work 150 References 150 Chapter 7 Surface Texturing Practices to Improve the Wear Behavior of Cutting Tools for Machining of Super Alloys 154 7.1 Introduction 154 7.2 Surface Texturing 157 7.3 Machining of Super Alloys Using Textured Tools 161 7.3.1 Inconel 718 and Ti6Al4V 161 7.4 Laser Surface Texturing (LST) 163 7.4.1 Influential Factors 164 7.4.2 Texturing Methodology 168 7.4.3 Texture Optimization 170 7.4.4 Tribology of Textured Surfaces 171 7.5 Conclusions 177 7.6 Future Scope 177 References 178 Chapter 8 Surface Engineering: Coatings and Surface Diagnostics 182 8.1 Introduction 183 8.1.1 Surface Engineering 183 8.1.2 Importance of Surface Engineering 183 8.2 Classification of Surface Engineering Processes 184 8.2.1 Microstructural Modification 184 8.2.1.1 Surface Transformation Hardening 184 8.2.1.2 Surface Melting 187 8.2.1.3 Shot Peening 188 8.3 Compositional Modification (Coating Deposition) 189 8.3.1 Electrochemical Methods 189 8.3.2 Conversion Coating 190 8.3.3 Hot Dipping 191 8.3.4 Vapor Deposition 192 8.3.5 Thermal Spraying 195 8.4 Surface Characterization 197 8.4.1 X-Ray Photoelectron Spectroscopy 198 8.4.1.1 Principle 198 8.4.2 Atomic Force Microscopy 198 8.4.3 Nanoindentation 199 8.5 Summary 200 8.6 Future Work 201 References 201 Chapter 9 Surface Coatings for Automotive Applications 206 9.1 Background and Introduction 206 9.2 Surface Coatings for Cutting Tools 210 9.3 Surface Coating Materials and Techniques 211 9.4 Methods of Coating the Surface 212 9.4.1 Gaseous State Processes 213 9.4.1.1 Applications of CVD Coatings 214 9.4.1.2 Applications of PVD Coatings 214 9.4.2 Molten and Semi-Molten State Processes 215 9.4.2.1 Laser Surface Treatments 215 9.4.2.2 Thermal-Sprayed Coatings 216 9.5 Recent Advances in Surface Coatings for Automotive Applications 217 9.6 Conclusions and Future Works 219 References 220 Chapter 10 Tribology Aspects in Manufacturing Processes 222 10.1 Introduction 222 10.1.1 Metal Working Operations 223 10.2 Role of Tribology in Metal Working 226 10.3 Role of Tribology in Industry 227 10.3.1 Fundamentals of Tribology 227 10.4 Classification of Metal Working Fluids 230 10.4.1 Formulation of Lubricant (Liquid (Oil-Based or Water-Based, Semi-Solid and Solid or Dry) 231 10.4.2 Manufacturing Process Adopted (Cutting Fluid, Grinding Fluid or Forming Fluid) 232 10.4.3 Quantity of Fluid 233 10.4.4 Additives for Lubricants 233 10.5 Wear 233 10.5.1 Wear during Cold Forming 234 10.5.2 Wear during Hot Forming 234 10.6 Tribology at High Temperature 235 10.6.1 Oxidation at High Temperature and Its Effect on Tribology Behaviour 235 10.6.2 Surface Coating and Their Tribological Behaviour 236 10.6.3 Lubrication at Elevated Temperature 236 10.6.4 Testing method (That Is Tribometers in Metal Forming at Elevated Temperature) 237 10.7 Test to Stimulate Hot Working Processes 238 10.7.1 Ring Compression Test 238 10.7.2 Block on Cylinder Test 239 10.8 Summary 240 References 241 Chapter 11 Electroless Coating Technique, Properties, and Applications 246 11.1 Introduction 247 11.2 Electroless Coating Technology 248 11.3 Process Mechanism for Electroless Coatings 249 11.4 Role of Individual Components in the Electroless Bath 251 11.4.1 Source of Nickel Ions 252 11.4.2 Reducing Agents 252 11.4.3 Complexing Agents 252 11.4.4 Accelerator 252 11.4.5 Other Process Parameter 252 11.5 Types of Electroless Coatings 254 11.5.1 Metallic Coatings 254 11.5.2 Electroless Nickel Alloy Coatings (e.g., Ni-P and Ni-B Alloys Deposits) 254 11.6 Electroless Nickel Composite Coatings 255 11.7 Inclusion of Second-Phase (X) Particles into Ni-P Matrix 257 11.8 Properties and Applications of Electroless Coatings 258 11.9 Summary 259 References 260 Index 264 tribochemistry;,tribocorrosion;,green,tribology;,biotribology;,industrial,tribology;,friction,science;,coatings tribochemistry,tribocorrosion,green tribology,biotribology,industrial tribology,friction science,coatings Tribology is a multidisciplinary science that encompasses mechanical engineering, materials science, surface engineering, lubricants, and additives chemistry with tremendous applications. __Tribology and Surface Engineering for Industrial Applications__ discusses the latest in tribology and surface engineering for industrial applications. This book: * Offers information on coatings and surface diagnostics * Explains a variety of techniques for improved performance * Describes applications in automotive, wheel and rail materials, manufacturing, and wind turbines Tribology is a multidisciplinary science that encompasses mechanical engineering, materials science, surface engineering, lubricants, and additives chemistry with tremendous applications. This book discusses the latest in tribology and surface engineering for industrial applications.