Friction and Wear of Ceramics

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 xiiiForeword by Dr. Sanak Mishra xviiForeword by Prof. Koji Kato xviiiPreface xixSection I Fundamentals of Ceramics: Processing and Properties 11 Introduction: Ceramics and Tribology 31.1 Introduction 31.2 Classification of Engineering Materials 61.3 Engineering Ceramics 81.4 Structural Ceramics: Typical Properties and Tribological Applications 91.5 Structure of the Book 141.6 Closure 17References 172 Processing of Bulk Ceramics and Coatings 212.1 Introduction 212.2 Conventional Processing of Ceramics 212.2.1 Sintering Mechanism 222.2.2 Conventional Processing of Ceramics 242.2.2.1 Powder Processing and Compaction 242.2.2.2 Pressureless Sintering 272.2.3 Advanced Processing of Ceramics 282.2.3.1 Hot Pressing 282.2.3.2 Microwave Sintering 282.2.3.3 Spark Plasma Sintering 292.3 Thermal Spray-Based Coating Deposition 302.3.1 Basics of Thermal Spray Deposition 332.3.1.1 Plasma Spray Deposition 332.3.1.2 Flame Spray Deposition 342.3.1.3 Wire Arc Spray Deposition 352.3.1.4 High-Velocity Oxy-Fuel Spray Deposition 362.3.1.5 Detonation Spray Coating 362.3.2 Bond Strength of Thermal Spray Coatings 392.3.2.1 Bond Mechanism 392.3.2.2 Test Methods 402.3.3 Coating Structure 422.3.3.1 Particle and Substrate Material Properties 422.3.3.2 Particle Temperature and Velocity 422.3.4 Case Study: WC-Co Coatings 422.4 Closure 49References 493 Conventional and Advanced Machining Processes 533.1 Introduction 533.2 Conventional Machining 543.3 Advanced Machining Processes 573.3.1 Electro-Discharge Machining 573.3.1.1 Working Principle 593.3.1.2 EDM Process Variables 613.3.1.3 EDM Parameters 623.3.1.4 Surface Analysis 633.3.1.5 EDM of Ceramic-Based Composites 643.4 Closure 66References 664 Mechanical Properties of Ceramics 714.1 Defining Stress and Strain 714.2 Comparison of Tensile Behavior 784.3 Brittle Fracture of Ceramics 804.4 Cracking in Brittle Materials 844.5 Experimental Assessment of Mechanical Properties 874.5.1 Hardness 874.5.2 Compressive Strength 884.5.3 Flexural Strength 894.5.4 Tensile Strength 914.5.5 Elastic Modulus 914.5.6 Fracture Toughness 954.5.6.1 Notched Beam Test 964.5.6.2 Indentation Microfracture Method 974.5.7 Practical Guidelines for Reliable Measurements 984.6 Closure 99References 100Section II Fundamentals of Tribology 1035 Contact Surface Characteristics 1055.1 Nature and Roughness of Contact Surfaces 1055.2 Surface Roughness Measurement 1085.2.1 Stylus Method 1085.2.2 Atomic Force Microscopy 1095.2.3 Optical Interferometry 1105.2.4 Laser Surface Profilometry 1115.2.5 Scanning Electron Microscopy 1115.3 Bearing Area Curve and Cumulative Distribution Function 1115.4 Nominal Versus Real Contact Area 1125.5 Hertzian Contact Stress 1155.6 Closure 116References 1186 Friction and Interface Temperature 1196.1 Theory of Friction 1196.1.1 Friction Laws and Mechanisms 1206.2 Types of Friction 1256.2.1 Static and Kinetic Friction 1256.2.2 Slip-Stick Friction 1266.2.3 Rolling Friction 1266.3 Friction of Engineering Material Classes 1276.4 Frictional Heating and Temperature at the Interface 1396.4.1 Heating Due to Friction 1406.4.2 Understanding the Temperature in the Contact: The Bulk and Flash Temperatures 1416.5 Analytical Models Used to Predict the Temperatures in the Contact 1456.6 Implications of the Important Contact Temperature Models 1466.6.1 Archard Model 1476.6.2 Kong–Ashby Model 1486.7 Closure 149References 1507 Wear of Ceramics and Lubrication 1557.1 Introduction 1557.2 Testing Methods and Quantification of Wear of Materials 1577.3 Classification of Wear Mechanisms 1587.3.1 Tribomechanical Wear 1597.3.1.1 Adhesive Wear 1597.3.1.2 Abrasive Wear 1617.3.1.3 Fatigue Wear 1647.3.1.4 Fretting Wear 1657.3.1.5 Erosive Wear 1677.3.2 Tribochemical Wear 1717.3.2.1 Oxidative Wear 1747.4 Lubrication 1757.4.1 Regimes of Lubrication and the Stribeck Curve 1757.4.2 Influence of Lubricant Composition, Contact Pressure, and Temperature on Lubrication 1787.5 Closure 181References 182Section III Case Study: Sliding Wear of Ceramics 1858 Sliding Wear of SiC Ceramics 1878.1 Introduction 1878.2 Materials and Experiments 1888.3 Friction and Wear Behavior of SiC Ceramics Sintered with a Small Amount of Yttria Additive 1898.4 Influence of Mechanical Properties on Sliding Wear of SiC Ceramics 1918.5 Wear Mechanisms 1918.6 Closure 192References 1939 Sliding Wear of SiC-WC Composites 1959.1 Introduction 1959.2 Microstructure and Mechanical Properties of SiC-WC Composites 1969.3 Influence of Mating Material and WC Content on Tribological Properties 1979.3.1 Friction and Wear Behavior 1979.3.2 Mechanisms of Material Removal 1989.3.3 Friction and Wear of SiC-WC Composites: System-Dependent Properties 2029.3.4 Wear Mechanisms 2029.4 Reciprocated Sliding Wear Behavior of SiC-WC Composites 2039.4.1 Frictional and Wear Behavior 2059.4.2 Critical Analysis of Wear Mechanisms 2069.4.2.1 Wear Debris Analysis 2069.4.2.2 Effect of Temperature 2089.4.2.3 Effect of Test Configuration on Wear Behavior 2089.5 Closure 209References 21010 Sliding Wear of Zirconia-Toughened Alumina 21510.1 Introduction 21510.2 Mechanical Properties of ZTA 21610.3 Sliding Wear Properties of ZTA 21910.4 Correlation with Theoretical Analysis 22210.5 Closure 224References 22511 Abrasive Wear of Detonation Sprayed WC-12Co Coatings 22711.1 Introduction 22711.2 Coatings and Abrasive Wear 22811.3 Abrasive Wear Results 23011.4 Surface and Subsurface Damage Mechanisms 23111.5 Closure 233References 23412 Solid–Lubricant Interaction and Friction at Lubricated Contacts 23712.1 Introduction 23712.2 Materials and Sliding Wear Experiments 23912.3 Wetting and Spreading Properties 24012.4 Surface Energies of Different Classes of Materials 24212.5 Wetting Evaluation of Engineering Surfaces 24212.6 Effect of Wetting on EHL Friction 24612.7 Correlation Between Spreading Parameter and Friction 24712.8 Closure 249References 250Section IV Case Study: Erosive Wear of Ceramics 25313 Erosive Wear of SiC-WC Composites 25513.1 Introduction 25513.2 Materials and Erosion Tests 25613.3 Influence of Type of Erodent on Erosive Wear Behavior 25613.4 Influence of Impingement Angle and WC Content on Erosive Wear Behavior 25813.5 Correlating Erosive Wear Behavior with Microstructural Characteristics 25913.6 Correlating Erosive Wear Behavior with Mechanical Properties 25913.7 Erosive Wear Behavior at High Temperature 26013.8 Closure 262References 26314 Thermo-Erosive Behavior of ZrB2-SiC Composites 26514.1 Introduction 26514.2 High-Temperature Erosion Tests and Computational Modeling 26714.3 Computational Modeling of Thermo-Erosive Behavior 26914.4 High-Temperature Erosion Test Results 27014.5 Transient Thermal Studies Using FE Analysis 27114.6 Coupled Thermo-Structural Analysis 27114.7 Thermo-Erosive Behavior 27314.8 Closure 274References 27515 Erosive Wear of WC-Co Coating 27915.1 Introduction 27915.2 Materials and Erosion Experiments 28015.3 Erosive Wear Mechanisms (Surface Damage) 28215.4 Erosive Wear Mechanisms (Subsurface Damage) 28715.5 Correlating Wear Mechanism with Erodent and Coating Properties 29015.6 Closure 293References 293Section V Case Study: Machining-Induced Wear of Cermets 29516 Crater Wear of TiCN Cermets in Conventional Machining 29716.1 Introduction 29716.2 TiCN Cermets and Machining Conditions 29816.3 Wear Mechanisms of TiCN-WC-Ni Cermets 29916.4 Machining with TiCN-WC-TaC-Ni-Co Cermet Tools 30016.5 Correlating Cermet Composition, Microstructure, and Wear DuringMachining 30416.6 Closure 306References 30617 Wear of TiCN-Based Cermets in Electrodischarge Machining 30917.1 Introduction 30917.2 Materials and EDM Tests 31017.3 Wear of TiCN-Cermets During EDM 31017.4 Mechanisms of Material Removal During EDM 31117.5 Closure 313References 313Section VI Future Scope 31718 Perspective 31918.1 Innovation Cycle for Wear-Resistant Materials 31918.2 In Situ Diagnosis of Tribological Interaction 32118.3 High-Temperature Wear Testing 32118.4 Modeling and Simulation in Tribology 32218.5 Tribomaterialomics– A New Concept 32318.6 Education and Mentoring of Next-Generation Researchers 327References 328Appendix: Appraisal 329A.I Multiple Choice Questions 329A.II Select the Appropriate Combination 350A.III Fill in the Blanks with the Most Appropriate Response 352A.IV Mention the Appropriate Material/Equipment in the Blank 353A.V Identify Whether the Following Statements are True/False 354A.VI Short Review Questions and Descriptive Questions 354A.VII Analytical Questions 363A.VIII Model Answers 366Index 369