Metallic Wear

DEEPTESH SINGH

Wear of Metals

What is Metallic Wear?

known as the Metallic Wear.

Wear is the result of erosion, abrasion,

impact, metal-to-metal contact, oxidation, and corrosion, or a

Introduction to Wear

Plastic deformation at the interface often leads to

wear, i.e., deformation induced wear. Wear can also be caused by chemical processes. There are many different kinds of wear mechanisms We have to analyze these wear mechanisms using mechanics, thermodynamics, etc. Tribology is a multi-disciplinary subject

Types of Wear:

There are generally 12 Types of Metallic

Wear:

1. Mild Adhesion
2. Severe Adhesion 3. Abrasion 4. Erosion

Types of Wear:

6. Contact Fatigue 7. Corrosion

8. Fretting Corrosion
9. Brinelling

10.Electro-Corrosion 11.Electrical Discharge 12.Cavitation Damage

Mild Adhesion:

Mild Adhesion:

Generally, removal of surface film material .

during relative motion. Mild Adhesion

Example:

Other names Normal/Common

Susceptible Machine Parts All

Mild Adhesion - How to detect it :

Unaided Eye Low rates of wear No damage Deeper original grinding marks still visible Microscopically Smooth micro plateaus among original grinding marks Slight coloration due to films Slight coloration due to films

Mild Adhesions Solutions:

Prevention
Mechanical None

LUBRICANT

None

Severe Adhesion:

Severe Adhesion:

Cold welding of metal surfaces due to intimate metal to metal contact.

Mechanism:
when two surfaces are brought together under load, asperities of the two surfaces adhere to each other. The conditions at the interface of these junctions are

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Detection:
Severe Adhesion - How to detect it : Unaided Eye Rough, torn, melted or plastically deformed metal, bands or streaks Microscopically Rough, irregular surface

High temperature oxidation

Metal from other surface adhering to other surface by spot tests or microprobe analysis

High friction, high rates of wear

Conditions Promoting Wear:

Conditions:
1. High loads, speeds and/or temperatures 2. Use of stainless steels or aluminum 3. Insufficient lubricant 4. Lack of anti-scuff additives 5. No break in 6. Abrasive wear interrupting film allowing

adhesion

Severe Adhesion Solutions:

1. Reduce load, speed and temperature 2. Improve oil cooling 3. Use compatible metals 4. Apply surface coatings such as phosphating 5. Modify surface, such as ion implantation LUBRICANT: Use more viscous oil to separate surfaces Use "extreme pressure" (anti-scuff) additives such as

Abrasion:

Abrasion is the wearing of surfaces by rubbing,

grinding, or other types of friction. It usually occurs due to metal-to metal contact. It is a scraping, grinding wear that rubs away metal surfaces and can be caused by the scouring action of sand, gravel, slag, earth, and other gritty material.
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Example

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Detection:
Abrasion - How to detect it :

Unaided Eye
Scratches or parallel furrows in the direction of motion, similar to "sanding"

Microscopically
Clean furrows, burrs, chips

High rates of wear

Embedded abrasive particles

Conditions Promoting Wear:

Conditions:
1. Hard particles contaminating oil 2. Insufficient metal hardness 3. Hard metal with rough surface against soft metal

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Prevention:

MECHANICAL Remove abrasive by improved air and oil filtering, clean oil

handling practices, improved seals, flushing and frequent oil changes Minimize shot peening, beading, or sand blasting of surfaces because abrasives cannot be completely removed Increase hardness of metal surfaces
LUBRICANT Use oil free of abrasive particles

Erosion:

Definition:

Cutting of materials by hard particles in a high velocity fluid impinging on a surface

Occurrence:

This type of wear results from sharp particles impinging on a surface such as the cutting of materials by hard particles in a high velocity fluid impinging on a surface. This action is very much

Mechanism:

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Erosion - How to detect it:

Unaided Eye

Microscopically

Smooth, broad grooves in direction Short V-shaped furrows by of fluid flow scanning electron microscopy
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Matte texture, clean metal

Embedded hard particles

Example:

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Erosion Solutions:

Prevention:
MECHANICAL:

Remove abrasive by improved air and oil filtering, clean oil

handling practices, improved seals, flushing and frequent oil changes Increase hardness of metal surfaces Reduce impact angle to less than 15 degrees
LUBRICANT: Use oil free of abrasive particles

Contact Fatigue:

Metal removed by cracking and pitting, due to cyclic elastic stress during rolling and sliding.

Occurrence:
This type of wear is produced when repeated sliding or rolling occurs over a track. The most common example is the action of a ball or roller

Contact Fatigue - How to detect it:

Detection:
Unaided Eye Microscopically Cracks, pits and spalls Combination of cracks and pits with sharp edges Subsurface cracks by metallographic cross-section.

Example

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Prevention:

MECHANICAL: Reduce contact pressures and frequency of cyclic

stress Use Use clean, dry oil high quality vacuum melted steels Use less abusive surface finish LUBRICANT:
Use more viscous oil

Corrosion Wear:

Corrosion wear is the gradual deterioration of

unprotected metal surfaces, caused by the effects of the atmosphere, acids, gases, alkalies, etc. This type of wear creates pits and perforations and may eventually dissolve metal parts.

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Mechanism:

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Corrosion - How to detect it:

Detection:
Unaided Eye
Corroded metal surface rust, FeOHO (hydrated iron oxide) is a Scale, films, pits containing common iron corrosion product corrosion products

Microscopically

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Example:

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Corrosion Solutions:

Prevention
MECHANICAL 1. 2. 3. 1.

Use more corrosion resistant metal (not stainless) Reduce operating temperature Eliminate corrosive material LUBRICANT Remove corrosive material such as too chemically active additive and contaminates

Fretting:

Definition:
Wear between two solid surfaces experiencing oscillatory relative motion of low amplitude.

Occurrence:
Fretting wear occurs where there is oscillatory

Mechanism:

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Fretting - How to detect it

Unaided Eye

Microscopically

Corroded stained surfaces

Thick films of oxide and

where damage on one metal. Red and black for surface is mirror image of steel mating surface Loose colored debris around

Example:

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Fretting - Solutions

MECHANICAL
1. Reduce or stop viscosity vibration by tighter fit or higher load 1. Use oil of lower 2. Improve lubrication between surfaces by

rougher (then honed) surface finish

LUBRICANT
2. Relubricate frequently

False Brinneling:

Definition:
Localized wear spots made by rolling elements on

raceways due to limited rolling/repeated impact.

Occurrence:

Brinelling is typically characterized by indentations on the

Localized wear spots formed by rolling elements on

raceways due to limited rolling/repeated impact. False inner or outer raceway of a rolling element bearing. The indentation corresponded to the position of the rolling

Example:

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False Brinelling - Solutions

Detection:
Unaided Eye Indentations on raceway Microscopically Indentations on raceway

Prevention MECHANICAL Reduce or eliminate impact Rotate bearings occasionally

LUBRICANT

Change viscosity

Cavitation:

Removal of metal by vapor cavity implosion in a

cavitating liquid.

Occurrence:
Cavitation happens, for example, in high-pressure

pumps adjacent to the intake ports and on the blades of a ship's propellers. When a sudden

Cavitation - How to detect it

D e t e c t i on:
Unaided Eye
Clean frosted or rough appearing metal

Microscopically
Clean, metallic bright rough metal, pits

Removal of softer phase from 2-phase metal Deep, rough pits or grooves (graphite phase in cast iron is susceptible)
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Cavitation - Solutions

Prevention:
MECHANICAL Use hard, tough metals, such as tool steel Reduce vibration, flow velocities and pressures Avoid restriction and obstructions to liquid flow LUBRICANT Avoid low vapor pressure, aerated, wet oils

Polishing:

Definition:
Continuous removal of surface films by very fine abrasives. Polishing wear is characterized by very shiny, very smooth, mirror like metal surfaces. Fine abrasives wear away the surface films as they form and reform

Mechanism:

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Polishing - How to detect it

Detection:
Unaided Eye Microscopically
Featureless surface except High wear but a bright mirror finish scratches at high magnification by electron microscopy

Example:

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Polishing - Solutions

Prevention
MECHANICAL None LUBRICANT Choose less chemically active additive Remove corrosive contaminant Remove abrasive