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Research Papers: Friction & Wear

Experimental and Finite Element Simulation of Wear in Nanostructured NiAl Coating

[+] Author and Article Information
H. Tavoosi, S. Ziaei-Rad

Department of Mechanical Engineering,
Isfahan University of Technology,
Isfahan 84156-83111, Iran

F. Karimzadeh

Department of Material Engineering,
Isfahan University of Technology,
Isfahan 84156-83111, Iran

S. Akbarzadeh

Department of Mechanical Engineering,
Isfahan University of Technology,
Isfahan 84156-83111, Iran
e-mail: s.akbarzadeh@cc.iut.ac.ir

1Corresponding author.

Contributed by the Tribology Division of ASME for publication in the JOURNAL OF TRIBOLOGY. Manuscript received January 7, 2015; final manuscript received May 12, 2015; published online July 1, 2015. Assoc. Editor: Dae-Eun Kim.

J. Tribol 137(4), 041601 (Oct 01, 2015) (6 pages) Paper No: TRIB-15-1008; doi: 10.1115/1.4030683 History: Received January 07, 2015; Revised May 12, 2015; Online July 01, 2015

In this paper, the wear of nanostructured NiAl coating was studied both experimentally and numerically. First, the nanocrystalline NiAl intermetallic powder was synthesized by mechanical alloying (MA) of aluminum and Ni powders. The coatings were deposited onto the low carbon steel substrate using high velocity oxy-fuel (HVOF) technique. Nanoindentation test was conducted to find out the mechanical properties of the coating. The dry wear tests were then performed using a pin-on-block test rig under different operating conditions. Finally, finite element (FE) method was employed to model the wear characteristics of the prepared nanostructured material. A three-dimensional (3D) FE model was created and used to simulate the pin-on-block experiments. The results show that the volume losses predicted by the numerical analysis are in good agreement with the experimental data.

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Figures

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Fig. 1

The force displacement diagram of nanoindentation test

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Fig. 2

Atomic force microscopy (AFM) images of nanostructured NiAl surface after indentation

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Fig. 3

Friction coefficient profiles for nanostructured NiAl coating: (a) 30 N, (b) 60 N, and (c) 90 N

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Fig. 4

Mass loss of coating during dry sliding wear tests for three different loads (maximum standard deviation is about 1 mg)

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Fig. 5

Scanning electron microscope (SEM) of the specimen surface with (a) 14× magnification and (b) 400× magnification

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Fig. 6

(a) Whole scale test setup of pin-on-block in dry sliding and (b) FE model

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Fig. 9

Comparison between block volume losses of experimental and numerical results along the 1000 m sliding under (a) 30 N, (b) 60 N, and (c) 90 N load (maximum standard deviation in experiment data is about 0.6 mm3)

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Fig. 8

Superposition of elastic deformation effect and wear on block surface under 30 N load at: (a) after 800 wear cycle, (b) after 2600 wear cycle, (c) after 6300 wear cycle, and (d) after 12500 wear cycle

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Fig. 7

Contact pressure profiles of whole scale and FE model in comparison with Hertz solution at 30 N load

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