Tribology and Surface Engineering for Industrial Applications

Cover
Half Title
Title Page
Copyright Page
Table of Contents
Preface
Editors
Contributors
Chapter 1 Mechanical and Sliding Wear Performance of AA2024-AlN/Si[sub(3)] N[sub(4)] Hybrid Alloy Composites Using Preference Selection Index Method
	1.1 Introduction
	1.2 Experimental Details and Methodology
		1.2.1 Materials, Design Aspects, and Fabrication Procedure
		1.2.2 Physical, Mechanical, Thermal Conductivity, and Fracture Toughness Characterization
		1.2.3 Dry Sliding Wear Tribometer
		1.2.4 PSI Method and Taguchi Design of Experiment Optimization
		1.2.5 Surface Morphology Studies
	1.3 Results and Discussion
		1.3.1 Physical, Mechanical, Thermal Conductivity, and Fracture Toughness Analysis
		1.3.2 Analysis Using PSI Method and Taguchi Design of Experiment Optimization
		1.3.3 Steady-State-Specific Wear Rate and Coefficient-of-Friction Analysis
		1.3.4 Worn Surface Micrograph Analysis
	1.4 Conclusions
	Acknowledgments
	References
Chapter 2 Wear Properties of UHMWPE: A Case Study of Gas Spring
	2.1 Introduction
	2.2 Tribological Properties of UHMWPE
	2.3 A Case Study: Wear Deformation on UHMWPE Piston Head in a Gas Spring
	2.4 Wear Tests for UHMWPE
	2.5 Conclusions
	References
Chapter 3 Tribology of Spray-Formed Aluminum Alloys and Their Composites
	3.1 Introduction
	3.2 Wear and Friction Behavior
		3.2.1 Test Operating Parameters
			3.2.1.1 Effect of Sliding Distance
			3.2.1.2 Effect of Normal Load
			3.2.1.3 Effect of Sliding Speed
		3.2.2 Material Parameters
			3.2.2.1 Effect of Hardness
			3.2.2.2 Effect of Multiple Reinforcements
			3.2.2.3 Amount of Reinforcement Particles
			3.2.2.4 Effect of Solid Lubricant
			3.2.2.5 Effect of Porosity
		3.2.3 Physical Parameters
			3.2.3.1 Effect of Environment
			3.2.3.2 Effect of Temperature
		3.2.4 Other Parameters
			3.2.4.1 Effect of Warm Rolling
			3.2.4.2 Effect of Hot Pressing
			3.2.4.3 Effect of Surface Treatment
			3.2.4.4 Effect of Fabrication Process
			3.2.4.5 Effect of Process Variables
	3.3 Summary
	References
Chapter 4 Ranking Analysis and Parametric Optimization of ZA27-SiC-Gr Alloy Composites Based on Mechanical and Sliding Wear Performance
	4.1 Introduction
	4.2 Materials and Methodology
		4.2.1 Material, Design Aspects, and Fabrication of ZA27-SiC-Gr Alloy Composites
		4.2.2 Physical and Mechanical Characterization
		4.2.3 Dry Sliding Wear Tribometer
		4.2.4 Taguchi Design of Experiment Optimization
		4.2.5 Surface Morphology Studies
		4.2.6 Hybrid AHP-TOPSIS Ranking Optimization Method
	4.3 Results and Discussion
		4.3.1 Physical and Mechanical Characterizations
		4.3.2 Taguchi Analysis
		4.3.3 Steady-State Wear/Friction Analysis (Effect of Sliding Distance)
		4.3.4 Worn Surface Damage Analysis
		4.3.5 Hybrid AHP-TOPSIS Ranking Optimization
	4.4 Conclusion
	Acknowledgments
	References
Chapter 5 Surface Texture Properties and Tribological Behavior of Additive Manufactured Parts
	5.1 Introduction
	5.2 Additive Manufactured Surfaces
		5.2.1 Additive Manufacturing Processes
		5.2.2 Surface Post-Processing of AM Parts
			5.2.2.1 Abrasive Blasting
			5.2.2.2 Shot Peening
			5.2.2.3 Polishing
			5.2.2.4 Laser-Assisted Surface Finishing
			5.2.2.5 Ultrasonic-Assisted Machining
			5.2.2.6 Precision Grinding
			5.2.2.7 Magnetic Field-Assisted Finishing
			5.2.2.8 Chemical Post-Processing
		5.2.3 Surface Texture Parameters and Their Effects on Tribological Behavior
			5.2.3.1 Arithmetic Mean Deviation
			5.2.3.2 Root Mean Square Height
			5.2.3.3 Maximum Height of Profile
			5.2.3.4 Skewness
			5.2.3.5 Kurtosis
			5.2.3.6 Mean Width of the Profile Elements
			5.2.3.7 Material Ratio of the Profile
		5.2.4 Additive Manufacturing Surfaces and Their Tribological Properties
	5.3 Conclusion and Future Remarks
	References
Chapter 6 Wear and Corrosion of Wind Turbines
	6.1 Introduction
	6.2 Components of Wind Turbines
	6.3 Materials Used for Wind Turbine Components
		6.3.1 Tower and Foundation
		6.3.2 Nacelle, Gearbox, and the Rotor Hub
		6.3.3 Rotor Blades
	6.4 Tribological Failure Analysis of Wind Turbine Components
		6.4.1 Vibration-Based Monitoring (Focus on Bearing Failure)
		6.4.2 Oil Debris-Based Monitoring (Deterioration of Lubricant)
		6.4.3 Blade Monitoring
	6.5 Corrosion Aspects of Wind Turbines
		6.5.1 Various Forms of Corrosion Occurring in Wind Turbine
		6.5.2 Corrosion Protection
			6.5.2.1 Active Corrosion Protection: Cathodic Corrosion Protection (CCP)
			6.5.2.2 Passive Corrosion Protection
	6.6 Corrosion Testing
		6.6.1 Field Test
		6.6.2 Laboratory Tests under Defined Artificial Stress Conditions
	6.7 Conclusion and Future Work
	References
Chapter 7 Surface Texturing Practices to Improve the Wear Behavior of Cutting Tools for Machining of Super Alloys
	7.1 Introduction
	7.2 Surface Texturing
	7.3 Machining of Super Alloys Using Textured Tools
		7.3.1 Inconel 718 and Ti6Al4V
	7.4 Laser Surface Texturing (LST)
		7.4.1 Influential Factors
		7.4.2 Texturing Methodology
		7.4.3 Texture Optimization
		7.4.4 Tribology of Textured Surfaces
	7.5 Conclusions
	7.6 Future Scope
	References
Chapter 8 Surface Engineering: Coatings and Surface Diagnostics
	8.1 Introduction
		8.1.1 Surface Engineering
		8.1.2 Importance of Surface Engineering
	8.2 Classification of Surface Engineering Processes
		8.2.1 Microstructural Modification
			8.2.1.1 Surface Transformation Hardening
			8.2.1.2 Surface Melting
			8.2.1.3 Shot Peening
	8.3 Compositional Modification (Coating Deposition)
		8.3.1 Electrochemical Methods
		8.3.2 Conversion Coating
		8.3.3 Hot Dipping
		8.3.4 Vapor Deposition
		8.3.5 Thermal Spraying
	8.4 Surface Characterization
		8.4.1 X-Ray Photoelectron Spectroscopy
			8.4.1.1 Principle
		8.4.2 Atomic Force Microscopy
		8.4.3 Nanoindentation
	8.5 Summary
	8.6 Future Work
	References
Chapter 9 Surface Coatings for Automotive Applications
	9.1 Background and Introduction
	9.2 Surface Coatings for Cutting Tools
	9.3 Surface Coating Materials and Techniques
	9.4 Methods of Coating the Surface
		9.4.1 Gaseous State Processes
			9.4.1.1 Applications of CVD Coatings
			9.4.1.2 Applications of PVD Coatings
		9.4.2 Molten and Semi-Molten State Processes
			9.4.2.1 Laser Surface Treatments
			9.4.2.2 Thermal-Sprayed Coatings
	9.5 Recent Advances in Surface Coatings for Automotive Applications
	9.6 Conclusions and Future Works
	References
Chapter 10 Tribology Aspects in Manufacturing Processes
	10.1 Introduction
		10.1.1 Metal Working Operations
	10.2 Role of Tribology in Metal Working
	10.3 Role of Tribology in Industry
		10.3.1 Fundamentals of Tribology
	10.4 Classification of Metal Working Fluids
		10.4.1 Formulation of Lubricant (Liquid (Oil-Based or Water-Based, Semi-Solid and Solid or Dry)
		10.4.2 Manufacturing Process Adopted (Cutting Fluid, Grinding Fluid or Forming Fluid)
		10.4.3 Quantity of Fluid
		10.4.4 Additives for Lubricants
	10.5 Wear
		10.5.1 Wear during Cold Forming
		10.5.2 Wear during Hot Forming
	10.6 Tribology at High Temperature
		10.6.1 Oxidation at High Temperature and Its Effect on Tribology Behaviour
		10.6.2 Surface Coating and Their Tribological Behaviour
		10.6.3 Lubrication at Elevated Temperature
		10.6.4 Testing method (That Is Tribometers in Metal Forming at Elevated Temperature)
	10.7 Test to Stimulate Hot Working Processes
		10.7.1 Ring Compression Test
		10.7.2 Block on Cylinder Test
	10.8 Summary
	References
Chapter 11 Electroless Coating Technique, Properties, and Applications
	11.1 Introduction
	11.2 Electroless Coating Technology
	11.3 Process Mechanism for Electroless Coatings
	11.4 Role of Individual Components in the Electroless Bath
		11.4.1 Source of Nickel Ions
		11.4.2 Reducing Agents
		11.4.3 Complexing Agents
		11.4.4 Accelerator
		11.4.5 Other Process Parameter
	11.5 Types of Electroless Coatings
		11.5.1 Metallic Coatings
		11.5.2 Electroless Nickel Alloy Coatings (e.g., Ni-P and Ni-B Alloys Deposits)
	11.6 Electroless Nickel Composite Coatings
	11.7 Inclusion of Second-Phase (X) Particles into Ni-P Matrix
	11.8 Properties and Applications of Electroless Coatings
	11.9 Summary
	References
Index