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Tribology International 101 (2016) 324–330

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Tribology International
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Mechanistic studies on degradation in sliding wear behavior of IN718


and Hastelloy X superalloys at 500 °C
K.G. Thirugnanasambantham a,b, S. Natarajan c,d,n
a
Department of Metallurgical and Materials Engineering, National Institute of Technology, Tiruchirapalli, Tamilnadu, India
b
Madanapalle Institute of Technology & Science, Madanapalle, Chittoor District, Andhra Pradesh, India
c
Department of Metallurgical and Materials Engineering, National Institute of Technology, Tiruchirapalli, Tamilnadu, India
d
Centre of Excellence in Corrosion and Surface Engineering (CECASE), National Institute of Technology, Tiruchirapalli, Tamilnadu, India

art ic l e i nf o a b s t r a c t

Article history: This technical paper deals with high temperature dry sliding wear behavior and its mechanism of Inconel
Received 22 January 2016 718 and Hastelloy X alloys. The sliding wear behavior of the Inconel 718 alloy and Hastelloy X was
Received in revised form investigated using a pin on disc equipment at 500 °C with varying normal load. Hastelloy X has shown
10 April 2016
the higher coefficient of friction in comparision to IN718. SEM features of worn samples reveal that
Accepted 14 April 2016
Available online 22 April 2016
delamination, ploughing and deep grooving are the dominant wear mechanisms for IN718, while for
Hastelloy X, it is shear band, cleavage formation, debris generation.
Keywords: & 2016 Elsevier Ltd. All rights reserved.
Superalloys
IN718
Hastelloy X
High temperature sliding wear mechanism
SEM

1. Introduction the performance and lifetime of mechanical components and


results in catastrophic failures in many cases.
Wear is a removal of material from the operating surfaces A typical example is relevant to the aerospace industry, where a
under the mechanical action of the two surfaces rubbing together variety of degradation problems exist in aircraft engines as a result
[1]. Relative motion between machine components almost inevi- of metal to metal wear and fretting. Thus mechanical components
tably leads to changes in the surface of engineering components operating in aerospace often require strength to withstand the
which degrades the performance and lifetime of mechanical synergetic attack combining wear and high temperature [9]. Nickel
based superalloys provide solutions to systems which are sub-
components and results in economic loss [2]. Wear may occur in a
jected to stress at high temperatures for prolonged periods. In
number of modes, that includes abrasion, adhesion and erosion
recent times, gas turbine technology for power generation and for
encompassing the field of tribology [3].
aeroengine applications places an increasing demand on the use of
In particular, wear at 400–500 °C is a serious problem in a large
Ni based superalloys [10,11].
number of industrial applications such as power generation, high IN718 and Hastelloy X alloys are used in a wide range of
temperature bearings, valve and valve seats in internal combustion applications including power generation equipment, aircraft
engines, moving assemblies for hypersonic aircraft and missiles engines, space shuttle main engine, land-based and marine tur-
[4–7]. bines [12,13].
Wear at elevated temperatures brings further complications in The crucial characteristics of Nickel base superalloys include
engineering materials, due to loss of mechanical strength of superior tribological properties, excellent mechanical strength,
materials and alterations in the surface conditions leading to outstanding resistance to loading under static, fatigue, and creep
changes in adhesion between the surfaces caused by the joint conditions; good surface stability, good oxidation and corrosion
action of temperature and tribological parameters [8]. It degrades resistance, and good phase stability at high temperatures[14–16].
Friction and wear characteristics of various superalloys have
been investigated by various researchers [17–21]. However, there
n
Corresponding author at: Department of Metallurgical and Materials is only little tribological data available in the literature about
Engineering, National Institute of Technology, Tiruchirapalli, Tamilnadu, India.
E-mail addresses: universalthiru@rediffmail.com
friction and sliding wear behavior of IN718 and Hastelloy X alloys.
(K.G. Thirugnanasambantham), sn@nitt.edu, Regarding mechanisms with which sliding wear phenomenon
drs_natarajan@yahoo.com (S. Natarajan). happens, virtually no report is available in literature on IN718 and

http://dx.doi.org/10.1016/j.triboint.2016.04.016
0301-679X/& 2016 Elsevier Ltd. All rights reserved.
K.G. Thirugnanasambantham, S. Natarajan / Tribology International 101 (2016) 324–330 325

Hastelloy superalloy. Thus main objective of this work is to study Table 2


the friction behavior and sliding wear mechanisms of IN718 and Sliding test parameters.
Hastelloy X alloys using a pin on disc universal tribometer at
Specimen size (Cylindrical) mm 88
500 °C, by varying the normal load. Further it is well known that Pin material IN718 and Hastelloy X
mechanism only always determines the wear rate and vice versa is Disc material EN 31
not true. Hence this paper lays more emphasis on mechanistic Sliding velocity (m/s) 2
Normal load (N) 10, 20, 30
aspects only.
Temperature 500 °C

2. Materials and methodology

In the present study, Inconel 718 and Hastelloy X are chosen as


the substrates and their nominal chemical compositions (in wt%)
are summarized in Table 1. Hardness of Inconel 718 and Hastelloy
X are 40 HRC and 31 HRC respectively. Samples with dimension of
8  8 mm sliced mm sliced using wire electrical discharge
machining (wire–cut) were employed for the dry sliding wear
ο
tests. Dry Sliding wear tests were carried out at 500 C as per ASTM
G76 standard on specimens using pin on disc tribometer, to
simulate sliding friction and wear behavior of IN718 and Hastelloy
X alloys. The temperature was elevated by setting the furnace
temperature in the tribometer and it was measured by attaching
the temperature sensor to the specimen holder. The testing con- Fig. 1. Variation of coefficient of friction of IN718 with distance at 2 m/s.
ditions is summarized in Table 2. Scanning electronic microscope
(Hitachi, S-2000H) was used to observe the surface morphology of
the worn samples to investigate the mechanisms of degradation.

3. Results and discussion

Figs. 1 and 2 illustrate the variations of the coefficient of friction


of the IN718 and Hastelloy X samples with increasing distance at
normal loads of 10, 20 and 30 N. The coefficient of friction (COF)
was recorded throughout each pin-on-disk test by utilizing the
tangential and normal load sensors of the tribometer. When two
contacting surfaces slide against each other, a frictional force is
generated opposite to the direction of sliding. During sliding, the
friction force is considered to be exerted in a direction perpendi-
cular to the normal load. The ratio of these forces is equal to the Fig. 2. Variation of coefficient of friction of Hastelloy X with distance at 2 m/s.
coefficient of friction. The variation of coefficient of friction with
sliding distance provides the basic data for understanding the The effect of wear debris retained within the interface can play
friction behavior of a material. an important role in the wear mechanism and its coefficient of
Figs. 1 and 2 shows that the friction coefficient of the IN718 and friction [22–24]. The effect of 'third bodies' on coefficient of fric-
Hastelloy X specimens under dry sliding condition, increases with tion is complex phenomena and it may give rise to a higher or
increasing normal load. As the applied load increases, the number lower coefficient of friction. This was attributed to the type of
of asperities interactions between the rubbing surfaces increases, motion of wear particles trapped within the wearing interface
resulting in increased friction coefficient. The gradual increase of [25]. The wear particles may skid over each other, act as rollers or
the friction coefficient can be associated to the real contact area become interlocked and undergo fracture. Based on type of motion
between the rubbing surfaces. of wear particles at sliding interface, the applied stress on the
Fig. 1 illustrates that the friction coefficient of the IN718 spe- worn surface, would change the friction coefficients involved in
cimens for all different loads that initially increased with the wear process.
increasing sliding distance until a peak value was reached, and Fig. 1 shows the oscillations in the friction coefficient behavior
then it gradually approached steady state. This is the so-called of the IN718 specimens, this should be attributed to the entrap-
running-in stage. The initial running- in corresponds to the con- ment of wear particles at the interface. Some wear particles may
tact of the asperities between the rubbing surfaces. At the begin- undergo rolling between the surfaces, which lower the friction
ning of sliding the asperities of the surface limit the sliding speed. coefficient. Some wear particles may act as an abrasive, giving rise
Meanwhile the friction leads to removal of some of the asperities to an abrasive-type mechanism which is generally considered to
during running-in stage. increase the coefficients of friction. This was attributed to the

Table 1
Materials chosen and their nominal chemical compositions (in wt%).

Material Ni Fe Cr Mo Co Mn W C Si S Cu Al Ti Cb þTa

Hastealloy X 49.4 18.4 20.9 8.7 0.8 0.6 0.3 0.06 0.2 – – – – –
Inconel 718 52.5 18.5 19 3.05 – 0.8 – 0.04 0.18 0.008 0.15 0.5 0.9 5.03
326 K.G. Thirugnanasambantham, S. Natarajan / Tribology International 101 (2016) 324–330

ploughing action of the particles [26]. This appeared due to the 2. It is well known that the lowest coefficient of friction results in
lack of adhesion of the debris to the worn surface resulting in higher wear resistance by minimizing plastic deformation.
ploughing effects on IN718 specimens. Investigating the wear mechanisms is more important than the
Fig. 2 shows the fluctuations in the friction coefficient behavior knowledge of actual wear rates from the design point of view [30].
of the Hastelloy X specimens. The strong adhesion develops Generally normal load plays a predominant role in determining
between rolling particles, then rolling will become restricted. the sliding wear mechanisms [31].
These particles will require a greater force to move, which
increases the friction coefficient. 3.1. Wear mechanisms of IN718
At 10 N, 20 N, 30 N, friction coefficient curve of the Hastelloy X
showed a noticeable change in the slope after about 650 m (Fig. 2) 3.1.1. Wear mechanisms of IN718 at 10 N
of sliding distance, which could indicate the sudden changes in the SEM (Fig. 3a and b), reveal the sequence of sliding wear
tangential (or friction) force resulting in the friction coefficients mechanisms of IN718 surface at 10 N and 2 m/s. When two sliding
fluctuations in a wavy form. surfaces come into contact, normal and tangential forces are
The friction coefficient of Hastelloy X was higher than the transmitted through contacting asperities. Fig. 3a reveals that due
friction coefficient of IN718 at all loads, shown in Figs. 1 and 2 to high yield strength, IN718 surface exhibit much less plastic
respectively. There remains the question of why the coefficient of deformation when subjected to tractional forces which create a
friction is higher on the Hastelloy X than IN718. It has been sug- pure shear stress state at the sliding interface. Due to tangential
gested that increases in friction may be more closely related to shearing action of asperities causes local pressure between con-
increases in deformation and adhesion [27,28]. The level of tacting asperities, as a result Hertzian contact stresses arise at the
adhesion is determined by the material’s ability to deform. Thus interface of contacting asperities, resulting in ploughing.
Friction coefficient of the IN718 and hastelloy X alloys are asso- These ploughing marks normally start with the score lines,
parallel to the sliding direction and later on these lines capitalize
ciated with their strength properties.
to form shallow ploughing as shown in Fig. 3a. The role of
At elevated temperatures Hastelloy X exhibit less yield strength
ploughing mechanism, is to reduce the energy of sliding asperity
while comparing to IN718 [4]. The yield strength is a major con-
during the sliding action, therefore, much less energy is available
sideration in the sliding wear of metals.
for initiating and propagating the cracks.
The softening of the alloys at elevated temperatures, resulting
Further repeated sliding action of asperities on ploughed sur-
in loss of their yield strength at the contact surfaces [29]. If
face, result in the formation of grooves along with plate like debris
Hertzian contact stress exceeds the shear strength of the sliding
built upon wear track surface of the samples. These are shown in
material, then yielding will occur, resulting in plastic deformation
Fig. 3b. The presence of grooves in the wear track parallel to the
related wear. This indicated increased deformation caused by the
sliding direction, indicate signs of abrasive wear.
reduction in strength of the materials. The deformation improves
the junction growth at asperity contacts in friction and the real 3.1.2. Wear mechanisms of IN718 at 30 N
area of contact. The synergic effect of deformation and adhesion At higher loads, the wear mechanism of IN718 was character-
increases the friction coefficient of Hastelloy X favouring the ized by two typical mechanisms: delamination and abrasion. SEM
severe wear damage to the surface. (Fig. 4), reveal the sequence of sliding wear mechanisms of IN718
The friction coefficient of the Hastelloy X is unstable and varies surface at 30 N and 2 m/s.
continuously due to stick slip motion. Rectangle on the graphs When two contacting surfaces slide against each other, friction
indicate where “seizure” occurs in terms of friction thresholds. At is introduced to the system. During simple sliding, the friction
30 N, there is a sharp rise initially to around 0.9 which would force, or traction force is considered to be exerted in a direction
imply severe seizure. The friction then fluctuates severely and perpendicular to the applied load and parallel to the direction of
reaches as high as 1.6. sliding. As the applied load increases, the number of asperity
IN718 exhibit good yield srength at elevated temperatures. contacts between the rubbing surfaces increases, resulting in
These material properties suppress the junction growth at asperity higher friction. At higher normal loads, Hertzian stress increases
contacts in friction and the real area of contact. Hence the friction due to higher friction coefficient on interface. Once these stresses
coefficient of IN718 is less than Hastelloy X as shown in Figs. 1 and exceed a certain critical level, the apparent area of contact

Formation
Shallow ploughing of grooves

Plate like
debris

Fig. 3. SEM images showing sequence of sliding damage of IN718 surface at 10 N, 2 m/s. (a) Ploughing. (b) Groove formation along with plate like debris.
K.G. Thirugnanasambantham, S. Natarajan / Tribology International 101 (2016) 324–330 327

Delaminated sheets Delaminated


layer

Deformed

thin

flat sheets
Delaminated layer broken
into smaller harder particles

Deep groove

Entrapment of hard particles Damaged wear track


in wear track

Fig. 4. SEM images showing sequence of sliding damage of IN718 surface at 30 N, 2 m/s. (a) Delaminated sheets (b) Delaminated layer broken into smaller harder particles.
(c) Entrapment of wear particles. (d) Deep grooving.

becomes equal to the real area of contact and significant frictional influence of plastic strain gradients. On the other hand, at a larger
heating ensues, resulting in local loss of yield strength of sliding depth, the plastic strain is small, so the driving force for nucleation
material. As friction increases, the location of the maximum shear is negligible. Thus, the competition between the hydrostatic stress
stress moves closer to the subsurface. According to the Von Mises and large plastic strain would determine a damage gradient with a
Yield Criterion [32], if Hertzian contact stress exceeds the shear maximum at a certain distance below the worn surface [34].
strength of the sliding material, then yielding will occur resulting Once strain accumulation reaches a critical level, cracks are
in plastic deformation related wear. nucleated just below the surface, and cracks tend to propagate
Owing to the high normal load and shear force, the IN718 parallel to the surface at a depth and reaches the surface of the
surface layers are deformed and compressed, resulting in the samples, and finally fracture occurs in the contact surface and the
formation of thin plate-like sheets (Fig. 4a). As time progresses, material is removed in the form of delaminated debris (Fig. 4a)
strain accumulation will increase in the deformed flattened layers. from the surface of sliding contacts. Similar observations have
The deformed layer sheets have load carrying capacity and reduces
been made by earlier investigators [34,35].
the contact pressure. Thus plastic shear strain decreases with The accumulated deformation at the sub-layer is a critical fac-
increasing depth, i.e energy transfer occurs through deformation,
tor for material removal from the IN718 surface. Thus mode of
which reduces the stress for further strain accumulation. Hence
wear was found to be delamination. The wear of IN718 surface
additional energy is required to detach the flattened layers from
during the initial run-in period was probably caused by a dela-
the surface, as corroborated by previous researchers [33].
mination type mechanism. After delamination, the next sub layer
Plastic-shear deformation accumulates in the surface layers
becomes as a new sliding surface. This process is continued,
with the continuous sliding action of asperities in the wear process
until the resulting strain at the sub-layer reaches the failure limit resulting in subsurface delamination. Attributing to the insuffi-
of the surface material. The location of the maximum shear stress, cient load carrying capacity due to continuous action sliding
where the failure most likely takes place, is much nearer to the cycles, the delaminated layer is broken into small hard particles
subsurface in the case where both normal and tangential loads are (Fig. 4b) and remain in the contact zone between pin and disc and
applied. promote wear damage in the IN718 surface.
Thus tangential forces introduce the shear stresses that tend to Wear debris produced in the wear of metals and alloys can be
cause plastic deformation and void nucleation. The hydrostatic characterized as one of either two types [36]. These are (1) passive
stresses developed delay void coalescence and ductile fracture. debris which is removed from the wear interface as soon as it is
Hydrostatic compressive stress should improve the ductility by formed and (2) active debris which after its formation participates
retarding the voids that tend to nucleate and propagate under the further in the wear processes.
328 K.G. Thirugnanasambantham, S. Natarajan / Tribology International 101 (2016) 324–330

In most theories of wear, the debris produced is assumed to be the formation of deep grooves (Fig. 4d) in the wear track parallel
removed from the area of contact as soon as it has been formed. to the sliding direction.
However, many studies [37–39] show that wear particles retained
within the wearing interface can play an important role in the 3.2. Wear mechanisms of Hastelloy X
wear mechanism and its coefficient of friction. The generation of
wear debris, which is retained within the wearing interface, can be At both 10 N and 30 N, mode of wear was found to be shear
seen as part of the running-in process of wear. bands in Hastelloy X surface.
The effect of 'third bodies’ on coefficient of friction is complex The density of shear band are significantly larger at 30 N (Fig. 6)
phenomena and it may give rise to a higher or lower coefficient of than 10 N (Fig. 5). This is mainly due to the strong shearing action
friction. This was attributed to the type of motion of wear particles accompanied with severe plastic deformation on the target sur-
trapped within the wearing interface. The wear particles may skid face, during sliding.
over each other, act as rollers or become interlocked and undergo When two contacting surfaces slide against each other, a fric-
fracture. Based on type of motion of wear particles at sliding tional force or traction force is generated opposite to the direction
interface, the applied stress on the worn surface, would change the of sliding. As the applied load increases, the number of asperity
mechanisms involved in the wear process. Jiang et al. [40] pro- contacts between the rubbing surfaces increases, resulting in
posed a number of possible mechanisms for the movement of higher friction. During sliding, traction force influence the local
wear debris. Here the wear particles may skid over each other, act increase in surface temperature of Hastelloy X. This generation of
as rollers or become interlocked and undergo fracture. frictional heat at the sliding interface can significantly reduce the
The entrapment of hard particles in wear track (Fig. 4c), leads to yield strength of the Hastelloy X. The traction force is directly
an increase of the applied stress on the worn surface and induced transferred to the alloy surface as shear stresses, which states that
the dynamics of the contacting bodies, which could change the the shear stress and normal load are proportional.
mechanism from two-body to three-body abrasion involved in the At higher normal loads, tractional stress increases due to higher
wear process, resulting in oscillations in the friction coefficients. friction coefficient on interface. According to the Von Mises Yield
(Fig. 1) Wear particles which are significantly harder than the Criterion, if tractional shear stresses exceeds the shear strength of
wearing materials, may act as an abrasive, giving rise to an the sliding material, then yielding will occur resulting in plastic
abrasive-type mechanism. deformation. Under the applied normal force, deformed layer at
Hence the entrapment of hard particles in the wear track, the surface subjected to tangential shears (i.e strong shearing is
causes high abrasion stress during sliding, eventually resulting in accompanied with severe plastic deformation ) during sliding,
results in localized distortion of the material and leading to for-
mation of shear bands in the direction of sliding friction, as cor-
roborated by previous researchers [41].
Multiple shear deformation bands are observed on the wear
track, as shown in Fig. 7, which illustrates that a concentration of

Shear band

Formation of multiple shear bands


Fig. 5. SEM image of worn surface of Hastelloy X at 10 N and V ¼2 m/s.

Fig. 7. SEM images showing multiple shear bands on Hastelloy X surface at 30 N,


2 m/s.

stoppage of the shear band propagation

Formation of high density shear band

Fig. 6. SEM image of worn surface of Hastelloy X at 30 N and V ¼ 2 m/s. Fig. 8. SEM image of worn surface of Hastelloy X at 10 N and V ¼ 2 m/s.
K.G. Thirugnanasambantham, S. Natarajan / Tribology International 101 (2016) 324–330 329

Formation of cleavages in shear bands

Entrapment of hard particles

Severe damage in shear


band
Delaminated debri

Fig. 9. SEM images showing sequence of sliding damage of Hastelloy X surface at 30 N. (a) Formation of cleavages in shear band and (b) severe damage in shear band.

large shear strain develops in a surface during sliding friction, as a the shear band is a critical factor for material removal. Once strain
result the plastic flows occurs in the form of highly localized shear accumulation reaches a critical level, the work-hardened layer is
deformation bands. Shear bands simply reflect the high sensitivity no longer able to sustain further deformation, i.e. shear bands is
of localized flow towards stress. Shear localization means that not sufficient to accommodate the further applied strain rate. At
almost all deformation is localized into bands in the material and this stage shear band begin to break down as delaminated debris,
that the surrounding material is more or less undeformed, at least shown in Fig. 9, as corroborated by previous researcher [46]. The
compared to the amount of deformation in the shear band, shown broken hard debris are entrapped in cleavages of shear bands
in Fig. 7. (Fig. 9a) and promote wear damage in the Hastelloy X surface. The
SEM (Figs. 5–7), reveal that shear band propagates in the entrapment of hard particles in crater (Fig. 9a), would change the
direction of maximum shearing stress. The presence of surface applied stress on the worn surface, resulting in sudden changes in
shear bands which had just been formed indicates that the criti- the tangential (or friction) force which eventually causes the
cally resolved shear stress is a maximum at the surface, as corro-
friction coefficients to oscillate in a wavy form (Fig. 2).
borated by previous researchers [42,43]. This contradicts many
Presence of debris remaining in the cleavages of shear bands,
wear theories which consider that the stress is maximum at below
leads to an increase of the applied stress on the worn surface,
the surface. Such predictions are based on Hertzian contact theory.
causes severe wear damage (Fig. 9b) in Hastelloy X surface. Thus
Nature of shear bands are dynamically unstable, leading to
acceleration of cleavages in shear band, lead to catastrophic failure
intermittency and serrated flow. This phenomenon occurs due to
under combined action of normal and tensile loading [47].
stress variations during deformation of asperities. The change in
the stress system was reflected in the change in texture on Has-
telloy X surface through shear-band initiation, propagation and
arrest. 4. Conclusion
During sliding, the material undergoes an element of strain, the
stress is raised by the strain hardening and lowered by the asso- Wear mechanisms of the superalloys are greatly influenced by
ciated rise in temperature. In other words this means that as the the normal load.
material is deformed it gets stronger due to work hardening but
weaker due to the temperature rise associated with the work  At 10 N, mechanism of sliding wear of IN718 occurs through
done. If locally the temperature effect is stronger than the work shallow ploughing and plate like debris, while at the 30 N,
hardening effect, the materials ability to form lengthy shear band material removal occurs through delaminated sheets and deep
rapidly. If the strain rate hardening effect is stronger than the grooving.
thermal-softening effects, then material can no longer be  At 10 N, mechanism of sliding wear of Hastelloy X occurs
deformed in this way [44,45]. The shear banding tendency through shear band formation, while at the 30 N, material
increases with increasing difference in flow stress and hardening removal occurs through shear band, cleavage formation, debris
behavior of the two phases. generation.
During sliding, stoppage of the shear band propagation takes  IN718 exhibit good yield srength and toughness at elevated
place when the stress drops below a certain value, shown in Fig. 8. temperatures while comparing to Hastelloy X. These material
If the applied stress is not high enough to maintain plastic defor- properties suppress the junction growth at asperity contacts in
mation, then subsequent rise of stress is necessary to reinitiation friction and the real area of contact. Hence the friction coeffi-
of shear band propagation. Thus shear localization and banding is cient of IN718 is less than Hastelloy X. The lowest coefficient of
a stress driven process. This process causes instability in plastic friction results in better wear resistance by minimizing plastic
flow in a band, which undergoes stick-slip motion. Hence stick-slip deformation.
motion of plastic flow is determined by the character of stress
distribution on the contact surface under the normal force. The
stick-slip mechanism of shear-band operation with stress drops
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