Types of Wear

Tribology is defined as the science and technology of
interacting surfaces in relative motion, having its origin

in the Greek word tribos meaning rubbing.
It is a study of friction, lubrication, and wear of

engineering surfaces
Understanding surface interactions in detail and then
prescribing improvements in given applications.
RJM, 9/16/06 All photos and figures -

Copyright, Prentice Hall
The work of the tribologist is truly
interdisciplinary, embodying physics,
chemistry, mechanics, thermodynamics,
and materials science.
encompassing a large, complex, and
interlinked area of machine design,
reliability, and performance where relative
motion between surfaces is involved.

Importance of Tribology
It is estimated that approximately one-third of the

world's energy resources in present use appear as
friction in one form or another.
The purpose of research in tribology is
understand, analyse and minimization and
elimination of unnecessary waste at all levels of
technology where the rubbing of surfaces is
involved.

 Resistance force acting against the direction
of motion in the plane of sliding motion
 Friction always opposes the motion. Limiting
value is proportional to normal reaction

between the contacting surfaces
 Independent of apparent area of contact
 Independent of sliding velocity

 The friction force is the resistance
encountered when one body moves relative
to another body with which it is in contact.
 The static friction force is how hard you
have to push something to move

 Dynamic friction force is how hard you push
to keep it moving.
 The ratio of the frictional force F to the
normal force R is called the coeffiecient of

friction, μ

Wear takes place
 Due to Interaction between the solids in
relative motion
 Mechanical action of fluid in motion
 Chemical action
 System effect
 Reason for mechanical failure
 Reason for deterioration
 13 types of wear

 Wear depends on
 Types of motion between the surfaces
( sliding, rolling, oscillating, etc.,)

 Types of surfaces having relative motion
◦ Hard, soft, wet, dry, etc

 Wear mechanism
◦ Adhesive, abrasive, chemical, etc

 During sliding friction of dry surfaces
 Sliding friciton of lubricated surfaces
 Rolling friction of dry surfaces
 Rolling friciton of lubricated surfaces
 During oscillating contact
 By moving solid particles
 By moving fluid particles

 Based on wear mechanism
◦ Adhesive wear ( galling wear) – 15%
◦ Abrasive wear (cutting wear) – 50%
◦ Corrosive wear (chemical) 5%
◦ Surface fatigue wear

 In practice it is difficult to predict the type of
wear mechanism. It may change from one
form to other
 Perfect sliding both adhesive and abrasive
wear take place

 During oscillation fretting wear along with
other types
 Some times transformation from one type to
other

Wear classification.

 When hard surface slides against a soft
surface the material from soft surface
ploughs out.
 Metal removal is due to plastic deformation of
small asperities or particles

 Plastic flow from softer material to harder

 One of the surface harder than the other
◦ Aluminium and steel
 Hard surface can be a third body
◦ Grit particle
◦ Abrasives
◦ Metal oxides
Eg:- shaft and bush , piston and cylinder

abrasion
F5-24: low stress abrasion wear – bushing sliding

on shaft

 Gouging abrasion
◦ Due to impact force and deformation of
the surface.- (eg. Showel, hammer,
pulveriser,die)
 Material removal due to the action of
repetitive compressive loading of hard

materials on a softer surface.
 Plastic deformation coupled with chip
removal

 Use composite materials
 High carbon/chromium alloys
 nickel /cobalt alloys
 Hard plating
 Case hardening
 CVD treatment

 Grinding abrasion.
◦ Due to rubbing of two surfaces with force when
abrasive particle is entraped (wear on bearing,
piston ring, etc)
◦ Also known as polishing wear – micro chip removal
– metal removal as fine particle due to continuous
rubbing just like polishing (low stress abrasion)
 Erosion abrasion
◦ Erosion of material from a solid surface by the
action of abrasive particle suspended in a fluid just
like slurry. (wear of pipe , duct and chute).

 Hardness of abrasive (Ha)
 Hardness of metal (Hm)
 Low wear rate if Ha<Hm
 High wear rate if Ha>Hm
 High modulus of plasticity - high wear rate
 Sharp cutting edge - more wear rate

 Abrasion wear increases with sharpness and
hardness of abradant
 Abrasion rate decreases as the size of the
abradant decreases. Less than 3microns no

scratching abrasion
 Abrasion rate is directly proportional to
sliding distance and load

 Elastomers resist low stress abrasion
 If the hardness of the abradant is more than
twice the hardness of the surface, abrasion

rate is significantly high

Improve the hardness of the work material
1.3 times Ha
Use elastic material
Apply lubricant
clean surfaces from foreign materials
Modulus of elasticity can be improved by
heat treatment
chrome plating

 Particles sliding on chute
 Ploughing sandy soil
 Sliding of piston inside cylinder
 Ash handling equipments
 Cutting tool and die
 Grinding wheel
 Wheel on road or rail
 Pipes carrying fluid
 Rock on sea shore

 Basic type of wear
 Two unlubricated surfaces in sliding contact
 Wear takes place due to the plastic
deformation of local particles and adhesion.

 Pressure is required for plastic deformation
 Pressure at the contacting aspirities leads to
local plastic deformation and adhesion

 Vanderwaals force of attraction between the
atoms of dissimilar metal

 Adhesive junctions are formed - bonds

 Initially a bonding is formed between the
surfaces
 The bond breaks when the surface start
sliding results in fracture

 The break takes place inside the softer
material having low mechanical strength

 Finally abrasive wear starts
 Eg. O-ring seals, bushings, gears, chains and
sprockets

Schematic illustration of the interface of two bodies in contact showing real
areas of contact at the asperities. In engineering surfaces, the ratio of the
apparent-to-real areas of contact can be as high as 4 to 5 orders of
magnitude.
Schematic illustration of (a) two contracting asperities, (b) adhesion between
two asperities, and (c) the formation of a wear particle.
Schematic illustration of abrasive wear in sliding. Longitudinal

scratches on a surface usually indicate abrasive wear.

Figure 33.11 Types of wear observed in a single die used
for hot forging. Source: After T. A. Dean.

Types of lubrication generally occurring in metalworking
operations. Source: After W. R. D. Wilson.
Types of Wear:
adhesion Adhesion wear –

localized bonding
between contacting
surfaces
: Galling wear – severe adhesion

adhesion actually leads to material flow up
from the surface.

 MRR due to adhesive wear depends on
◦ Area of contact of surface (A)
◦ Sliding distance (L)
◦ Applied load (W)
 W=A.H , (H-indentation hardness)
 Wear rate Q = k.AL = k.W.L/H
 k,wear coef.

 Surfaces in rolling contact
 Cyclic deformation due to compression,
tension or twist.
 Surface fatigue
 Cracks develop just below the surface
 It propagates parallel to the surface until it
seperates from base metal
 Reasons: cyclic stress formation on the surface
 Sudden changes in the shape may produce
stress concentration

Rubbing action and corrosion
 can be reduced by
◦ High surface hardening

◦ Highly polished surface
◦ Free from scratches

F 5-27 – Pitting surface
fatigue – large roller
thrust bearing race –
Surface fatigue
compressive stress
developed between roller
bearing and race =
pitting. Material actually
fatigued and removed
from surface!!

Surface fatigue
F5-28: Impact wear

Surface fatigue
F 5-30: Brinelling – brinelling of bearing race due to static overload. Note

brinelling more of a static failure (indentation) versus fatigue or wear failure.
Key: Bonds
between
atoms!
Key:
Dislocation
s
F 3-27: Factors that affect

wear at various size levels.
Key: Grain
Size
Key:
Surface
asperities
Key:
Surface
confromanc
e
Types of Erosion

Types of Erosion
solid particle
erosion due to fly
erosion ash.
Slurry erosion
erosion
due to pumping
slurry mixture of
silica and water

Coated Dual Sprocket Chain
2010 SME Annual Meeting & Exhibit

RJM, 9/16/06 Phoenix, Arizona All photos and figures -
Taber Test – common
test for abrasion
resistance of
elastomers/polymers

300,000 tons
Key Property: Abrasion resistance?? Tear

Strength?? Coef of Friction??
 Corrosive environment
 Rubbing surfaces
 Protective coating breaks due to fatigue
loading
 Corrosion spreads quikly
 Pitting and craking
 Chemical wear

 Surfaces at rest subjected to slight frictional
slip (minute)
 Oscillatory movement of small amplitude (not
continuous relative motion) is known as

fretting motion
 Fretting motion leads to fretting wear or
fretting corrosion
 Pitting corrosion leads to fatigue failure due
to stress concentration


Types of Wear

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Types of Wear

Uploaded by

Copyright:

Available Formats

Tribology is defined as the science and technology of

interacting surfaces in relative motion, having its origin

It is a study of friction, lubrication, and wear of

RJM, 9/16/06 All photos and figures -

RJM, 9/16/06 All photos and figures -

It is estimated that approximately one-third of the

RJM, 9/16/06 All photos and figures -

value is proportional to normal reaction

RJM, 9/16/06 All photos and figures -

have to push something to move

normal force R is called the coeffiecient of

RJM, 9/16/06 All photos and figures -

RJM, 9/16/06 All photos and figures -

( sliding, rolling, oscillating, etc.,)

◦ Hard, soft, wet, dry, etc

RJM, 9/16/06 All photos and figures -

RJM, 9/16/06 All photos and figures -

RJM, 9/16/06 All photos and figures -

wear take place

RJM, 9/16/06 All photos and figures -

RJM, 9/16/06 All photos and figures -

small asperities or particles

RJM, 9/16/06 All photos and figures -

RJM, 9/16/06 All photos and figures -

F5-24: low stress abrasion wear – bushing sliding

RJM, 9/16/06 All photos and figures -

repetitive compressive loading of hard

RJM, 9/16/06 All photos and figures -

RJM, 9/16/06 All photos and figures -

RJM, 9/16/06 All photos and figures -

RJM, 9/16/06 All photos and figures -

abradant decreases. Less than 3microns no

sliding distance and load

twice the hardness of the surface, abrasion

RJM, 9/16/06 All photos and figures -

RJM, 9/16/06 All photos and figures -

RJM, 9/16/06 All photos and figures -

deformation of local particles and adhesion.

local plastic deformation and adhesion

atoms of dissimilar metal

RJM, 9/16/06 All photos and figures -

sliding results in fracture

material having low mechanical strength

RJM, 9/16/06 All photos and figures -

Schematic illustration of abrasive wear in sliding. Longitudinal

RJM, 9/16/06 All photos and figures -

RJM, 9/16/06 All photos and figures -

adhesion Adhesion wear –

: Galling wear – severe adhesion

RJM, 9/16/06 All photos and figures -

RJM, 9/16/06 All photos and figures -

RJM, 9/16/06 All photos and figures -

◦ High surface hardening

RJM, 9/16/06 All photos and figures -

RJM, 9/16/06 All photos and figures -

F5-28: Impact wear

F 5-30: Brinelling – brinelling of bearing race due to static overload. Note

F 3-27: Factors that affect

RJM, 9/16/06 All photos and figures -

RJM, 9/16/06 All photos and figures -

2010 SME Annual Meeting & Exhibit

RJM, 9/16/06 All photos and figures -

Key Property: Abrasion resistance?? Tear